1. Presents:
August 31 – September 2, 2015
Washington D.C.for Defense and Aerospace
Featured Speakers:
Next Generation Requirements
for Advanced Manufacturing
Initiatives
Featured Participating OEMs:
Gain Step-by-Step Understanding
of Critical Topics and Initiatives
www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org
3rd
Neal Orringer
Vice President
for Alliances and
Partnerships
3D Systems
Jeff Haynes
Program Manager
Aerojet
Rocketdyne
LJ Holmes
Principal Investigator
for Materials
and Technology
Development in Additive
Manufacturing
US Army Research
Laboratory
Mark Johnson
Director Advanced
Manufacturing Office
Department of
Energy
Mike Daly
Chief Technology
Officer
Raytheon
Suraj Rawal
Principal Research
Scientist
Lockheed Martin
Identifying and Resolving Introduced Defective
Components and Processes
Future Manufacturing Requirements of the AFRL
Qualification Via Analysis Vs Qualification Via
Imperial Testing
Defending Against Digital Theft and Espionage in
Additive Manufacturing
Requirements in Metals Additive Manufacturing for
the U.S. Navy
3D Printing for Lightweight Super Strong Materials
Rapid Prototypes to Production on the Battlefield
Generating 3D Models Through Reverse
Engineering to Resolve Unique Field Challenges
Sea and Aerospace Advancements in Additive
Manufacturing
Newest Developments in Additive Manufacturing
for Rocket Engines
Sponsor: Media Partners:
Tools, Technologies, and Techniques for Evolving Additive Manufacturing Programs...
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2. www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org2
Dear Colleague:
Additive Manufacturing is rapidly maturing as a mainstream production method. Every day the brightest minds
from the Department of Defense are finding new and exciting ways to utilize what’s currently available and the top
OEM’s are working tirelessly to achieve new process capabilities. 2015 is already shaping up to be an exciting year as
new breakthroughs are being achieved in many areas including:
·· Metals
·· Multi-material printing
·· Embedding
·· Parts reduction
·· Improved qualifications
·· Standards development
As we all know, despite the advancements Additive Manufacturing is still not a perfect science. Additive
Manufacturing can advance but not without industry leaders coming together to collaborate with the leading
experts from the military, labs, educational institutions, industry partners, and the OEM’s.
Additive Manufacturing for Defense and Aerospace returns for its third installment to bring together the best
of breed program managers, engineers, researchers, policy makers and solution providers all working towards
advancing additive manufacturing initiatives across the defense and aerospace industries. By creating a forum
for working toward the implementation of the latest technologies in additive manufacturing, this conference
will provide education, collaboration, business development, networking, benchmarking, and brainstorming
opportunities to accelerate your efforts moving forward.
Join us to benchmark, seize new opportunities, collaborate, overcome manufacturing challenges, and to raise the
bar on your efforts!
Sincerely,
Trevor Sosvielle
Program Director
August 31 – September 2, 2015
Washington D.C.
Next Generation
Requirements for Advanced
Manufacturing Initiatives
New for 2015:3rd
Military Requirements Briefings
Cyber Security Focus Day
DoD Leadership
The OEM Perspective
P.S. Don’t miss our Cyber Security
Focus Day to learn how to defend against
digital theft and espionage in additive
manufacturing
Hear the newest requirements from Program and division
leads from ARL, AFRL, and ARDEC and understand the
mission critical tech requirements for 2016 and beyond!
Learn about* the latest in Espionage, Digital Theft,Process
Impairment, Process Denial Attack, Defective Components
& Processes, and reducing the impact of successful
breaches. Implement changes to your manufacturing to
keep your systems protected from the biggest threats.
Hear the future manufacturing vision of core military
branches and understand where military budgets are
headed for the future.
Learn more about manufacturing initiatives from
Lockeed Martin, Raytheon, Harris, and Aerojet
Rocketdyne
for Defense and Aerospace
3. www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org3
Jeff Haynes
Program Manager
Rocketdyne
LJ Holmes
Principal Investigator for
Materials and Technology
Development in Additive
Manufacturing
US Army Research Laboratory
Paul Witherell
Senior Researcher
NIST
Mark Johnson
Director Advanced
Manufacturing Office
Department of Energy
Mike Daly
Chief Technology Officer
Raytheon
Suraj Rawal
Principal Research Scientist
Lockheed Martin
SESSION: Establishing Standards in Additive
Manufacturing
Mr. Larry R. Holmes, Jr. is the ARL Principal Investigator for Additive
Manufacturing Materials and Technology Development, and leads this area
of research as well as all other activities within the MiCRO Lab. The Army
has a large investment portfolio in Advanced Manufacturing and this is
expected to grow steadily in coming years. Mr. Holmes and colleagues
throughout the Army Research Development and Engineering Command
(RDECOM) are tasked with guiding many of these activities. Mr. Holmes
will present the ARL working roadmaps, how ARL supports the rest of
RDECOM, and will discuss current research projects supporting this mission
area. Avenues for ARL-University or ARL-Industry collaboration will also
be discussed. Mr. Holmes earned his BS in Aerospace Engineering from
Embry-Riddle Aeronautical University in 2002, and his MS in Mechanical
Engineering from the University of Wisconsin-Madison in 2009.
SESSION: The State of Additive Manufacturing at the
DOE 2015
Dr. Mark Johnson has joined Energy Efficiency and Renewable Energy as
Director of the Advanced Manufacturing Office (AMO). Previously, Dr.
Johnson has been a Program Director in the Advanced Research Projects
Agency – Energy (ARPA-E) where he had been the longest serving Program
Director, having been with ARPA-E from its first year of formation in
2010 until mid-2013. While at ARPA-E, Dr. Johnson had started initiatives
on areas of energy storage and critical materials, as well as projects
in small business, advanced semiconductor, novel wind architectures,
superconductors and electric machines.
SESSION: Defending Against Digital Theft and
Espionage in Additive Manufacturing
Michael K. Daly is a leader in intelligence, surveillance and reconnaissance;
advanced cyber solutions; weather and environmental solutions;
information-based solutions for law enforcement and homeland security;
and training, logistics, engineering, product support, and operational
support services and solutions for Mission Support, homeland security,
space, civil aviation, counter proliferation and counterterrorism. Daly is the
CTO for the CSM business that provides cyber solutions to domestic and
international government and commercial customers, delivers quick-reaction
mission solutions, and provides support to high consequence special
missions. Daly is a Principle Engineering Fellow and provides leadership
in Raytheon’s cyber technologies, managing research and development
investments and operating an array of cyber technology innovation centers
across Raytheon. He supports the National Security Telecommunications
Advisory Committee to the President of the United States.
SESSION: Qualification Via Analysis Vs Qualification
Via Imperial Testing
Dr. Paul W. Witherell is a Mechanical Engineer in the Life Cycle Engineering
(LCE) Group of the Systems Integration Division (SID) of the Engineering
Laboratory (EL) at the National Institute of Standards and Technology (NIST).
His primary objectives at NIST are to develop and transfer knowledge to
industry, including knowledge about information models for sustainable
manufacturing, green products, and system level analysis. His specific job
focus is on identifying integration and technology issues that promote
industry acceptance of information models, product representation
standards, and open architecture that will enable designers to develop
products that are sustainable and manufactured globally in a distributed
and collaborative environment. Dr. Witherell’s primary areas of interest
are Sustainable Manufacturing, Design for Sustainability, Knowledge
Representation in Product Development, Design Optimization, Ontology, and
Semantic Relatedness.
SESSION: Newest Developments in Additive
Manufacturing for Rocket Engines
Jeff Haynes currently holds the position as the Program Manager for Aerojet
Rocketdyne Additive Manufacturing Development. Jeff has managed this
technology development for over five years from initial trials to current full
propulsion program qualification and production insertion. In this role,
Jeff has compiled a strong, multi-discipline team to transition the additive
manufacturing process into a viable liquid rocket engine product form.
Prior to this, Jeff was the Materials Engineering Manager for a significant
number of propulsion programs including: J-2X nozzle extension, RD-
180 co-production, RL60 upper stage engine, Hypersonic X-51 scramjet,
Space Shuttle Main Engine Turbopump Development, Space Shuttle Solid
Rocket Booster Ablative Insulation. His extensive propulsion background
combined with materials & processes knowledge enables him to develop
new manufacturing technologies, such as additive manufacturing, with
the experience to ensure proper attention to critical aspects of the product
development.
SESSION: Printing Super Alloys for Hyper Sonic
Applications
Dr. Rawal is the Principal Research Scientist in the Advanced Materials and
Nanostructures Group of Advanced Technology Center, Lockheed Martin
Space Systems Company. Dr. Rawal received his Ph.D. in Materials Science
and Engineering from Brown University, RI, USA. Dr. Rawal has about
30 years of experience in the applied materials research for spacecraft
systems, and he has successfully inserted new materials technologies into
the components of several space crafts such as MGS, Mars 98, Genesis,
Stardust, MRO, XSS-11, JUNO, GRAIL and special programs. He has been
program manager and principal investigator of several contract research
and development (CR&D) programs sponsored by AFRL, BMDO, DARPA,
NASA, and ONR. Dr. Rawal represents LM in the advisory panels of Minority
Nanotechnology Leadership Institutions, AFOSR sponsored Multi-University
Research Initiative (MURI) programs at Case Western, Rice University,
and Stanford University, and the Mechanical Engineering Department of
Colorado State University, University of Denver, and University of Colorado
(Boulder). Dr. Rawal has received several Lockheed Martin awards, including
inventor, author, and technical achievement, and has authored over 70
articles on advanced composites, thermal management, and structure/
property relationships. Dr. Rawal has 9 patents, and 4 trade secrets.
Speakers at a Glance
4. www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org4
Workshop Day August 31st
, 2015
08:00 Registration
08:45 Chairperson Welcome and Opening Remarks
09:00 WORKSHOP A: Defending Against Digital Theft and Espionage in Additive Manufacturing
While additive manufacturing affords many benefits, given the digital nature of the process it has
opened new vulnerabilities in theft and data protection. Poorly defended systems are susceptible to
sophisticated attacks that could make it possible to reproduce top technology.
This session will explore:
·· The newest defensive strategies in file protection
·· Techniques in intrusion detection, prevention, and identification
·· Understanding the newest advanced threat actor tactics
·· Establishing a prevention and reaction framework
Mike Daly
Chief Technology Officer
Raytheon
Ed Tackett
Director of Educational Programs
UL AMCC at University of Louisville
10:30 Morning Networking & Refreshment Break
10:45 WORKSHOP B: THE GLOBAL SHORTAGE IN SKILLED LABOR: FOSTERING LABOR COMPETENCY IN THE RAPIDLY EVOLVING FIELD OF ADDITIVE MANUFACTURING
The additive manufacturing market for production parts is expected to increase to $30 billion
over the next decade. However, the development of the necessary awareness, knowledge, & skills
will struggle to keep up with the rapid pace of adoption. The industry lacks good mechanisms
to delivery consistent, complete, messages about these technologies & to transfer knowledge
from research to commercial applications. This workshop will explore the challenges that exist
and methods proposed to overcome in developing training programs for beginners all the way to
experienced additive manufacturing systems users.
·· Identify the factors creating demand for AM training
·· Define the needs for AM training & professional certification
·· Define how AM training & professional certification fosters product conformance to
technical requirements
Paul Bates
Lead 3D Printing Development Engineer
UL Labs
Charles Miller
Gordon Engineering Fellow
Raytheon
12:15 Lunch
13:15 WORKSHOP C: FOUNDATIONS OF 3D PRINTING
This workshop will present you with comprehensive introductory knowledge of the 3D
printing industry. Covering terms and definitions, software and hardware, and safety & quality
considerations, Foundations introduces you to print process challenges, the benefits and
limitations of various technologies, and safety and quality considerations.
This workshop will cover:
·· Review of the seven unique 3D printing processes and basic applications.
·· Fundamental systems and support required for 3D printing
·· Computer-aided design, scanning and repair software
·· Quality and safety considerations
14:45 Afternoon Refreshment Break
15:00 WORKSHOP D: LOGISTICS SYSTEMS ENGINEERING AND ADDITIVE MANUFACTURING
This workshop will closely examine the logistics opportunities, breakthroughs, challenges, and
benefits realized by proper planning in the Additive Manufacturing arena.
This workshop explores:
·· Part substitution for those delivered by dangerous or costly supply lines
·· Enabling mass customization
·· Benefits of taking a service based approach to additive manufacturing
16:30 Chairperson Closing Remarks
16:45 End of Workshop Day
5. Main Conference Day One
www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org5
September 1st
, 2015
08:00 Registration & Coffee
08:45 Chairperson’s Welcome and Opening Remarks
Jeff Beebout
Chief Technical Officer
CC3D
09:00 The State of Additive Manufacturing at the DOE 2015
The DOE has had some significant breakthroughs in 2015 and as a result will also have
new requirements moving forward.
This session will both explore the newest developments and changing needs in
manufacturing at the Department of Energy.
·· Innovations in manufacturing processes
·· Reductions in production emissions
·· New DOE and industry partnership opportunities
·· Novel additive manufacturing applications by the AMO
Mark Johnson
Director Advanced Manufacturing Office
Department of Energy
09:45 A Paradigm Shift for AM Qualification: Incorporating Simulation and
Analysis
It’s no secret that additive manufacturing as a process requires extensive testing and
analysis before it can be deemed safe for defense or aerospace usage. To date no
additively manufactured part has been used in a defense critical capacity. This session will
explore the following concepts:
·· De facto approach to qualification has manufacturers blanket testing parts and coupons
·· Modeling has not matured enough to provide a viable alternative to qualification of
mission-critical parts
·· The de facto approach impedes innovation for the manufacture and qualification of
less-critical AM parts
·· When used/applied correctly, modeling and simulation has role to play in AM part
qualification
Dr. Paul William Witherell
Senior Researcher
National Institute of Standards and Technology
10:30 Morning Networking & Refreshment Break
11:15 Large Scale Fully Dense Metallic Additive Manufacturing
Recent research at Texas State university has yielded promising results and improvements
in metal manufacturing capabilities. This session will look at what’s coming in the next
frontier of large scale metal manufacturing:
·· Breakthroughs in printing fully functional metal parts
·· Software development for adaptive and angular tool path generation
·· Achieving reliable results and statistical optimization
·· Mastering fully, dense high strength, and reproducible parts
·· Understanding the critical sciences and methodologies behind successful functional
parts through metal printing
Bahram Asiabanpour
Associate Professor of Manufacturing Engineering
Texas State University
12:00 Networking Luncheon
13:00 Re-Envisioning Processes and Materials to Achieve Drastic Print Speed Improvements
Recently CC3D has achieved speed increases in 3d printing by as many as nine times by using focused
energy to rapidly cure polymers along with continuous strand carbon fiber, aramid, and fiberglass
that have not been traditionally used in 3D printing. This breakthrough process has tremendous
applications for aerospace and defense from, drones, to body armor, and onto advanced structures and
infrastructure. This session will explore:
·· Breakthroughs in part and material strength utilizing continuous fiber and high strength monomers
·· Improving overall part functionality with use of optically, fluidically, and electrically conductive materials
·· Expanding capabilities in size, speed and scale of printing
Ken Tyler
President and Principal Investigator
CC3D
14:00 Additive Manufacturing Methods, Techniques, Procedures, & Applications
In this session we will explore:
·· Printed Electronics
·· 3D Printing for Weapon Systems
·· Materials Development & Qualification
·· Integration - Electronics, Structures, and Enhanced Capabilities
·· Technology Transition to Industrial Base & the Field Base & The Field
James Zunino
Materials Engineer / ARDEC Project Officer
US. Army - ARDEC
14:45 Afternoon Refreshment & Networking Break
15:30 Harnessing Space Based Printing Developments for Terrestrial Applications
Made in Space has unquestionably seen significant developments recently in 3D printing in austere
developments. The question to ask now is how these novel applications can benefit other 3D printing
operations. This session will explore:
·· Sustainability in closed loop environments
·· New materials developments and applications
·· Developing additive manufacturing construction techniques
·· Improving manufacturing stability in remote locations
Jason Dunn
CTO
Made in Space
16:15 Printing Super Alloys for Hyper Sonic Applications
Additive manufacturing has offered significant advantages in reducing the manufacturing processes
necessary to create super strong and lightweight alloys for craft that travel at hyper sonic speeds. This
session will explore the latest:
·· Developing a printing methodology to print on demand parts from super strength light weight alloys
·· Creating a qualification regiment for parts from never before seen materials
·· Reducing weight characteristics for super alloy parts Increasing affordability
Suraj Rawal
Technical Fellow at Advanced Technology Center
Lockheed Martin
17:00 Closing Remarks
17:15 End of Main Conference Day One
6. www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org6
Main Conference Day Two September 2nd
2015
07:45 Registration & Coffee
08:30 Chairperson’s Recap of Conference Day One
Jeff Beebout
Chief Technical Officer
CC3D
08:45 KEYNOTE: Developments in Additive Manufacturing at
Marshall Space Flight Center
2015 has been a banner year for developments in Additive Manufacturing at
NASA with several exciting developments in novel applications and technical
breakthroughs. This session will explore MSFC’s most recent accomplishments and
what’s on the horizon.
·· Developments in material characterizations
·· The latest data from 3D printing efforts at the International Space Station
·· Breakthroughs in copper printing
·· Newest accomplishments in 3D
Dr. Raymond Clinton
Deputy director of the MSFC Science & Technology Office
NASA
09:30 PANEL: Establishing Standards in Additive Manufacturing
While additive manufacturing is quickly approaching full adoption by the military
there is still a significant lack of a quality standards protocol. This panel will explore
divisions such as ARDEC and ARL’s efforts to resolve this:
James Zunino
Materials Engineer / ARDEC Project Officer
US. Army – ARDEC
LJ Holmes
Principal Investigator for Materials and Technology Development in
Additive Manufacturing
US Army Research Laboratory
Chris Krampitz
Director | AM Technology Strategy & Innovation
UL
10:30 Morning Networking & Refreshment Break
11:00 Public-Private Partnership to Advance U.S. Competitiveness
and Security
Renewed attention by the federal government-- both to 3D printing and cyber
physical systems— now has the potential to catalyze unprecedented levels of
innovation in wide-reaching fields, ranging from medical and nutrition to automotive,
propulsion, shipbuilding, aerospace/defense, and logistics fields.
In this session you will learn to:
·· Navigate the current technology trajectory (in a range of technologies,
materials, speeds, and process/parameters)
·· Understand the conflation of 3D digital and physical systems (design
optimization; 3D scanning for reverse engineering, monitoring, and post-
process inspection)
·· Align with areas of common interest with the federal government for advancing
qualification and adoption
Neal Orringer
Vice President for Alliances and Partnerships
3D Systems
11:45 Additive Manufacturing for Lightweight Precision Space
Structures
Additive manufacturing presents significant opportunity for the future of space
based antennae. Utilizing Ti6-AI-4V alloy has created an ability to create strong,
lightweight, highly conductive, and highly reflective material. In this session we will
explore:
·· Designing and testing parts for an antenna reflector (up to 3.5m diameter) for
space applications
·· Investing in material characterization of Ti6-Al-4V, including fatigue
·· Investing in Additive Manufacturing internal tools and external relationships
·· Space antennas, avionic novel approaches and future opportunities with
additive manufacturing at Harris
Tom Campbell
Director of Innovation
Harris
12:30 Networking Luncheon
13:30 Intellectual Property Law and Defense Manufacturing
This panel will feature the nation’s strongest legal firms who specialize in intellectual
property law, to discuss what does and does not fall under “fair use” and how to reclaim
misused product and design.
William Cass
Partner
Cantor Colburn LLP
7. www.AdditiveManufacturingforDefense.com • 1-800-882-8684 • idga@idga.org7
Main Conference Day Two Continued
14:15 Utilizing Additive Manufacturing to Embed Equipment into
Structures
One of the greatest applications of additive manufacturing is what it has offered in terms of
printed electronics. From reduced bulk, to enhanced features it’s an exciting frontier. In this
session you will learn:
·· Currently utilized methodologies from pick and place to direct print electronics
·· Developments in lightweight super strong micro-composites
·· The latest in on demand printing in the field
·· Predicted challenges moving forward in printed electronics
LJ Holmes
Principal Investigator Materials Dev
Army Research Laboratory
15:00 Afternoon Refreshment & Networking Break
15:30 Newest Developments in Additive Manufacturing for Rocket
Engines
RocketDyne’s recent initiatives show that rocket engines can be made entirely from additive
manufacturing. What other products can this influence? What are the overall implications
of this advancement? In this session you will learn:
·· Key design considerations for additive manufacturing
·· To manage materials characterization and design allowables
·· Best practices for additive manufactured engine validation testing.
Jeff Haynes
Program Manager
Aerojet Rocketdyne
16:15 Closing Remarks
16:30 End of Main Conference Day Two
“Very Professional, Highly Technical Speeches
from Experts in the AM Field/ Overall Best
Conference I’ve been to in ten years!”
Mark Skeehan, Staff Engineer, Lockheed Martin
“Shows the current SOTA for Govt and where
they plan on going and whats realistic.”
Adam Verdon, Mechanical Engineer,
Additive Harris Corporation
