1. Additive
Manufacturing
Consortium
An Overview
Ian D. Harris, Ph.D.
Technical Director, AMC
Technology Leader, Arc Welding
(614)688-5131
iharris@ewi.org

2. About EWI
Most extensive joining expertise in the western hemisphere
Located in Columbus, Ohio in a 132,000 square foot facility
$20 M in capital equipment
Mix of industry and government clients
Not-for-profit 501(c)(3) organization with revenue ~$30 MM and 134
employees

3. EWI Mission
Advance our customers’ manufacturing
competitiveness through innovation in joining
and allied technologies

4. About EWI
EWI bridges the gap between fundamental
research and production processes
- EWI finds, develops, and deploys new technologies
and materials
Fundamental
Research
Technology
Development
Technology
Application
Universities,
National Labs &
Inventors
Member
Companies
& Suppliers

5. Possibilities of Metal Additive
Manufacturing
Produce net-shape components by
successive metal build-up
Offer potentially disruptive
competitive advantages
Many U.S. companies and
researchers exploring AM
Many emerging AM technologies
- Based on laser, electron beam, arc,
high-power ultrasonics, etc.
- Using powder, wire, strip, sheetNickel-alloy pressure
vessel components

6. AM – Progressive Layers
Build in layers, Stress relieve/PWHT, Machine

7. AM Processes for Metals
EBW freeform fabrication - EB(FFF)
Laser powder and wire for FFF
LAM, LENS, DMLS, from companies such as
Arcam, EOS, POM – powder and wire based
laser and EB metals AM in confined envelope
Arc processes – GTAW-HW, GMAW-P, PTA
(wire and powder) based on commercially
available equipment for FFF
VHP UAM – very high power ultrasonic AM

8. Example Metals AM Processes
Concept Laser DCM®
EOS DMLS®
MTT SLM®
Phenix Systems
Optomec
LENS®
MTS Aeromet LAM
(No longer in
business).
Sciaky EBFFF
Arcam EBM®

9. Deposition Rate vs Resolution
Courtesy Boeing
Decreased Resolution
IncreasedDepositionRate

10. Example Applications
EB FFF and DMLS parts for aerospace
components

11. Example Applications
Land vehicles
- OEM
- Repair
Power generation and nuclear

12. Arc-Based Additive
Manufacturing
Demonstration of low cost arc-based
processes for Titanium AM
- GMAW-P
- RWF-GMAW
- PAW (Cold Wire)
- PTA (Powder)
- GTAW (Hot Wire) GMAW-P
PAW (Cold Wire)GTAW (Hot Wire) RWF-GMAW
PTA (Powder)
Proprietary to Lockheed Martin
Copyright 2009

13. Emerging Apps
Range of emerging applications … rapid
prototyping, low volume tooling, direct parts
manufacture, tailored materials, MMC, embedded
fibers, smart materials, sensors, cladding, armor,
thermal management
Embedded Ni Tape
0.003” Diameter NiTi
Wire (400X)

14. Potential Competitive
Advantages
Reduce material waste and energy usage
Lower cost (fewer operations, reduced inventory,
simplified supply chain)
Support lean/agile manufacturing (shorter lead
time, less hard tooling, reduce batch size)
Enable new product design features (internal
features, tailored materials, reduced parts)
Reduce time to launch new products
Produce replacement parts for legacy systems
Support environmental sustainability

15. Realities of Metal Additive
Manufacturing
Relatively few U.S. industrial applications
beyond prototyping. Some perceptions:
- Performance of AM components not sufficiently
characterized
- ROI not sufficiently understood to support business
justification
- Not sufficiently productive, cost effective, or capable of
producing part sizes and alloys needed
Multidisciplinary solutions are needed
- No one company has the capacity to address all the
needs
- Shared investment is needed to quickly close gaps

16. Additive Manufacturing…. Need
for Collaboration
Pooling of Resources
Developing from MRL 1–9 at each OEM is costly/time consuming
Network of end users, OEMs, service bureaus and academia
Need more coordinated effort…. generate a critical mass
Business Case
Cost modeling, Need mature process costs
Technical Challenges
Material property database
Process development/distortion control
Equipment OEMs
Voice of the Customer… size capacity, build times, etc.
Controls/Requirements
Design rules/guidelines for AM, F42 Committee
 Low cost input materials
 Cost effective NDE
 Process control (real time)

17. Collaboration Needed
Wide Range of Processes Necessitates Investigating
Each Process in Detail – this is very expensive and requires
collaboration
Initial Acceptance Values Based on LAM Process Form
Lower Bound for Tensile Properties, Typical for
Fatigue Crack Initiation
Stage 2 Evaluation of Several Processes Necessary to
Fully Validate Use of LAM Values for All Approvals of
Proposed AMS 4999 Revision
Stage 2 Evaluation of 6 to 7 Processes Needed for
Certainty of Generating MMPDS Allowables

18. AM in Europe
Most metal AM capital equipment is built in
Europe by Arcam, EOS and others
Large, informal, network of users for plastics
and metals
Loughborough University, England hosts
annual AM conference, all materials and
markets
Fraunhofer Institutes have a coordinated focus
on AM in Germany
There is a concern in the US with technology
lag

19. AM Evaluation Stages
Evaluation Stages – AMS-4999 Revision
- 1 Initial Screening
- 2 Process/Source Approval
- 3 Deposition Parameter Approval
- 4 Approval on Non-Critical Flight Hardware
- 5 Approval of Critical Flight Hardware
MMPDS data generation
Non-flight Hardware Qualification stops at
Stage 4

20. The Answer: AMC
The Additive Manufacturing Consortium (AMC)
was founded to provide a U.S. AM forum
National consortium of industry, government,
and research organizations
Mission: Advance the manufacturing readiness
of metal AM technologies to benefit consortium
members

21. Time to deployment
ManufacturingReadiness
University &
Federal Labs
Manufacturers
& Suppliers
Additive
Manufacturing
Consortium
MRL 3-7
Significant commercial
impacts in 2-5 years
MRL 8-10
Incremental improvements
and implementation
Short time horizon
MRL <3
High-risk basic research
and education
Long time horizon
Advancing Manufacturing
Readiness

22. AMC Structure
Encompass a wide spectrum of
manufacturers
Include technology and material
suppliers
Engage a national technology
network of research partners;
“National Test-Bed Center”
Creates a non-competitive
environment for industry to share
experience and best-practices
Leverages public and private
funding sources
Distinct from university-led
centers which often focus on
education and basic-research

23. Setting AMC Priorities
Discussions with stakeholders
- Industry, universities, government
Review of past efforts
- 2009 Roadmap for Additive Manufacturing
- 2009 Air Force additive manufacturing workshop
- 2009 EWI Ultrasonic Additive Manufacturing symposium
2010 AMC Meeting Ideation: “What should be the
highest priority AMC activities?”
- 3 breakout groups; 125 ideas contributed; 64 ideas had votes;
distilled into 15 themes
AMC members ultimately identify the priorities

24. AMC Business Priorities
Sustained consortium funding
Education & supplier development
Business analysis
Additive manufacturing solutions network
Technology/IP assessments
Collaborative leadership

25. AMC Technical Priorities
Property database
Quality control
Distortion control
Equipment development
Feedstock/input materials
Design rules
Standards
Process modeling/optimization
AM knowledgebase

26. Proposed 1st year goals &
deliverables
Obtain broad industry & government support
Conduct state-of-the-art review of metal AM
technology
Establish a database for collecting metal AM
property information
Organize “National Test Bed Center” research
partners network
Identify technology priorities and create
development plan

27. AMC Member Structure
Member types
- Full members: Major manufacturers / end-users
- Supplier member: Equipment/material suppliers:
- Associate member: SME component suppliers
- Research partners: Universities/labs (by invitation only)
- Government: Partnering agencies
Seeking members to identify 1st year priorities
- All members and research partners attend AMC
meetings and receive research results
- Full members and partnering agencies eligible to serve
on AMC Industrial Advisory Board

28. Benefits
Members identify AMC priorities
Members receive results regularly; 2 year
moratorium on public release
Programs engage a broad range of technical
resources
Continuity allows long-term planning to advance
AM manufacturing readiness
Collaboration with industry and government
facilitates acceptance and commercialization
AMC provides program management to oversee
projects and deliver results

29. Benefits
Funding leveraged with other members,
government programs, and other EWI programs
Full members and associate members receive a
worldwide, non-exclusive license to use IP from
member-funded programs
Supplier members receive first opportunity to
commercialize developments
Research partners have access to funding
opportunities
Regular update meetings allow members to
interact with colleagues and review activities

30. AMC Differentiation
National center - through collaboration with
other centers and programs
AMS 4999 and MMPDS configured data and
data sharing – National standards and data for
aerospace and other designers
Consortium uses equipment and human
resources at existng centers – no need to
replicate activity – this is happening now
Funding from government agencies as well as
congressional requests – all data available to
all AMC members

31. AMC Differentiation
Navy SBIR awarded – AMC member Applied
Optimization/EWI effort – results available to
AMC members
Coordinating needs in process, material,
properties and modeling
Army, Navy and AF along with NASA –
significant synergy
DOE Green and sustainability aspects
Nationally directed programs
Linked into ASTM F42 activities

32. EWI’s Role
About EWI
- Non-profit corporation
- Largest material joining technology application
center in the Western Hemisphere
- Mission to advance our customers’ manufacturing
competitiveness through innovation in joining and
allied technology
- Broad range of technical capabilities and expertise
- Experience in managing centers / consortia
- Staff of full time program managers
AMC Role: Organize, operate, seek funding,
program manage, contribute to technology
development activities
Ultrasonic additive
manufacturing
system

33. AMC - Current Member Status
Air Force (partner)
NASA (partner)
Army (partner)
GE
P&W
R-R
Honeywell
Lockheed Martin
Northrop Grumman
GDLS
Morris Technologies
Applied Optimization
The Ohio State University (partner)
University of Kentucky (partner)
University of Texas, Austin (partner)
University of North Carolina (partner)
October 1, 2010 AMC membership year
The First AMC Members Meeting is scheduled for Dec 7, 2010

34. Questions?
Ian Harris
iharris@ewi.org
614.688-5131
Rene 142 Laser
powder deposition