E. W. Palsrok, Dir. Workforce Development

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Micro-Fabrication Nano-Fabrication
Visualization, Planning Knowledge Management
Solid Free-Form Fabrication
Modeling and Simulation

Reconfigurable Tools and Systems
Smart Systems

Sensors
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definition of disruptive is as follows

• technological developments that have reached
  sufficient critical mass or tipping point to
  cause a significant proportion of manufacturers
  to fundamentally alter their planning,
  operations, structure or processes.

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Presentation Outline

• Scope A broad description of this category for
  the purposes of this presentation. Note These
  descriptions are not intended to be formal
  technical definitions.
• Current Practice A characterization of the
  state-of-the art of each category
• Future Trends A brief description of some of
  the trends in cutting-edge research, including
  some specific examples of those trends provided
  by industry executives. Industry recommendations
  for action in connection with these trends are
  also reported.
• Disruptive State An estimate of the impact of
  these technology categories when they become
  disruptive
• Environmental and/or Energy-related Impacts
  Comments on the impact of these technologies on
  the environment and on energy efficiency
• Areas for Further Research - Where appropriate,
  the report includes suggested areas for further
  research.

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Micro-Fabrication Nano-Fabrication
Visualization, Planning Knowledge Management
Reconfigurable Tools and Systems
Solid Free-Form Fabrication
Advanced Technologies Categories
Sensors
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Micro Nano-fabrication . . .

• will introduce a much higher level of agility
  into the industrial base over the longer term.
• represents the most promising approach to make
  large objects into precision products through
  tools such as molecular machine design, molecular
  manipulation and construction, and molecular
  modeling design tools
• will be common for switches, filters, and motors.
  
• will allow the DoD to focus on the use of
  molecular manufacturing for improving the
  performance of existing military systems, and to
  develop defense strategies against future
  nanomachine-based weapons.

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Scope Micro Nano Fabrication

• Micro fabrication - Working with material at the
  micron scale. This would include depositing
  materials onto the surface of a substrate and
  patterning the deposited thin film for
  fabrication of microelectronic circuits.
• Nano-fabrication - Working with material at the
  nano-scale. This is essentially the creation of
  materials and parts through the manipulation of
  matter at the atomic, molecular level.

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Current Practice Micro Nano Fabrication

• Cost is currently a significant restraint on the
  widespread use of these technologies in
  manufacturing
• Adoption limited until improvements in size,
  weight, and power.
• U.S. is closer to maturing these technologies
  than many think (ex. carbon nanotubes and
  nanomotors are already being made and
  nanocomputers are becoming a reality)
• Micro/nano machines obsolescence and strength
  problems
• On balance, although micro-fabrication and
  nano-fabrication will have far-reaching impacts
  on production systems, these processes are
  currently being implemented in industry at a
  relatively slow rate.

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Future Trends Micro Nano Fabrication

• Because of increased federal funding, cited
  above, research in these technology areas is
  moving ahead at a more rapid pace.
• growing recognition these technologies provide
  more agility in the industrial base over the
  longer term. For example, micro- and
  nano-manufacturing represent approaches in the
  future with the capability to make large objects
  into precision products through tools such as
  molecular machine design, molecular manipulation
  (such as growing a table instead of a tree) and
  construction, and molecular modeling design
  tools.

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Disruptive State Micro Nano Fabrication

• Molecular manufacturing will be the most
  disruptive factor within supply chains over the
  long term. There is no supply chain that goes
  directly from raw chemicals to a finished,
  atomically-precise product, in one step
• Some products will be made using generic raw
  materials such as silica (sand), obviating the
  need for mining and processing of raw materials
• Products designed and made at the point of use or
  sale, eliminating the geographical dispersion of
  the supply base and making distributed
  manufacturing a reality
• Micro-nano designer chemical compounds developed
  will revolutionize the consumer-goods industries.
  (Grow furniture not wood, nano products add 50
  increased strength less cost)

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Environmental and/or energy-related impacts
Micro Nano Fabrication

• In the short term, these technologies are
  unlikely to have a significant impact on the
  environment or on energy costs. These
  technologies will lead to higher energy costs in
  their early developmental stages due to current
  processing technology.
• However, advanced micro-and nano-fabrication are
  exciting from the aspect that fewer energy and
  fixed resources will be consumed once these
  technologies mature. For example, as these
  technologies are more widely implemented, they
  will lead to scrap reduction and less waste due
  to the build up process versus removal of
  material to obtain the end product.

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Areas for Further Research Micro Nano
Fabrication

• There is a need to identify specific products,
  forms, materials and manufacturing processes for
  pilot studies versus just developing
  nano-science. An example here is use of nanotubes
  for an atomic clock versus just developing nano
  tubes. Tools to manipulate and manufacture
  molecular structures and significant investment
  in the design and manufacture of
  nano-electromechanical devices are examples of
  current gaps in the advancement of this
  technology and benefit realization.
• A technology roadmap needs to be developed,
  including standards and metrics, and a benefit
  analysis providing the business case to
  accelerate RD in micro- and nano-fabrication.

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Micro-Fabrication Nano-Fabrication
Modeling and Simulation
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Scope Modeling and Simulation

• Using high-speed computers to build virtual
  representations of parts, processes and systems,
  simulate their interaction with one another, and
  observe that process in a way that is useful.
• This technology allows the visualization of
  things before they are actually created. The
  capacity for innovation is greatly improved as
  the time and cost required to experiment with new
  materials and simulate new processes is
  dramatically reduced.

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Current Practice Modeling Simulation (MS)

• Advanced (MS) is mentioned as a need in many
  industry roadmaps. It was the technology category
  most frequently cited by industry participants in
  this project.
• Full potential coming only with significant
  advances in computing power and software,
  allowing iterative virtual development and
  testing of product and process design as well as
  manufacturing processes which reduces the number
  of unnecessary changes and enables rapid response
  to desired ones.
• MS in the aerospace and defense sectors is
  already "disruptive." Recent advances in three
  dimensional (3D) graphics packages and related
  simulation software have greatly improved the
  ability to accurately depict reality within
  aerospace manufacturing systems.
• The integration of machine kinematics (branch of
  mechanics describing the motion of objects
  without the consideration of the masses or forces
  that bring about the motion) for example, is now
  readily available so that movements of machines
  in the real vs. virtual world accurately
  represent actual movements. This capability
  enables manufacturing equipment and processes to
  interface precisely with digital product designs
  (components, assemblies, or just parts).

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Current Practice (MS) continued

• There are two kinds of modeling today
  descriptive (observed or recorded laboratory
  data) and predictive (descriptive model becomes
  predictive when you use it to predict behavior of
  a new system).
• These disciplines need to be brought together, in
  order to substantially realize their potential
  benefits. The benefits include reduced testing
  and time required to design products and bring
  them to the marketplace. While MS of global
  supply chain process and product packages has
  generated significant savings, due to the cost of
  development process simulation and modeling they
  have returned modest results unless high volume
  production is required.

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Future Trends Modeling Simulation

• One of the barriers ahead to effective use of MS
  is the inability of modeling tools and platforms
  to interoperate. Standards efforts such as the
  Standard for the Exchange of Product Model Data
  (STEP - ISO10303) have made progress, but
  ultimately cannot keep up with the demands for
  new and different data sets covering such areas
  as cost data, simulation results, and test
  results. Visualization has been put forth as an
  alternative but 3D visualization cannot carry all
  of the information necessary to support
  collaborative design and, over time, the same
  issues of model complexity and interoperability
  will again appear.
• DoD is pursuing Defense Transformation in every
  aspect of their operations from war fighting to
  acquisition to the support of systems and troops.
  New systems are very complex, as are the
  scenarios in which they operate. Acquisition and
  support of these systems depends increasingly on
  analysis of performance, cost and support
  requirements. Much of this analysis is done
  through MS. MS will play a larger part in
  sustainment and logistics support processes
• The Army has launched a new set of models (Combat
  21 and others) to assess the performance of
  systems in urban combat situations. MS is used
  throughout the design of the system and as part
  of the manufacturing engineering process, which
  will become a requirement for engineering and
  manufacturing readiness.

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Disruptive State Modeling Simulation

• With virtual factory simulation, industry will
  have the capabilities to evaluate other
  manufacturers skills, machine capabilities, etc.
  This will have a huge impact on supply chain
  management. Companies will create an auction
  market place for capacities of machines and
  talents. Modeling will be especially useful
  within supply chains to prevent mistakes, and
  reduce labor and overhead costs.
• With advanced computer power and software,
  modeling will dramatically reduce the number of
  unnecessary changes and enable very rapid
  response times. Companies will have interactive,
  predictive capabilities for advanced MS of
  highly complex production systems.

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Environmental and/or Energy-Related Impacts
Modeling Simulation

• Simulation results have less environmental
  impact, faster technology insertion, more
  optimized products. These have a positive impact
  both on the environment and on energy
  conservation. MS can increasingly replace
  physical testing, and build/bust development.
  Researchers should be able to identify
  environmental impacts before system build with
  MS.
• Better control of manufacturing process through
  simulations will lead to reduced energy
  consumption and better asset utilization.

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Areas for Further Research Modeling Simulation

• To enable adaptive simulations, further
  research is needed on the use of micro/nano
  sensors to provide inputs into MS
• Real incentives must be defined to clarify the
  need for using MS, which could include such as
  the impact of relocation of work force
  suppliers to other vital areas, model
  interoperability, and review of lessons learned
  from pre- and post-visuals of models.
• U.S. mfrs need standards for MS, since there are
  too many different models, which make integration
  difficult or impossible.
• Standards need to be established by key users and
  developers to facilitate interoperability. The
  building of standardized ontologies and
  improvement in the ability of simulations to
  interoperate with one another and with other
  engineer and manufacturing execution systems need
  additional development.

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Micro-Fabrication Nano-Fabrication
Modeling and Simulation

Reconfigurable Tools and Systems
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Reconfigurable Tools and Systems . . .

• will enable much shorter product life cycles,
  reduced lot sizes, and cheaper, more flexible
  manufacturing processes and making mass
  customization a reality for many manufacturers.
• will change the layout and number of machine
  tools needed to manufacture, requiring less floor
  space and fewer facilities.
• with further refinements, will allow machines to
  work directly from product designs, correct
  problems on the fly, detect and perform
  maintenance adjustments, and adapt themselves to
  changing conditions.

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Scope - Reconfigurable Tools and Systems . . .

• Software, tools or machines that can perform
  multiple functions including functions not
  anticipated in the original design and without
  requiring new tool production.
• As much as reconfigurable tools and systems may
  affect manufacturing, this study showed key
  disruptions may come from cross-technology/cross-c
  utting issues and developments. Timely, new and
  effective approaches and tools (including
  software and the application of simulation and
  visioning tools to technology management) will be
  critical and are evolving.

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Current Practice Reconfigurable Tools and
Systems . . .

• This is already becoming a disruptive technology
  category, for example, military fighter aircraft
  manufacturing. Today, reconfigurable tools
  provide substantial cost savings benefits
  (potential) not only for very expensive hard
  tools, but also for the elimination of their
  maintenance in the aircraft industry.
• Industry is producing aircraft with laser
  alignment vs. hard /special tooling. Efforts in
  the area of wire harness fabrication have yielded
  a "flexible tool" approach providing the same
  type of advantages. Within the last ten years
  this technology has also been used in machine
  tools to allow for more flexibility and agility.
• In response to market demand, one camera company
  was very successful in using this process with
  single-use disposable camerassame platform with
  derivatives for black and white, color,
  underwater, flash, wide angle cameras, etc., The
  auto industry, aerospace industry and chemical
  industry are making increasing use of this
  technology.

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Future Trends Reconfigurable Tools and Systems
. . .

• This technology will realize greater
  implementation when the manufacturing process
  benefits are clearly capable of lowering costs,
  increasing reliability, and providing greater
  consistency. Future research will focus on
  increasing the capability to using this
  technology with multiple manufacturing processes.
  
• Future research will also focus on new concepts
  that utilize alternative production processes vs.
  hard tooling, i.e. powdered metals,
  stereo-lithography/metal printing vs. machining
  of metals. Other trends more high-speed
  machining (HSM) processes by using monolithic
  structures in place of assemblies, a precept
  often enabled by HSM elimination of assembly
  jigs with the use of laser projection graded
  metal interfaces may make joint areas stronger
  and not the inherent weak point.
• As military products move towards mass
  customization the ability to reconfigure tooling
  and test equipment will mean increased readiness
  and adaptability, faster production time, with
  less risk. Simplicity of use is also key to the
  extent of future deployment of this important
  technology category.

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Disruptive State Reconfigurable Tools and
Systems . . .

• Reconfigurable tools and systems will enable much
  shorter product life cycles, reduced lot sizes,
  and cheaper, more flexible manufacturing
  processes. These capabilities will help make mass
  customization a reality for many manufacturers.
• Reconfigurable tools and systems will
• Change the layout and number of machine tools
  needed to manufacture, requiring less floor space
  and fewer facilities.
• Allow machines to work directly from product
  designs
• Correct problems on the fly
• Detect and perform maintenance adjustments
• Adapt themselves to changing conditions.

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Environmental and/or Energy-Related Impacts
Reconfigurable Tools and Systems . . .

• This technology should have positive impact
  environmentally.
• Rebuilding parts without fixtures (e.g. laser
  additive manufacturing) will reduce the need for
  new parts, reducing energy and material
  consumption.

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Areas for further research Reconfigurable
Tools and Systems . . .

• Industry needs to study and identify regions of
  standardized modularity (size and performance
  ranges) that fit all target applications so the
  real value is quantified
• Studies needed qualify quantify cost
  effectiveness, reliability, simplicity, and
  improved cost models.
• Industrial partnerships, (OEMs) and machine tool
  builders, for more flexible and reconfigurable
  machines and solutions, including software and
  funding profiles.

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Micro-Fabrication Nano-Fabrication
Modeling and Simulation

Reconfigurable Tools and Systems

Sensors
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Sensors will . . .

• enable new, paradigm-shifting mfg processes
  leading to far greater flexibility, adaptability
  and real-time control
• enable efficient virtual factory operations and
  cost reduction- possible more disruption than
  micro or nano-fabrication
• give detailed real-time feedback during the mfg
  process, continuously monitoring the health of
  mfg platforms products being manufactured
• be embedded in large product parts (e.g., an auto
  chassis) monitoring the entire life cycle of
  parts throughout their life
• advance process technology, causing more
  disruption.
• improve performance by intelligent machine tools
  many miniature sensors linked together for
  process monitoring
• cause control processes to use adaptive
  intelligence (adaptive response) moving from
  pre-programmed function (a set of givens)
• become common occurrences in manufacturing
  production processes.
• allow distance sensing and in some cases be
  wireless with small power requirements and the
  ability to transmit and/or receive signals over
  significant distances.
• be reduced in size sufficient that advanced
  micro-sensors will be embedded in Electro-optics
  systems and advanced radio frequency products.

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Scope - Sensors

• These are devices that respond to external
  stimuli and feed that data into a larger
  monitoring, diagnostic and actuation systems

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Current Practice Sensors

• Sensor technology is changing rapidly from
  extended sensors to embedded sensors. Currently
  the commercial industrial base is incorporating
  sensors in all phases of manufacturing and into
  the product. For example, Caterpillar is now
  incorporating sensors into the steel frames of
  their equipment.
• More broadly, sensor fusion sharing of
  information between sensors and other functions
  is an important enabling input today into active
  safety systems, automatic suspension systems on
  cars, as well as climate and heating controls. A
  trade-off being debated related to cost is over
  the number of sensors versus the ability to
  interpret and extrapolate data. Sensors are
  proving their value for lean manufacturing by
  detecting problems early, enhancing product
  quality, reducing scrap and improving
  reliability.

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Future Trends Sensors

• Sensor fusion (combination of and reaction to
  input from multiple sensors), chemical and
  molecular signal generation sensors are on the
  horizon.
• Evolving into miniaturized smart systems.
  Developing wireless networking applications
  linking tiny sensors the size one cubic
  millimeter. Smaller power usage as sensors
  usually off. Need more advanced knowledge
  management programs to use the information from
  these sensors.
• Sensor interface standards are critical. Control
  and communication methodology must progress to
  enable the increases in data input for system
  management.
• Two philosophies - redundancy vs. robustness - no
  clear answer yet. Adding sensors cannot degrade
  the robustness of the production system. The next
  frontier is to make sensing capability inherent
  to the material, not just stuck on or
  molded-in .
• New sensors emerging that, e.g. friend-or-foe
  (FOF), new bio-sensors, gas-detect, optic,
  fatigue, and integrated multi-sensors. These used
  in all areas of manufacturing measurement and
  monitoring. Redundancy will play a larger role as
  advanced sensor technology matures to eliminate
  false readings.
• Some of the funding for radio frequency (RF),
  electro-optic, and bio sensors is being provided
  by individual companies.
• Urgent national security requirement for DOD to
  remain in a leadership role in the areas of
  advanced sensors. For example, the manufacture of
  Combat ID Hot Sensors should remain in the
  U.S. for critical national security reasons.
• Sensor technology is one of the most active areas
  of international research (e.g., bio-sensing in
  Europe may be more advanced than in the U.S.).
  Therefore, U.S. manufacturers will need to
  accelerate their research and development (RD)
  in this arena to remain globally competitive.

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Disruptive State Sensors

• Advanced sensors key to efficient virtual factory
  operations and cost reduction, and the enabler to
  realizing the full benefits of other technologies
  they will be game-changers for the foreseeable
  future.
• Will give detailed real-time feedback during the
  manufacturing process, continuously monitoring
  the health of manufacturing platforms. Ex
  sensors embedded in automotive chasses could
  monitor each chassis throughout its life, from
  the initial manufacturing, to testing, to
  performance in the field.
• Sensors will continue to mature and reach cost
  target goals as micro-electro-mechanical machines
  (MEMs) and nano-technologies become more robust
  and sharply increase demand for various new
  applications. As current radio frequency
  identification (RFID) sensors get cheaper, uses
  for sensor capabilities will expand.
• Miniature sensors will play a key part in the
  advancement of process technology, causing more
  disruption. Intelligent machine tools will rely
  heavily on increased use of sensing of functions.
  These tools will become heavily dependent on many
  miniature sensors linked together for process
  monitoring. The ability to control processes will
  move from pre-programmed functions (a set of
  givens) to adaptive intelligence (adaptive
  response) enabled by sensors.

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Environmental and/or Energy-Related Impacts
-Sensors

• Advanced sensors key to efficient virtual factory
  operations and cost reduction, and the enabler to
  realizing the full benefits of other technologies
  they will be game-changers for the foreseeable
  future.
• Will give detailed real-time feedback during the
  manufacturing process, continuously monitoring
  the health of manufacturing platforms. Ex
  sensors embedded in automotive chasses could
  monitor each chassis throughout its life, from
  the initial manufacturing, to testing, to
  performance in the field.
• Sensors will continue to mature and reach cost
  target goals as micro-electro-mechanical machines
  (MEMs) and nano-technologies become more robust
  and sharply increase demand for various new
  applications. As current radio frequency
  identification (RFID) sensors get cheaper, uses
  for sensor capabilities will expand.
• Miniature sensors will play a key part in the
  advancement of process technology, causing more
  disruption. Intelligent machine tools will rely
  heavily on increased use of sensing of functions.
  These tools will become heavily dependent on many
  miniature sensors linked together for process
  monitoring. The ability to control processes will
  move from pre-programmed functions (a set of
  givens) to adaptive intelligence (adaptive
  response) enabled by sensors.

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Areas for further research Sensors

• Some types of sensors (e.g.., electro optic
  sensors) are being developed globally faster than
  in the U.S. The U.S. needs to remain in the lead
  in certain defense-critical advanced sensor
  technologies, requiring the U.S. to aggressively
  monitor--and utilize--the latest developments in
  sensor research internationally
• Software development and integration for advanced
  sensors need funding profiles and technology
  roadmaps. These roadmaps should illuminate the
  long-term durability of embedded sensors, data
  acquisition, action-integration and control
  systems/mechanisms needed for sensors to enhance
  controls in automated manufacturing.
• There is currently a huge gap between the
  technology available today and the realization of
  potential benefits in application. Areas that
  need to be addressed include applications that
  they could impact, integration, and embedding
  software. Sensor robustness, accuracy,
  reliability and manufacturing costs need to be
  addressed. A study to clarify gaps in development
  and the funding required should be started.

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Micro-Fabrication Nano-Fabrication
Modeling and Simulation

Reconfigurable Tools and Systems
Smart Systems

Sensors
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Smart Systems will . . .

• reduce cost and time in the development of new
  systems
• enhance first-part correct manufacturing (FPC)
  which is the ability to transition from design
  concept to a finished product with absolute
  certainty that a part or product will be produced
  correctly, automatically documenting how each
  part is made, with the ability to transition
  from one to many without interruption.
• self adapt to automatically reduce scrap, rework,
  and setup costs. The application of smart systems
  will involve the use of modeling and simulation
  and knowledge management.

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Scope Smart Systems

• Computer-integrated, electro-mechanical systems
  and processes that have the capacity to learn

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Current Practice Smart Systems

• Smart systems are in development both for
  products and for manufacturing processes.
  Machines already have better understanding of
  manufacturing processes and are better able to
  optimize production, working directly from
  product designs, sensing and correcting problems
  in process through embedded sensors.

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Future Trends Smart Systems

• Intelligent machine tools that are integrated
  into the manufacturing enterprise will be the
  future for manufacturing. Future smart systems
  will be centered on a virtual network of support
  resources and companies. Through virtual systems
  analysis, the impact of 'buy vs. make' will be
  readily apparent early in the quoting or planning
  process. The critical metric of the future will
  be time--the time to design, produce and
  deliver to the customer.
• Smart systems are dependent upon advanced
  sensors, software development, and even modeling
  and simulation for future development. U.S.
  manufacturers have not been able to work
  effectively across industry because of limited
  general purpose software.
• With more dependence in micro-nano and
  bio-technologies, the need for smart systems to
  control these will increase significantly. While
  the demand for more adaptive machining will
  grow, it can be accomplished only with smart
  systems.
• Smart systems will provide the new supply chain
  environment with a virtual or extended capability
  that may extend through several organizations.
  Most if not all information will be handled
  electronically with electronic money as the
  primary exchange. Each OEM or customer will have
  access to a broader network of suppliers with
  standard certifications identified.
• Federal programs that seek to extend the
  knowledge base for smart systems and their
  applications, such as the Defense Advanced
  Research Project Agency (DARPA) Challenge program
  (Prize competition for a driverless cars) could
  be a key development tool for smart systems in
  the future.

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Areas for Further Research Smart Systems

• A study would be useful on the current needs of
  smart systems. For successful advancement, both
  an incremental approach and integration
  demonstrations are required. Researchers will
  need stronger feedback on processing/mechanism/too
  ls to improve existing processes. This research
  should examine the linkage to advanced sensors
  that already exists in the field of modeling and
  simulation. Embedding sensor technology into
  mainstream products such as programmable logic
  controllers (PLCs), and new materials require new
  manufacturing methods and integration to make
  this a smart system.
• A roadmap on smart systems needs to be developed
  and include the following
• Integration of multiple cross function
  technologies/ capabilities
• Cost and ROI analysis in specific applications.
• Smart systems have been very narrowly focused,
  and broader analysis is needed (i.e. across
  industry sectors, and across technologies).

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Micro-Fabrication Nano-Fabrication
Solid Free-Form Fabrication
Modeling and Simulation

Reconfigurable Tools and Systems
Smart Systems

Sensors
43
Solid Free-Form Fabrication (SFFF) will. . .

• probably lead to industry changes that would
  alter the industrial base with a large payoff for
  limited (less than 100 units) production.
• allow industry to make more complex shapes with
  fewer material defects than conventional
  machining or molding due to purity of material
  and more efficient heating. Graded metal
  interfaces may make joint areas stronger and
  not the inherent weak point.

44
Scope - Solid Free-Form Fabrication (SFFF)

• SFFF can be called layered manufacturing,
  additive manufacturing or growing parts. It is
  the ability to create a product (solid) directly
  from powder, liquids without the use of molds or
  tooling.

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Scope - Solid Free-Form Fabrication (SFFF)

• SFFF can be called layered manufacturing,
  additive manufacturing or growing parts. It is
  the ability to create a product (solid) directly
  from powder, liquids without the use of molds or
  tooling.

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Current Practice - Solid Free-Form Fabrication
(SFFF)

• Some industries are already using fused
  deposition modeling (e.g., Stratysys-plastics) to
  make tooling details and secondary structures.
  Further, additive manufacturing of metal
  structures (laser, e-beam, welding) continues to
  evolve and is looking for a niche. DoD is already
  building worm machining parts in the field.
• Rapid Prototyping is a subset of SFFF.
  Currently it is used in metal rapid prototyping
  and heavily used in digital requirements for
  composites. Today this process is cost effective
  for one-off manufacturing (i.e. prototype,
  specialty products). The use of this technology
  for composites tooling is still in its infancy.

47
Future Practice - Solid Free-Form Fabrication
(SFFF)

• Rapid prototyping can generate great savings and
  flexibility. As the process becomes more cost
  effective, SFFF will grow in proportion to the
  material advances and to the accuracy of the end
  product. SFFF needs more RD to make the process
  faster and expand the limits on current
  materials.
• SFFF will become very pervasive as cost comes
  down. The ability to produce complex parts versus
  multiple parts which require significant assembly
  makes this technology category attractive. One
  could imagine layer-by-layer manufacturing
  (deposit, heat, treat, and machine) as opposed to
  just additive. Because of the computing
  requirements, SFFF can overwhelm conventional CAD
  capabilities. There is a need for CAD development
  to support SFFF.
• The increasing trend of transitioning the range
  of techniques from model building to
  prototyping to production parts has made this a
  viable manufacturing option. It allows one to
  create very complex prototypes prior to costly
  manufacture of a product, i.e., using stereo
  lithography. Another potentially disruptive SFFF
  process is the new method of screen printing
  metal powder with a binder and then sintering
  that product to form a final product.

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Disruptive State Solid Free-Form Fabrication
(SFFF)

• SFFF could lead to industry changes that would
  alter the industrial base with a large payoff for
  limited (rate/low quality less than 100)
  production. SFFF will allow industry to make more
  complex shapes with fewer material defects than
  conventional machining or molding due to purity
  of material and less heat required to build the
  product.

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Environmental and/or Energy-Related Impacts
Solid Free-Form Fabrication (SFFF)

• This technology presents tremendous potential for
  scrap reduction and associated avoidance of
  process energy waste. The ability to build
  products directly from powder or liquid versus
  machinery requires less energy and yields less
  scrap. Example a titanium jet and rotor blade
  made from powder required only 5 machinery.
  Direct machining from a block of titanium
  produces 96 chips.

50
Areas for Further Research Solid Free-Form
Fabrication (SFFF)

• Studies need to be conducted on how to improve
  methods and new materials so that producing parts
  through SFFF can be made more effective,
  especially as an aid to mass customization.
• Research on designer materials is needed
  beginning with a study of lessons learned on the
  use of current materials.
• Standardization of models and the ability to
  integrate models done on different systems will
  help this technology. A technology gap analysis
  across different systems would show areas in
  which CAD techniques could be improved to better
  support SFFF.
• Software limitations rooted in the predominant
  languages used today should also be examined to
  identify ways to better support SFFF.

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Micro-Fabrication Nano-Fabrication
Visualization, Planning Knowledge Management
Solid Free-Form Fabrication
Modeling and Simulation

Reconfigurable Tools and Systems
Smart Systems

Sensors
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Visualization, Planning Knowledge Management .
. .

• is a category of technologies that have the
  potential to enable industry to collect,
  synthesize, rapidly transfer, and utilize large
  quantities of data. This capability will
  effectively use new modeling and simulation
  capabilities.
• use on shop floor control systems will enable a
  much higher level of integration between original
  equipment manufacturers (OEMs) and their
  suppliers.

53
Scope - Visualization, Planning Knowledge
Management

• Virtual reality systems that can be used on
  relatively low-end desk top computers.

54
Current Trends -Visualization, Planning
Knowledge Management

• There are elements within all three of the topics
  listed that are potentially disruptive. These
  technologies are a must to achieve desired levels
  of productivity, supply chain robustness, and a
  more disciplined approached to manufacturing
  management.
• Knowledge management is the key enabler here.
  Being able to get the critical information needed
  to manufacturers in a timely fashion is vital to
  having a competitive advantage.
• 3D visualization is beginning to penetrate wider
  audiences, down to 3rd tier suppliers.
  Visualization already allows users to see inside
  large-scale 3D representations of products and
  components. Ex. Motorola engineers use an
  advanced visualization technology to see inside a
  cell phone as it breaks on impact with a hard
  surface facilitating improved construction. DoDs
  Future Combat Systems (FCS) analytical tool is
  taking advantage of this technology to increase
  the visualization capabilities of the agile
  soldier.

55
Future Trends -Visualization, Planning
Knowledge Management

• These technologies are essential for increasing
  the robustness of supply chains, including
  defense supply chains.
• DoD is likely to intensify efforts to get
  information about advanced production
  technologies disseminated more broadly throughout
  the defense supply chain, especially since prime
  defense contractors are relying increasingly on
  their supply chains for manufacturing and
  innovation.
• Promising Precision Theory in mathematics needs
  greater attention and is an underlying
  requirement to see fuller realization of
  technology visualization. Math-based processes
  for visualization and knowledge management are
  needed.
• Research on Knowledge Management standards is
  urgently needed to make knowledge management
  information more useful across industry sectors.
• Technology to mine data is available and some
  decision making tools are available, but
  enterprise integration is lacking..

56
Disruptive State -Visualization, Planning
Knowledge Management

• These items have the potential to enable industry
  to collect, sort, synthesize, rapidly transfer,
  and utilize large quantities of data. This
  capability will effectively use new modeling and
  simulation capabilities.
• Shop floor control systems using visualization,
  planning and technology will enable a much higher
  level of integration between OEMS and their
  suppliers. Advanced software quality assurance
  (SQA) programs will greatly enhance the data base
  capabilities underlying knowledge management.

57
Environmental and/or Energy-Related Impacts
-Visualization, Planning Knowledge Management

• NONE KNOWN AT THIS TIME

58
Areas of Other Research -Visualization, Planning
Knowledge Management

• Need ways to communicate information about
  visualization and knowledge management to SMEs
  (Small Manufacturing Entities) in all industrial
  sectors. Virtual reality applications used to
  simulate various fighter pilot scenarios to
  enhance training prior to actual combat are
  compelling examples of visualization that
  Manufacturing Extension Partnership (MEP) centers
  can use to help the broader industrial-technology
  community understand the power of this
  technology.
• A high priority is standards for knowledge
  management transfer so the knowledge transfer is
  more useful across industry sectors.

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Electricity Electronics

Mechanical Pumps
Hydraulics

• Advanced Manufacturing Curriculum

Machine Tool
CAD CAM Rapid Prototyping

Welding
Pneumatics

Robotics