Visualization, Micro-
Planning & Fabrication
Knowledge Nano-
Management Fabrication
Solid Free- Advanced Modeling and
Form Simulation
Fabrication Technologies
Categories
Reconfigurable
Tools and
Smart Systems Systems
Sensors
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Visualization, Micro-
Planning & Fabrication
Knowledge Nano-
Management Fabrication
Solid Free- Reconfigurable
Form Advanced Tools and
Fabrication Technologies Systems
Categories
Sensors
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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)
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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 R&D in micro-
and nano-fabrication.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Micro-
Fabrication
Nano-
Fabrication
Modeling and
Advanced Simulation
Technologies
Categories
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Current Practice – Modeling & Simulation (M&S)
Advanced (M&S) 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.
M&S 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).
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Current Practice – (M&S) 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
M&S 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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Future Trends – Modeling & Simulation
One of the barriers ahead to effective use of M&S 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 M&S. M&S 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. M&S 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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Disruptive State – Modeling & Simulation
With virtual factory simulation, industry will have the
capabilities to evaluate other manufacturer‘s 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 M&S of highly complex production
systems. E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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. M&S can increasingly replace
physical testing, and ―build/bust‖ development.
Researchers should be able to identify environmental
impacts before system build with M&S.
Better control of manufacturing process through
simulations will lead to reduced energy consumption and
better asset utilization.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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 M&S
Real incentives must be defined to clarify the need for using M&S,
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 M&S, 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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Micro-
Fabrication
Nano-
Fabrication
Modeling and
Advanced Simulation
Technologies
Categories
Reconfigurable
Tools and
Systems
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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-cutting 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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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
cameras—same 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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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:
1. Change the layout and number of machine tools needed to
manufacture, requiring less floor space and fewer facilities.
2. Allow machines to work directly from product designs
3. Correct problems ―on the fly‖
4. Detect and perform maintenance adjustments
5. Adapt themselves to changing conditions.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Micro-
Fabrication
Nano-
Fabrication
Modeling and
Advanced Simulation
Technologies
Categories
Reconfigurable
Tools and
Systems
Sensors
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Scope - Sensors
These are devices that respond to external
stimuli and feed that data into a larger
monitoring, diagnostic and actuation
systems
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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 (R&D) in this arena to remain globally competitive.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Micro-
Fabrication
Nano-
Fabrication
Modeling and
Advanced Simulation
Technologies
Categories
Reconfigurable
Tools and
Smart Systems Systems
Sensors
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Scope – Smart Systems
Computer-integrated, electro-mechanical
systems and processes that have the
capacity to learn
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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/tools 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:
1. Integration of multiple cross function technologies/ capabilities
2. Cost and ROI analysis in specific applications.
3. Smart systems have been very narrowly focused, and broader
analysis is needed (i.e. across industry sectors, and across
technologies).
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Micro-
Fabrication
Nano-
Fabrication
Solid Free- Advanced Modeling and
Form Simulation
Fabrication Technologies
Categories
Reconfigurable
Tools and
Smart Systems Systems
Sensors
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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 R&D 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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Visualization, Micro-
Planning & Fabrication
Knowledge Nano-
Management Fabrication
Solid Free- Advanced Modeling and
Form Simulation
Fabrication Technologies
Categories
Reconfigurable
Tools and
Smart Systems Systems
Sensors
E. W. Palsrok, Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Scope - Visualization, Planning &
Knowledge Management
Virtual reality systems that can be used
on relatively low-end desk top computers.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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. DoD‘s Future Combat Systems (FCS) analytical
tool is taking advantage of this technology to increase the visualization
capabilities of the ―agile‖ soldier.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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..
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
Environmental and/or Energy-Related Impacts -
Visualization, Planning & Knowledge Management
NONE KNOWN AT THIS TIME
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
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.
E.W. Palsrok-Dir. Workforce Development
West Shore Community College
% of Opinions - 35 Top Executives
Timelines to Disruption
60%
50%
40%
% Responding
30%
3-5 Yrs
6-10 Yrs
20% 11-15 Yrs
10%
0%
Micro & Nano Modeling & Reconfigurable Sensors Smart Systems Visualization,
Solid Free Form
Fabrication Simulation Tools & Systems Fabrication Planning &
Know ledge
Management
E.W. Palsrok-Dir. Workforce Development
Technology Topics West Shore Community College
Electricity
Electronics
Mechanical & Hydraulics
Pumps
Physics
CAD – CAM & Machine Tool
Rapid Chem Math
Biology
Prototyping
Welding
Pneumatics
Robotics
E. W. Palsrok, Dir. Workforce Development
West Shore Community College