American Makes Unveils 7 Cutting-Edge Additive Manufacturing Projects with $11M Investment

In an aggressive move to drive technological innovation in manufacturing, American Makes, in collaboration with the National Center for Defense Manufacturing and Machining (NCDMM), announced the unveiling of seven groundbreaking projects. With a total investment of $11 million from the federal government and industry, the project highlights the United States' emphasis on developing additive manufacturing capacity while concurrently cultivating a knowledgeable, forward-thinking workforce.

At the root of this release is a two-pronged strategy that targets both revolutionary technology and comprehensive workforce training. One American Makes operations director commented on the need to pair industrial R&D with robust education and social services programs. The dual effort should not just speed up innovative technology creation and commercialization, but also ensure that manufacturing workers possess the necessary competencies to capitalize on these advancements.

The projects will tackle five key technical areas—design, materials, processes, value chain, and the additive manufacturing genome—while simultaneously covering workforce, education, and social service (WEO) program requirements. The integrated approach is intended to spur the creation of innovative solutions that are commercially relevant and viable in the long term.

Headed by Carnegie Mellon University and supported by industry partners like Lockheed Martin and Siemens, the project will address the challenges involved in designing and producing 3D core structures for aerospace. Using finite element analysis, nonlinear high-dimensional optimization, and advanced design-for-additive-manufacturing (DFAM) methods, the group seeks to break through the constraints of traditional manual design approaches. Simultaneously, a set of computer lectures, software packages, and tutorials will be created to assist in industry training.

Led by the University of Texas at El Paso (UTEP), the project aims at the merging of large-scale additive manufacturing capability with in-situ wiring systems. Through the creation of hardware and software solutions, the project is to translate complex 3D wiring patterns into five-axis machining paths to be directly run on BAAM (Big Area Additive Manufacturing) machines.

Additionally, the project seeks to start distance-based engineering training courses in order to equip new graduates with skills to meet possible future industry employment.

Headed by a subsidiary of Lincoln Electric, the project will create a large metal part-producing, scalable, multi-axis robot system. Through the refinement of an existing "CAD-to-path" software tool and conducting wide-ranging process testing, the project will work towards closing the void between existing prototype solutions and an integrated commercial 3D printing system. The end product is expected to be a robust software tool with the potential to fulfill both mid- and large-scale manufacturing demands. Biomimetic Materials for Multi-Jet Printing (MJP)

Led by 3D Systems and in cooperation with leading military research laboratories, the effort will bridge the biomimetic printable materials shortfall for the medical community. The study will normalize raw materials, create benchmarked performance standards, and optimize microstructural controls. Concurrent with the technical advancement, customized training modules for medical professionals will be created to incorporate these new materials into surgical planning.

This project, led by Phoenix Analysis and Design Technologies in partnership with Honeywell and Arizona State University, is dedicated to the development of a non-empirical, physics-based model capable of accurately forecasting the performance of lattice structures that have been 3D printed. By incorporating a number of additive manufacturing processes such as fused deposition modeling, laser powder bed fusion, and electron beam melting, the project aims at enabling enhanced material efficiency as well as design simulation optimization. An online "live" textbook and tailored courses will be included in the educational outreach for successful technology transfer.

With the support of industry partners such as Ford and academic partners such as Penn State, this project aims to transform the metal casting industry. Through the creation of next-generation sand printers, the project team plans to make the production of cores and molds more streamlined so that the integration of additive manufacturing into conventional casting workflows can be both economically feasible and scalable. Comprehensive seminars, mentorship, and online modules are envisioned to facilitate workforce training and enable industry-wide adoption. Multi-Material 3D Printing of Embedded Electronic Structures and Devices In a project headed by Raytheon and with the participation of industry giants like GE, the initiative aims to combine 3D printed structural components and electronics. It aims to break the constraints of 2D designs by providing integrated, high-density, and affordable solutions for aerospace, defense, biomedical, and commercial uses.

To provide a seamless transition from research to the real world, the project incorporates the creation of web-based certification courses and laboratory training programs for engineers at all levels.

A New Era in Manufacturing These seven projects are about more than just technological achievements—they are a sign of a wise philosophy that combines innovation with practical workforce development. As these projects mature, they are poised to spur a staggering transformation in the way industries approach the design, manufacture, and integration of sophisticated processes and materials.

At Kazida Global, with over 30 years of machine tools industry experience, we understand the importance of staying in step with a rapidly developing industry. As we expand our global reach, insights from projects like these are invaluable. They not only look to the future of manufacturing but also to the global shift toward smarter, more efficient production processes. By staying abreast of the current trends and investing in state-of-the-art technologies, we are committed to delivering innovative solutions to our clients worldwide. This innovation wave, driven by private and public investments, promises a bright future for additive manufacturing. It once again demonstrates the critical contribution made by cooperation among industry, academia, and government to sustaining competitive advantage and achieving sustainable development in the world economy.