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ADDITIVE MANUFACTURING/3D PRINTING FEATURE


machine learning system that utilises artificial intelligence (AI) to ensure future design work becomes even smarter. “The AI engine in the design phase has


learning and heuristics capabilities,” said Dr. Bogomolny. “It creates repeatability, accuracy, standards, and the ability to streamline the operation through remembered systematic processes that can be applied repeatedly allowing automation to begin taking place in developing the output.”


Beyond manufacturIng executIon


Once a component has gone through the DfAM and simulation processes it can then automatically move to a manufacturing execution system provided by AMFG. Headquartered in Austin, Texas, AMFG designs MES and workflow software that enable businesses to more easily transition to digital manufacturing. The AMFG software manages the production of


the additive or subtractive manufacturing system. This includes auto scheduling, auto routing of parts, and managing all 3D printers – both internally for the Navy, or manufacturer, as well as any external solutions that may be required. “The system will guide certain decisions


like logistically where that part should be produced based on certain requirements, based on resources, and any complexities within the workflow to execute that project effectively,” explained Luke Bierman, head of U.S. sales for AMFG. However, this solution will go way beyond


the execution and management of these manufacturing systems. It is also able to capture data-driven insights from the beginning concept through to the end of the process where that component has now been validated or certified. “This is where it really gets to be cutting edge,


because you can take that data from the entire process and continually improve that part,” enthused Shuppert. “Not only are you going to be making them faster and more efficiently, but each component can now be easily revised


The Additive


Manufacturing process


as technology advances to create an even more superior version.” The system can also capture intelligence


around what is actually happening to the component throughout its lifecycle, known as product lifecycle management (PLM). This data would be used to create a digital twin which will provide further insights into both the part’s design and maintenance requirements. “Let’s say you have a component that needs to


be switched out every four years,” says Bierman. “The software can then schedule a replacement component to be printed and delivered right before that maintenance is set to occur. So, you can see where this begins to create a smart industry that is both proactive and intuitive.” This type of data could also greatly reduce


the heavy burden currently being placed on the DoD and the Defence Logistics Agency (DLA) by minimising, or even eliminating, supply chain problems and the need for massive areas of inventory. “If you’re able to execute components


anywhere in the world in under 24 hours, maybe you don’t produce and store all these components in order to satisfy some sort of


critical inventory,” says Bierman. “You could now just create them on-demand using a virtual inventory.”


InspectIon and certIfIcatIon


Quality, security and traceability were also key factors for this new integrated system. For the DoD, parts must be certified before they can be deployed for service. “Every part has to meet certain requirements,


whether that is AS9100 for aerospace, IATF 16949 for automotive, or a certified part for the Navy,” explains Bierman. “Through this platform, we can verify that the component is 100% capable of being used for its application.” That process begins as soon as the part is


manufactured and then inspected with either an industrial CT scan or laser scanning device. The software takes the original CAD file and can find any geometrical deviations and advance or eliminate the component automatically. These capabilities can be further expanded when needed to incorporate non-linear acoustics or wave stimulation – like MASER – as the inspection method. All the inspection data is again processed


back into the AI where it is able to learn how to decrease the number of disqualified parts in the future. “Once that’s certified, we can take all that


metadata and upload it into a repository of certified components that going forward can be consistently executed around the globe at any site that meets those requirements to execute that with the same exact process,” said Shuppert. That repository of data analytics could then be


The Navy want to be able to just push a button and have that part start printing directly on the ship’s 3D printer


applied to future projects for not just the Navy, but across the entire military supply chain. The final goal of this strategy was to optimise


cybersecurity protections throughout the process. This requires the digital manufacturing interface to adhere to any Cybersecurity Maturity Model Certification (CMMC) level requested by the Navy, which can be as high as Level V. The DoD is also looking to increase the security of its digital data and network connections. As part of that, digital twin technology will be used to validate and prevent tampering with the DoD’s digital supply chain.


CAD / CAM Services www.cadcam.org


NOVEMBER 2022 DESIGN SOLUTIONS 53


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