Convergent Manufacturing: A Future of Additive, Subtractive, and Transformative Manufacturing Proceedings of a Workshop (2022) / Chapter Skim
Currently Skimming:
2 Resilient Design and Multifunctional Materials
2 Resilient Design and Multifunctional Materials
Pages 3-25
The Chapter Skim interface presents what we've algorithmically identified as the most significant single chunk of text within every page in the chapter.
Select key terms on the right to highlight them within pages of the chapter.
From page 3... ...
He highlighted ongoing nationwide initiatives to develop a convergent manufacturing platform and described a vision for the future to deliver agile, resilient, and versatile advanced solutions in a unified manufacturing platform for the mission, equipped with the convergence of designs, materials, tools, and processes to augment soldiers' functionality for combat and to reduce dependency on supply chains for critical materials and their applications. Traditional manufacturing processes are discretized in terms of their applicability and material-specific process optimization; have limited adaptability in terms of materials and design configurations; and require assembly, finishing, and packaging with separate sequential processing steps, increasing overall cost and turnaround time for logistics (see Bapat et al., forthcoming)
|
From page 4... ...
He emphasized that convergence in a unified manufactur ing platform enables progress beyond Industry 4.0,1 with the use of digital and physical footprints in designs from nature, heterogeneous critical materials2 for multifunctionality, manufacturing tools for resilience, manufacturing processes for agility, and a sensor network for detection of critical interfaces (see Malshe et al., 2021)
|
From page 5... ...
Convergent manufacturing is a key objective for the Army over the next 15 years, which could be realized with the ongoing automation of traditional manufacturing industrial practices and by combining multiple technologies into a single robust and agile manufacturing capability. He asserted that with the convergence of digital and physical manufacturing domains, integration of traditional manufacturing and hybrid manufacturing, advanced manufacturing, intelligent design philosophies, improved digital enterprise, virtual manufacturing, automation, and improved quality inspection, systems could be more capable and available to address multidomain objectives.
|
From page 6... ...
TACOM set the following two strategic goals to support the Army's 2018 Additive Manufacturing Campaign Plan: (1) augment supply chain responsiveness in the strategic support area now to produce parts used in the organic industrial base and (2)
|
From page 7... ...
Although this concept is simple, it is very difficult to execute. One approach would be to leverage advanced technologies across the entire Army organic industrial base to complement traditional manufacturing when the need arises.
|
From page 8... ...
as a platform to develop a digital twin9; the goal is to better define what portions of the M113 should have evolutionary technical data developed and integrated into the future acquisition plan. A digital thread enables data sharing across industrial operations and sustainment operations at the tactical and operational levels.
|
From page 9... ...
Kurfess acknowledged that the digital thread enables rapid movement of new technologies into operations. PANEL 1: MULTIFUNCTIONAL MATERIALS DESIGN Charles Kuehmann, Vice President of Materials Engineering, Tesla/SpaceX Kuehmann explained that despite the existence of an advanced design toolbox to develop multifunctional materials, a question remains about which materials to design, with consideration for the following hierarchy: (1)
|
From page 10... ...
" She emphasized that processes for manufacturing strong and heavy materials as well as those for manufacturing lightweight and weak materials are well established; however, it is important to consider how to make materials that are simultaneously lightweight and mechanically resilient. To achieve this, she proposed applying the concept of architecture to materials design.
|
From page 11... ...
This technique is also amenable to custom resin synthesis. Greer outlined several other applications, including the use of additive manu facturing for nano-photonics; vat polymerization for a hydrogel infusion additive manufacturing process to swell in metal ions from their salts and convert printed metal oxides to metals; biomolecular surface functionalization to target agents for chemotherapy; the use of machine learning processes to create bio-scaffold design
|
From page 12... ...
Wei Chen, Wilson-Cook Professor in Engineering Design, Northwestern University Chen remarked that multifunctional materials represent the future, owing to their superior performance. Most existing systems are designed by trial and error or are based on engineers' intuition; instead, it is important to develop efficient and intelligent computational design methods to automate the design process of these heterogeneous materials.
|
From page 13... ...
techniques for fast 3D design integration and exploration; creating a multiscale design framework for heterogeneous systems to exploit hybrid manufacturing capability; and integrating manufacturing process impact into topology optimization. LaShanda Korley, Distinguished Professor, Departments of Materials Science and Engineering and Chemical and Biomolecular Engineering, University of Delaware Korley discussed the convergence of molecular design, assembly, and manufacturing through a bio-inspired lens, with particular emphasis on how molecular design of functional materials enables strategic property development.
|
From page 14... ...
Question and Answer Session Moderator Christina Baker, Director of Additive Manufacturing, PPG Indus tries, asked how students could best prepare for future work in convergent manu facturing as well as what critical research gaps remain to achieve multifunctional convergent hybrid manufacturing. Kuehmann emphasized that to push back against design requirements, one would need a broad understanding of how sys tems work; therefore, students should seek fundamental knowledge in a broad range of systems (i.e., materials students would take mechanical design classes)
|
From page 15... ...
Korley advocated for taking advantage of advances in catalytic technology and new synthesizing schemes that start with natural materials to create specific building blocks, which could be added to the existing value chain as building blocks for new materials that capture many of the properties and add functionality and sustainability. Baker also inquired about the potential for integrating nanoscale additive manufacturing into larger-scale additive manufacturing, and Greer described this integration of nanoscale additive manufacturing as a real challenge.
|
From page 16... ...
Abhir Adhate, Product Director, Modeling & Simulations, Sentient Science Adhate emphasized the value of rapid and accurate material microstructural tools for heterogeneous materials development and design. Additive manufactur ing techniques allow for the embedding of heterogeneous materials in compo nents in new and interesting ways.
|
From page 17... ...
Convergent platforms rely on models as part of quality assurance, and he stressed that understanding the intended microstructure at the interfaces of heterogeneous materials is critical for quality assurance. To achieve agile, versatile, and resilient manufacturing capabilities at the point of need, convergent manufac turing platforms would need in situ monitoring and defect correction capabilities, which require the ability to quickly develop material models, share material models seamlessly, and maintain open access to machine APIs.
|
From page 18... ...
. The initial product created via two-photon lithography undergoes advanced metrol ogy and biological validation before machine learning is applied to compare the new product to the original system.
|
From page 19... ...
Question and Answer Session Moderator Jian Cao, Cardiss Collins Professor and Founding Director of the Northwestern Initiative for Manufacturing Science and Innovation, Northwestern University, observed "point of need" as a common thread among all the panelists' presentations in this workshop, particularly in relation to repurposing, detection and repair, surface interaction, democratization of biomanufacturing processes, and supply chain agility. She asked about the barriers at the point of need as well as the system-level implementation of technology needed to overcome them.
|
From page 20... ...
This approach would offer the benefits of modularity without the detriments of additional interfaces -- it minimizes the total consumption of dangerous or scarce materials by recovering them for safe reuse. Cao wondered what manufacturing methods could be used to design material with a heterogeneous interface to enable easy separation for later reuse.
|
From page 21... ...
Adhate suggested open machine APIs and a common language between them to enable convergence. Dravid stressed the need for better workforce development to address gaps in manufacturing, with a value chain of talent at both the college and community college levels.
|
From page 22... ...
He added that most computer-aided design software only assumes uniform material properties -- a gap that should be addressed. Cao asked about the challenges of processing multiple materials within a single system, and Dravid used electron microscopy as an example and discussed the dichotomy between hard (e.g., metals)
|
From page 23... ...
Wolf posed a question about the roles of the digital twin and digitization in supporting the evolution of manufacturing capabilities. Adhate remarked that the digital twin is most useful when good telemetry from the field can support sustainment.
|
From page 24... ...
Adhate emphasized that undergraduate and graduate programs should prepare engineers with the right design mentality10 to effectively exploit heterogeneous and multifunctional materials. Toussaint commented that data have to be extracted at multiple scales in a variety of environments and then fused, and he suggested rediscovering the types of metrics and measures needed at these various scales and the types of metrology platforms required to extract these data.
|
From page 25... ...
2020. Extreme mechanical resilience of self-assembled nanolabyrinthine materials.
|
Key Terms
This material may be derived from roughly machine-read images, and so is provided only to facilitate research.
More
information on Chapter Skim is available.