America Makes and the National Center for Defense Manufacturing and Machining (NCDMM) have announced the winners of a $6.6 million grant project. The project, funded by the Office of the Secretary of Defense Manufacturing Technology Program (OSD ManTech), is called IMPACT 2.0 (Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis) and aims to use additive manufacturing technologies to improve lead times, productivity and yields in the casting and forging industry.
Additive manufacturing (AM) has shown particular promise in the aerospace and defense sector, as it enables shorter production times and lower component weights. These advantages are crucial for the development of new systems as well as for the maintenance of existing systems. A key aspect of the project is the development of data-based qualifications and performance standards to ensure the use of the technology in extreme environments. The focus here is on the integration of new metallic materials whose properties are to be optimally utilized.
“For nearly two decades, challenges related to capability and capacity have significantly impacted the U.S. casting and forging industry, creating obstacles in sourcing essential components for critical military equipment and support platforms,” said John Martin, Research Director at America Makes.
Martin emphasized that the expansion and scaling of additive manufacturing methods under real production conditions is necessary in order to minimize risks in the supply chain. IMPACT 2.0 will enable project teams to develop practical solutions for these strategically important manufacturing processes. In the long term, the project aims to strengthen the stability of the defense industry and the economy.
“Addressing these challenges is crucial for defense and economic stability. While many additive manufacturing technologies can enhance casting operations and have proven effective across other sectors of the supply chain, augmenting and scaling these capabilities while testing them in real-world demand situations is essential. The IMPACT 2.0 project call is designed to pinpoint the strengths and limitations of these integrated manufacturing approaches. This initiative will empower our members and project teams to research, develop, and execute cutting-edge solutions in the casting and forging sector, a strategic move to mitigate supply chain risks that pose a threat to both the nation’s defense and economy,” Martin added.
With the increasing establishment of AM technologies in the casting and forging industry, new standards could be created and supply chains in a critical area could be sustainably optimized.
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