As part of a DARPA-funded project, Worcester Polytechnic Institute (WPI) in Massachusetts is working on a new additive manufacturing process that will transform metal scraps into high-quality components. The research team is receiving around 6.3 million US dollars for the project entitled “Rubble to Rockets”. The aim is to be able to manufacture functional components without access to conventional supply chains, even under difficult conditions such as on the battlefield or in remote regions.
At the heart of the project is a data-driven approach to processing scrap metals and mixed alloys. Using machine learning, the system analyzes the composition and behavior of different materials before they are processed through an additive process.
“This work is crucial as it allows us to build high-quality components from unknown source materials with new confidence,” said Associate Professor Danielle Cote, Harold L. Jurist ’61 and Heather E. Jurist Dean’s Professor of Mechanical and Materials Engineering, and the lead researcher on the project. “Our goal is not just to build a single solution but to create a framework that guides future innovations. By improving our predictions and understanding of material performance, we can pave the way for new advancements in additive manufacturing from diverse and unpredictable sources.”
Among other things, the AI platform from Citrine Informatics, which can predict material properties across different compositions, serves as the technological basis. The resulting automation of material characterization should save time and resources without compromising the quality of the end products. A prototype of a sounding rocket will later be used to test the mechanical properties of the components obtained in this way under real loads.
“The future of manufacturing is at the intersection of so many disciplines, including software, robotics, AI, materials science, and mechanical engineering,” said Aaron Birt ’17, CEO of Solvus Global, a subcontractor on the grant. “This is one of those rare opportunities that demonstrates the breadth of technical expertise required to deliver a solution for manufacturing at the point of need anywhere on Earth, the moon, or beyond. That proposition shows the genuine ability of this team to imagine and deliver solutions of tomorrow.”
“VALIS was founded on the mission of delivering enabling technology to maximize the recovery of valuable materials for future generations,” said Emily Molstad ’19, MS ’19 co-founder and CEO of VALIS Insights, a grant subcontractor. “We see the recycling industry becoming more and more vertically integrated as raw material producers and manufacturers aim to secure a reliable supply of scrap material and increase recycled content to drive down costs. The technology being developed through this program will unlock new levels of upcycling capabilities not only in remote, resource restricted locations, but across the recycling value chain with the potential to strengthen domestic manufacturing capabilities.”
In the long term, applications outside of military contexts are also planned, for example in energy supply, aviation or disaster relief. In addition to the WPI, companies such as Siemens, Nightshade Corporation and two start-ups led by alumni are also involved. The project period is expected to end in November 2027.
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