The Grainger College of Engineering at the University of Illinois Urbana-Champaign is establishing a new center for large-scale additive manufacturing dedicated specifically to the production of metal components for military applications. The project is being funded with 9.06 million US dollars, including 8.15 million from the US Department of Defense. The aim is to develop new processes with which large metal parts can be manufactured directly on site as required – particularly for the maintenance and modernization of military ground vehicles.
“We are building the world’s first university research center focused on large metal additive manufacturing,” Illinois Grainger Engineering mechanical science and engineering professor Bill King, said. “We will conduct fundamental research on material properties and part quality, and we will have a factory demonstration facility to develop new processes and technologies. Grainger Engineering is uniquely positioned to lead this center with our expertise across multiple engineering disciplines and our proven track record of delivering working solutions.”
The cooperation with the US Army’s DEVCOM Ground Vehicle Systems Center (GVSC) and the Rock Island Arsenal Joint Manufacturing and Technology Center (RIA-JMTC) will help to systematically investigate fundamental issues relating to material properties, process control and component quality. At the same time, industrial processes are being developed for scalable application.
“At GVSC, we remain at the forefront of advancing Army readiness by pushing the boundaries of Advanced Manufacturing. Partnering with Grainger Engineering gives us access to world-class research that will help us answer fundamental questions about large-scale metal additive manufacturing and bring those answers to bear on real-world applications,” said David Gorsich, Chief Scientist at GVSC.
A central element of the new center will be a demonstration factory with two large-format metal 3D printers. This will enable the development and validation of new design and manufacturing processes, including sensor technology, material analysis and simulation-based process control. This will make it possible to research the production of complex components with dimensions of several feet under realistic conditions – an order of magnitude that has been little studied to date.
Illinois Grainger Engineering Dean Rashid Bashir added, “The launch of this new manufacturing center, under the leadership of Bill King, marks a significant step forward in our commitment to transforming technologies that serve our nation’s defense and manufacturing sectors. At Grainger Engineering, we are tackling the most pressing challenges in advanced manufacturing and engineering the future through innovation, impact, and excellence.”
“With today’s announced funding, the University of Illinois Urbana-Champaign will be at the forefront of cutting-edge education, research, and development that fortifies our national defense,” U.S. Senator Dick Durbin said. “By supporting large metal additive manufacturing research in collaboration with Rock Island Arsenal, this project will reduce U.S. dependence on foreign manufacturing for metals, contribute more resilient ground vehicles for the Army in the future, and create jobs for Illinoisans. I will continue to push for federal funding that supports national defense operations in our state.”
“It’s wonderful that this area of manufacturing strength within Illinois Grainger Engineering has connected so well with RIA-JMTC and GVSC,” University of Illinois System Vice President for Economic Development and Innovation Jay Walsh said. “This project will create huge impact for manufacturers connected to the Army’s supply chain, bolster the Quad Cities’ workforce, drive innovation in manufacturing and expand economic opportunities across the state.”
“To illustrate the difference, imagine that a vehicle breaks down and needs a new part which is not available in your warehouse,” King said. “With traditional manufacturing, you would need to build a production process from scratch. Two years can pass from the order to the delivery of the first part. With additive manufacturing, you just load the design onto the machine, it prints off the part right then and there, and you know exactly where it came from and how it was made.”
“It’s exciting that we’re going to have this capability because the costs involved in high-end manufacturing don’t often leave room for R&D,” King said. “With this environment, we have room for learning, discovery and development while also addressing important, practical questions for the military.”
In the long term, research at the center should help to make the US Army’s supply chains more resilient, reduce storage costs and improve responsiveness in the field. At the same time, an economic boost is expected for the region around Rock Island, particularly through cooperation with small and medium-sized companies from the manufacturing sector.
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