Workshop Descriptions

Accelerating Fuel Cell Development – Attacking Cost and Size

The goal of this workshop is to identify key technological issues hindering the widespread usage of fuel cell devices. Three areas will be addressed:

  1. Applying lower cost manufacturing methods to system components and near net shape parts,
  2. Applying micro- and nano- technologies to alternative fuel cell configurations and designs, and
  3. Developing inspection and measurement techniques for achieving high dimensional tolerance.

Building off common issues, collaborative projects will be further defined, including project participants and possible funding sources.

Specific Objectives

Project Resources Required

A willingness to work collaboratively in the development of high volume applications of fuel cells, including furnishing resources, in-kind work and other active contributions to a project.

Who Should Attend

Companies and organizations involved in any aspect of the applications of fuel cells including designs, material supply, manufacture, and use.

Background

At the 13th Annual NCMS Technical Conference in Orlando, Florida, a fuel cell workshop identified 14 broad areas for collaboration. In subsequent discussions with the workshop participants, these opportunities were narrowed down to three areas, which are the subject of this two-day workshop.

Agenda

Monday 9/27

9:00am Introductions and Workshop Objectives
Chuck Ryan, Program manager, NCMS
9:30am Introduction to Fuel Cells
Joseph King, International Fuel Cells
10:15am Break

Topic Area: Applying Lower Cost Manufacturing Methods to System Components and Near Net Shape Parts

10:30am Bipolar Plate Processing
Jim Dayton, IFC
11:15am Fabrication of Ultra Low Pt-Loaded MEAs Using Large-Area Vacuum Deposition Techniques
Jim Arps, Southwest Research Institute
12:00pm Lunch
1:30pm Electrochemical Technologies for Low-Cost Manufacturing of Fuel Cell Components
Maria Inman, Faraday Technologies
2:15pm Silicone Gasketing via Screen Printing Process
Roy Harwell, Harwell International
3:00pm Break
3:15pm Attack Costs Early and Often: Predictive Process Management is the Way to High-Volume, Low Cost Fuel Cell Manufacturing
Rob Gardier, Praedictus Corp.
4:00pm Session Summary and Actions
4:30pm Adjourn
Tuesday 9/28
9:00am Workshop Update
Chuck Ryan, NCMS
Topic Area: Applying Micro- and Nano-Technologies to Alternative Fuel Cell Configurations and Designs
9:15am Microelectromechanical Systems (MEMS) Manufacturing Technologies as Applied to the Development of Embedded Micro Fuel-Cells
Tubular and Three-Electrode Configurations as Alternative Fuel-Cell Designs: Catch the Wave
Michael Miller, SwRI
10:15am Break
10:30am Microprocessing and Microdevices
Margaret Steinbugler, IFC
11:15am Session Summary and Actions
12:00pm Lunch
Topic Area: Inspection and Measurement Techniques for Achieving High Dimensional Tolerance
1:30pm Fuel Cell Stack Leak Characterization
Ross Bailey, Ballard Power Systems
2:15pm Preparing for Collaboration
2:30pm Break
2:45pm Summarize Topic Areas and General Discussions about Needs in the Manufacture of Fuel Cells
Workshop Participants
3:30pm Identifying Common Issues, Defining Collaborative Projects, and Action Steps
Chuck Ryan
4:30pm Adjourn

Contact: Chuck Ryan, 734-995-4905

Business Integration for Automating Manufacturing Value Chain Processes

The goal of this workshop is to bring together industry, DoD maintenance/logistics, and technology provider organizations to form one or more collaborative projects to extend, explore and validate the production readiness of the Computer Aided Business Integration (CABI) framework that has been defined and prototyped by NCMS Project Endeavor. The CABI framework is an information system architecture implemented with commercial technology that provides a platform for efficient, flexible integration and management of business processes, data, and legacy systems as well as new applications, within an enterprise or across a supply chain, and for Internet E-Commerce. The project will include one or more pilot implementations in the defense maintenance and logistics community and commercial industry.

Specific Objectives

Project Resources Required

Attendees from industry and the defense community should be ready to define a business problem with a realistic opportunity for a pilot implementation of a CABI-based solution that will generate conclusions and metrics reasonably representative of a production environment. This will require commitment by management of human and information technology resources. Attendees should be aware of cost share/in-kind requirements and their own company mechanisms for involvement.

Who Should Attend

Companies planning to attend this session should include a combination of business management as well as technical expertise. Emphasis will be placed on identifying significant opportunities for measurably improving business process performance in engineering, manufacturing, maintenance, and E-commerce/supply chain domains.

Background

NCMS and a consortium of industry and technology provider members have collaborated over two years in Project Endeavor and a Phase 1 pilot under the DoD CTMA program to define and prototype a cost effective, flexible information technology architecture that can be implemented with commercial (COTS) technology across manufacturing industries to get more value from the investment in existing systems and solve problems like:

Achievements have been demonstrated. A follow-on phase is to be proposed.

Agenda

9:00am Introduction
Bill Waddell, Program Manager, NCMS
9:20am The Target Business Problems
Mike Fancher, CEO, Concentus Technology Corporation
10:00am Review of the CABI Framework and State of the Technology
Jay Ramanathan, CTO, Concentus Technology Corporation
10:45am Break
11:00am Readiness Issues, Opportunities
Mike Fancher
11:30am Tobyhanna Pilot Status
James Kachmarsky, Tobyhanna Army Depot
12:00pm Lunch
1:30pm Discussion of Concepts for Phase 2
Bill Waddell
2:00pm Break
2:15pm Defining Possible Collaborative Project(s) and Project Participants
Workshop Participants
Bill Waddell
3:30pm Wrap-up
Bill Waddell
4:00pm Adjourn

Contact: Bill Waddell, 231-264-9774

Elimination of Phoscoating in Metal Forming Processes

The goal of this workshop is to discuss practical ways in which phoscoating can be eliminated from critical metal forming processes; forgings and extrusions. Users and technology providers will jointly consider whether a collaborative project can be formed based on promising technologies, innovative metal forming applications, and the availability of process trials on the shop floor.

Specific Objectives

Project Resources Required

NCMS will be seeking user facilities to validate and evaluate promising phoscoating replacements. A history of the phoscoating process and its requirements will enable a focused look at replacement candidates. At least 4 promising technologies will be presented for consideration as a collaborative project foundation.

Who Should Attend

Senior product and manufacturing engineering and procurement resources responsible for metal forming and metal forming support (procurement, quality, environmental) should consider attending this innovative workshop. Technology providers will rely on the technical assessment of the users to determine whether they should plan for a collaborative offering.

Background

Kinefac Corporation believes that phoscoatings can be replaced for many of the precise metal forming applications and processes currently utilized by U.S. companies. They have agreed to co-lead a workshop for the investigation of this topic with resources from GM Delphi Saginaw.

Agenda

9:00am Workshop Objectives
Kerry Barnett, NCMS
9:30am The Phoscoating Dilemma
Howard Gries, President, Kinefac Corporation
10:30am Impact of Phoscoating on Future Business
Ravi Duggirala, Delphi Saginaw Systems
11:15am Promising Technology Areas
TBD
12:00pm Lunch
2:00pm Promising Technologies
TBD
3:00pm Break
3:15pm Economic Impact of Phoscoating Replacement
TBD
4:15pm Collaborative Opportunities
Kerry Barnett
5:15pm Adjourn

Contact: Kerry Barnett, 734-995-4974

Environmentally Friendly Machining

The goal of this workshop is to identify participants and develop a scope of effort for a set of collaborative projects on the topic of environmentally friendly machining. The primary focus will be on the elimination or minimization of Metal Working Fluids which will have significant impacts on investment cost, variable cost, production system flexibility and environmental concerns. Additional focus areas may include airborne particulates, noise, energy consumption, etc.

Specific Objectives

This project seeks to identify and integrate available island solutions for environmentally friendly machining, identify technological gaps and pursue development for these needs. This work will form the basis for a complete concept for an environmentally friendly machining production system that will reduce both economic and environmental costs.

Some of the technical challenges to be addressed for such a system include:

Project Resources Required

Who Should Attend

Users

Developers

Commercializers

Background

The use of MWF’s often comes at great financial and environmental costs. The use of MWFs leads to significant investment and variable costs for MWF system components such as:

For many production systems, particularly high-volume transfer lines, central MWF systems greatly constrain equipment flexibility since machinery must be placed in proximity to the central swarf tunnel. Utilization of MWFs also has environmental consequences, both human and ecological. Oral and physical contact with MWFs for production workers is a concern, as is environment.

Agenda

9:00am Introductions and Purpose
Mike Gnam, NCMS
9:30am EFM Project Vision
Rich Furness, Engineering Specialist, Ford
10:00am Ford Initiatives
Jon Johnson, Ford
10:30am Break
10:45am Caterpillar Perspective
TBD, Caterpillar
11:15am Integrating Health & Environment in the Mfg Enterprise
Dr. Bert Erdel, MAPAL
12:00pm Lunch
1:30pm Dry Machining in Prismatic Parts
Phil Szuba, Ph.D, Manager of R&D , Lamb Technicon
2:00pm Cross-Huller Perspective
Russ Manasse, Cross- Huller (invited)
2:30pm Break
2:45 pm Group Discussion of Future Project(s)
Rich Furness, Ford
4:00pm Next Steps
Mike Gnam, NCMS
4:30pm Adjourn

Contact: Mike Gnam, 734-995-4971

Environmental Roadmapping Initiative (ERI)

The goal of this workshop is to initiate environmental roadmaps for sectors concerned with their future environmental action plan. NCMS, in partnership with the EPA, is starting a new opportunity for industry sectors to chart their own environmental course into the coming century. The workshop will explain the details of the program and seek input from participants regarding environmental needs. Currently, environmental roadmapping activities are underway for both the construction industry and municipalities.

Specific Objectives

Who Should Attend

Agenda

12:00pm Lunch
1:30pm The ERI Opportunity — Goals, Funding
NCMS
2:15pm Environmental Management Systems and ERI
Paul Chalmer, Program Manager, NCMS
2:50pm Break
3:00pm Sector Opportunities in ERI
Group discussion
4:00pm Next Steps
Group
4:30pm Adjourn

Contact: Paul Chalmer, 734-995-4911

First Part Correct – Aluminum Components from Forgings

The goal of this workshop is to understand and quantify the distortion of large forged aluminum components and develop a means to eliminate or mitigate its effects by design and manufacturing process techniques. The project deliverables will be the analytical models of the parts selected for this study and actual samples produced with both existing and new strategies. Design and manufacturing specifications will be provided for the entire process from concept drawings, best manufacturing practices, to final inspection. A forging knowledge base, consisting of knowledge of the product, tooling, process, shape-sequencing, and material properties will be generated.

Specific Objectives

Project Resources Required

This workshop takes a system-level view of the forging process. It touches upon design and processing issues for net shape geometries, materials, dies/tooling, lubricants, and equipment. An emerging project will require resources with expertise in manufacturing processing (tooling, dies, lubricants, equipment, controls), materials science, modeling and analysis, intelligent software systems, and high performance computing.

Who Should Attend

This workshop will focus on large aluminum forgings, however, elements of the workshop should prove interesting to anyone connected with the manufacture of forgings, from conceptual design through final inspection. The workshop also should be of interest to users of forgings.

Background

The U.S. forging industry provides critical components to products that represent 20% of the gross national product while profits for this highly competitive industry are only on the order of 1 to 2%. The industry has seen a 25% reduction in commercial membership with the loss of over 100 forging plants since 1980. Much of this erosion is the result of manufacturing shifts to competitors in Pacific Rim countries that typically provide government subsidies to their critical-technology areas. To compete successfully, domestic forging companies need to produce quality forgings with shorter lead times and at better value.

Agenda

Monday, 9/27
12:00pm Lunch
1:30pm Introduction and Expectations
Daniel Maas, CTO, NCMS
1:50pm Keynote: Defining Problems and Requirements from an OEM Perspective - Boeing
Brian Dods, Manufacturing Specialist, Boeing St. Louis
2:30pm Defining Problems and Requirements from an OEM Perspective – Sikorsky
Steve Varanay, Chief, Manufacturing Technology, Sikorsky Aircraft Corporation
3:00pm Future Requirements for TACOM
Vickie Furman, US Army TARDEC
3:20pm Break
3:40pm Discuss Challenges Facing the Forging Industry
George Mochnal, Director, Research & Education, Forging Industry Association
4:05pm Forging Industry efforts to Improve Forging user Friendliness
Bill Richards, Manager of Concurrent Engineering, Alcoa Forged Products
4:30pm Capabilities of Precision Forgings
Phil Keeler, President, Aluminum Precision Products
4:55pm Summary of what we have learned so far
Bill Kuhlman, Consultant, Metalworking Consultant Group
5:15pm Adjourn
Tuesday, 9/28
9:00am Supply Stream Management to make Forgings Easier to use
John Culp, Manager R&D, Weber Metals
9:20am Discuss State of the Art of Aluminum Forging Processes
Dennis Masterson, Consultant, Metalworking Consultant Group & DPM Enterprises
9:45am Discuss State of the Art of Machine Tools for Machining Aluminum Forgings
Rich Curless, Vice President, Technology, Cincinnati Machine
10:10am Discuss State of the Art of Die Materials, Die Manufacturing and Lubrication
Taylan Altan, Professor & Director, Net Shape Manufacturing, OSU
10:35am Break
10:50am Discuss State of the Art of Residual Stress Measurements
George Alers, NIST
11:15am Discuss State of the Art of Machining Dynamics
Yusuf Altintas (invited), Professor, University of British Columbia
11:40am Discuss State of the Art of Machining Process Modeling
Paul Bayer, Technical Director, Third Wave Systems
12:00pm Lunch
1:30pm Computational Analysis of Forging Optimization
Mike Chiesa, Sandia National Labs
1:50pm Material Modeling – Constitutive Models Incorporating Recrystallization Effects
Doug Bammann, Sandia National Labs
2:10pm Forging Advisor System
Gerry Ludtka, Senior Development Staff, Oak Ridge National Laboratory
2:40pm Panel Discussion
Bill Kuhlman, Brian Dods, Bill Harris for Steve Varanay, Dennis Masterson, Vickie Furman, George Mochnal
3:10pm Break
3:30pm Develop Action Plans
All

Contact: Daniel Maas, 734-995-4934

High-Performance Spindles and Tooling for Milling and Drilling High Nickel Steel Alloys, Titanium and Cast Iron

The goal of this workshop is to structure a project to provide the technology that will forecast the cutting capability of a machining spindle system before it is built and tested. Over the past two years, significant advancements have been made in key components of machining spindles. The same is true of cutting tools, tool coatings, and tool holders. These advancements make feasible a potentially significant increase in productivity, particularly for tough materials that require high cutting torques. However, a fundamental question remains unanswered: "Can a machining system that incorporates these advancements take the aggressive cuts of which they are capable without chattering?" Currently, no one can answer this question adequately, but unless this question is answered, process planning can only offer a starting point; the final process is still a matter of trial-and-error.

Specific Objectives

Project Resources Required

Machine tool builders; tool manufacturers; tool coating suppliers; spindle builders; toolholder suppliers; software developers skilled in the integration of mechanical dynamics, motor electromagnetics; and heat transfer.

Who Should Attend

Tool and tool coating suppliers; motor and motor drive suppliers; bearing suppliers; spindle designers, analyzers, and builders; and representatives from companies that are responsible for assimilating advanced equipment for milling and drilling components made from cast iron, steel, and similar materials.

Background

This project would draw heavily upon the lessons learned under the recent completed NCMS/NIST-ATP Spindles project. Tools, tool coating and tool holders will be in the project scope but fixtures and other items related to workpieces will be secondary considerations.

Agenda

9:00am Spindle Needs for Automotive Manufacturing
Michael Habel, Ford (invited)
9:30am Design and Analysis of High Performance Motors
Dr. Rudolpho Palma, Ford
10:00am Advanced Motor Drives
Don Yost, MTS Automation-Performance Controls
10:30am Advanced Bearings for Advanced Spindles
William Harbottle, Timken
11:00am Spindle Manufacturing
Thomas O'Brien, Setco
11:30am Spindle Performance Analysis
Dr. Jiri Tlusty, Manufacturing Laboratories, Inc.
12:00pm Lunch
1:30pm Advanced Tooling Systems – Tooling and Coatings
David Leslie, Star Cutter
Joel Erickson, Star Cutter
2:00pm Advanced Machine Tools for Advanced Spindles
Richard Curless, Cincinnati Machine (invited)
2:30pm Spindle Performance Validation Testing
Dr. Thomas Delio, Manufacturing Laboratories, Inc.
3:00pm Project Scope
NCMS
3:30pm Statement of Work Outline and Schedule
NCMS
4:00pm Open Discussion
All
4:30pm Adjourn

Contact: Jack McCabe, 734-995-4919

Increasing Product Quality Through State-of-the-Art Nuclear Inspection Services

The goal of this workshop is to revolutionize the way parts and complex fluid-filled systems are inspected and tested using nuclear services. Specifically, the workshop will attempt to close the gap between those who need to validate their product and process models and designs and the available state-of-the-art nuclear inspection and testing capabilities. In addition, the session will provide attendees with information on nuclear services, access to industry experts, resources and contacts on collaborating with NCMS and the McClellan reactor facility.

Specific Objectives

Specific objectives of this workshop are to:

Project Resources Required

A willingness to work collaboratively in the area of nuclear services including furnishing specific project ideas, resources, in-kind work and other active contributions to defined projects.

Who Should Attend

Designers, system engineers, NDE inspection staff, QA/QC managers, sales managers, product managers, and line managers. This workshop is targeted to those who are responsible for delivering quality products to meet specific customer expectations, and who have a desire to have a competitive advantage by addressing potential problems before they surface.

Background

This workshop will focus on state of the art methods that will provide valuable knowledge and an approach to managers and staff responsible for designing, manufacturing products, and interfacing with the customer. The McClellan Nuclear Radiation Center will provide some case histories where some of the advanced inspection techniques have yielded cost effective dividends and improved product quality.

Agenda

9:00am Introductions and Workshop Objectives
Connie Philips, Senior Program Manager, NCMS
9:15am Pyrotechnic Valve Radiometric Analysis
William Smith, Project Manager, NASA-SMPT3 Boeing
9:45am Advanced Radiography Techniques for Manufacturing Applications
Robert McGee, NDE Technical Specialist, Ford Motor Company
10:10am Neutron Radiography for Industry
George Strabel, Staff Specialist NDT, Howmet
10:30am Break
10:45am Boron Neutron Capture Therapy
Susan Autry-Conwell, BNCT Project Manager, Dept of Neurological Surgery, University of California, Davis
11:15am Nuclear Research Agenda at the Reactor and How You Can Participate
Dr. Wade Richards, Director of the McClellan Nuclear Radiation Center (MNRC)
11:45am Workshop Summary and Next Steps for Participation
Connie Philips
12:00pm Lunch

Contact: Constance J.S. Philips, 734-995-7051

Large Panel Rapid Prototyping System

The goal for this workshop is to complete the formation for a project that will produce a prototype system for the production of large panels using rapid prototyping technology. Several companies have defined project objectives to meet their needs and have begun the process of organizing a collaborative project.

Specific Objectives

Project Resources Required

This proposed project is targeted to develop and validate a large panel rapid prototyping system designed by Stratasys, Inc. It is organized as a vertical pilot application team. Specific project resource requirements are not yet identified.

Who Should Attend

Designers, producers and/or users of large thin panels used in aerospace and automotive applications should attend this session. The technology should be of particular interest to designers for its potential to reduce the time needed to evaluate many styling, form, and fit iterations. Producers and/or users of large thin panels such as outer body panels, fenders, trunk lids, floor pans, and so forth will find this session interesting and rewarding.

Background

Large, thin section panels for automotive, aerospace and other applications are produced today by bending or stamping sheet metal. The stamping process in particular is very time consuming, requiring the development of an expensive die set before panels can be produced for validation. This project will develop the ability to rapidly and economically produce large, thin section panels.

Agenda

9:00am Session Introduction
Tony Haynes, Program Manager, NCMS
9:15am Automotive Needs
Doug Mitchell (Ford)
Paul Williams (DaimlerChrysler)
9:30am Aerospace Needs
TBD
9:45am Break
10:00am The Proposed Technology
Jerry Lehr, Stratasys
11:00am Project Organization Workshop
Tony Haynes
12:00pm Lunch

Contact: Tony Haynes, 734-995-4930

Manufacturing Technology Innovation & Development Through the Supply Chain

The objective of this workshop is to explore requirements for leveraged collaborations between technology end-users and suppliers to facilitate and accelerate technology development, implementation, and replication. Due to ever increasing business pressures, it is imperative to establish leveraged relationships and strive for breakthrough technological innovations. In the cycle of a technology development project, the steps to reach implementation and replication are often the most difficult. It is during these steps that the existence of a true leveraged development relationship is absolutely essential. While this is a general topic, this workshop will specifically address manufacturing innovation for machinery and tooling. The workshop will seek to identify participants and establish a collaborative working group/project to address organizational roles and responsibilities to facilitate manufacturing innovation between equipment suppliers and users.

Specific Objectives

Project Resources Required

Who Should Attend

Persons responsible for or engaged in:

Background

This workshop is motivated by difficulties in the manufacturing technology project development cycle expressed by many NCMS constituencies. Specifically, challenges with initiating leveraged, collaborative projects, project execution speed, and the ability to successfully reach implementation readiness have often been voiced. Various NCMS steering committees and Colloquiums have raised these issues, as have some of our partnering organizations such as the Management Roundtable and various universities. Additionally, the NCMS CTMA (DoD) initiative has expressed interest as it confronts the problems of supply chain development and innovation. This topic has also been a major component of an existing complementary NCMS project, Management of Accelerated Technology Insertion.

Agenda

9:00am Workshop Overview and Introductions
Mike Gnam, NCMS
9:30am Ford Manufacturing Issues
Rich Furness, Ford
10:00am Pratt & Whitney Perspective
TBD, Pratt & Whitney (invited)
10:30am Break
10:45am DoD Organic Maintenance Challenges
TBD
11:15am Ford Supply Chain Issues
Peter Gable, Ford Purchasing
12:00pm Lunch
1:30pm Caterpillar Perspective
TBD, Caterpillar
2:00pm Supplier Perspective
Ralph Resnick, CTO, Extrude Hone
2:30pm Supplier Perspective
TBD, Lamb Technicon
3:00pm Break
3:15pm Group Discussion of Future Project(s)
Rich Furness
4:30pm Next Steps
Mike Gnam
5:00pm Adjourn

Contact: Mike Gnam, 734-995-4971

MEMS and Microtechnology

The goal of this workshop is to explore the area of MEMS (microelectromechanical systems) and microtechnology to determine a scope of activities for the formation of a significant effort to speed up the commercialization of MEMS devices. The focus of the workshop will be on identifying both the roadblocks to commercialization and the collaborative R&D efforts needed to overcome these roadblocks. Potential participants on the team that emerges from this workshop include companies interested in MEMs technology, universities, and national laboratories. This team will pursue funding opportunities to drive MEMS and microtechnology toward commercialization.

Specific Objectives

Project Resources Required

NCMS members have a strong interest in the MEMS area for future products. At least two critical target areas of MEMS will be identified. This will result in straw man proposal concepts and initial team formation.

Who Should Attend

Senior product and manufacturing engineering personnel with a basic knowledge of MEMS technology and the impact of this technology on market areas, products, or system design. Both manufacturers of MEMS and OEMs with strong MEMS technology needs are encouraged to attend.

Background

NCMS membership believes that MEMS will have a large impact on the future designs of their systems and products. NCMS will spearhead an effort to form teams in this important emerging area to identify commercialization roadblocks and to form initial proposal concepts.

Agenda

9:00am Workshop Objectives, MEMS Opportunities, NCMS Roles
W. D. Seelig, NCMS
9:30am Roadblocks to the Commercialization of MEMs
Dr. Robert Mehalso
10:00am ATP Interest in MEMS
Jack Boudreaux
10:45am Break
11:00am Potential Program in Fabrication Facility Flexibility
TBD
11:15am Potential Program in Modeling and Software
John Gilbert, Microcosm
11:30am Potential Program in Process Equipment
Jay Sasserath, Plasmatherm
11:45am Potential program in packaging
Ray Rust, PM, Precision Optoelectronic Assembly Project
12:00pm Lunch/Networking
1:30pm Group Discussion: Roadblocks, Priorities and Proposal Opportunities
Dr. Robert Mehalso
3:00pm Proposal and Preliminary Teaming Discussions
  • Fabrication facility flexibility
  • Modeling and Software
  • Process equipment
  • Packaging
Facilitators: W. D. Seelig, Robert Mehalso, Jack McCabe, and Tony Haynes
4:30pm Group Discussion and Summary
W. D. Seelig

Interested Participants

The following companies and organizations have expressed interest in exploring collaborative opportunities in this workshop:

Users/OEMs: Ford, John Deere, Merck, Baxter Healthcare, Kodak, Xerox
Fabricators: Texas Instruments, Cronos, Intellisense
Equipment Manufacturers Ultratech Stepper, Karl Suss, Electronic Visions, ASM Lithography Potomac Photonics, Plasmatherm
Software and Modeling: Tanner, Microcosm Technologies
Government Agencies: NIST
Universities: University of New Mexico, Michigan Tech, University of Michigan
National Labs: Sandia National Labs

Contact: Wyck Seelig, 734-995-4915

Metals Processing Challenge: Best Practices and Beyond

The goal of this workshop is to understand current best practices in the steel production, forging and heat treating industries and how they impact each other. It is also the goal to understand how, by working together, these industries can improve these practices and reduce the negative impact. To illustrate these points, a specific family of components will be used during the workshop when discussing the applicability to the steel, forging and heat treating industries. The challenges in metals processing will be discussed and engineering functional requirements evaluated.

Specific Objectives

Project Resources Required

Attendees should walk into this workshop with practical knowledge of the current state of the steel producing, forging or heat treating processes and then leave having learned of opportunities to work with other industries to improve the current state-of-the-art. Attendees should have processing expertise and be willing to discuss and share knowledge of where the industries should be and where they will need to go in order to make the desired leaps in technology development.

Who Should Attend

Managers and engineers responsible for steel producing, forging and heat treating processing with practical knowledge of these metals processes. Attendees should have the desire to improve their company’s competitive position in the marketplace by improving their processes.

Background

As a result of the August, 1998 Joint Vision Roadmap Workshop, a Joint Industry Alliance (JIA) has been formed for the steel, forging, and heat treating industries. The goal of the JIA is to identify and foster research for the required cross-cutting technologies required by all three industries. This workshop is a continuation of this effort to enhance the communication in this metals processing community.

Agenda

9:00am Introductions and Objectives
Tracy Pattok, NCMS
9:15am JIA Mission and Background
David Anderson, AISI
9:45am Current Industry Conditions
Paul Dimitry, MacSteel
10:30am Break
10:45am Current Industry Conditions
John Hubbard, Bodycote Hinderliter
Dave Kuhlmann, Dana
11:30am Ideal Processing Parameters
David Anderson, AISI
Robert Gaster, Deere (ASM/HTS)
George Pfaffmann, Tocco (ASM/HTS)
George Mochnal, FIA
12:00pm Lunch
1:30pm Summary of Ideal Processing Parameters
All
2:00pm Definition of Joint Industry Actions
All
3:30pm Break
3:45pm Action Plan Definition
All
4:15pm Wrap Up – Action Items
Tracy Pattok, NCMS
4:30pm Adjourn

Contact: Tracy Pattok, 734-995-4926

Next Generation Inspection Systems

The goal of this workshop is to develop the technology to support the interchangeability between sensors, both contact and non contact, regardless of their unique technology, with minimum programming for both CMM’s and on-machine inspection applications in much the same manner that cutting tools are managed utilizing a tool changer.

Specific Objectives

To form a collaborative effort to identify requirements, evaluate results through pilots and drive the development and application of:

  1. Open architecture controls,
  2. Interchangeable sensors and manipulators,
  3. Data acquisition and analysis,
  4. CAD (math based) programming techniques,
  5. Advanced metrology.

Project Resources Required

Manufacturing end users and CTMA Depot partners to provide support for pilot applications as well as technology providers in the area of advanced sensors and machine controls, hardware and software.

Who Should Attend

Anyone involved in manufacture and inspection of prismatic parts.

Background

The proposed work will leverage technology developed in recently completed NGIS I and II Projects.

Agenda

9:00am Introduction Overview of NGIS I & II
Bill Waddell, NCMS
9:30am Depot On Machine Inspection Requirements
Robert King, Technology Insertion Engineer, Naval Aviation Depot, Cherry Point, NC
10:15am Break
10:30am NGIS Phase I & II Technology
Jay Nilsson, Consultant
11:15am NIST NGIS Program
Bill Rippey, NIST
12:00pm Lunch
1:30pm Phase III Target Business Problems
Bill Waddell
2:15pm Break
2:30pm Wrap-Up and Defining Possible Phase III Collaborative Project
Bill Waddell
3:30pm Adjourn

Contact: Bill Waddell, 231-264-9774

Solid Free Form Direct Metal Deposition Applications

The goal of this workshop is to introduce the approach known as Solid Free Form Direct Metal Deposition (SFF/DMD) to initiate discussion on how this technology can be applied to the following applications:

  1. Plastic injection mold tooling
  2. Repair and overhaul
  3. Short run manufacturing
  4. Functional prototyping for form, fit, and function

Laser Engineered Net ShapingTM (LENSTM), a new technology from Sandia National Laboratory, allows for the direct fabrication of metallic parts and features directly from a CAD file. It is anticipated that several common areas of SFF/DMD development related to the above fields will surface as a result of these discussions and the basis for a collaborative project will be formed.

Specific Objectives

Project Resources Required

Potential project participants must be willing to contribute cost share and/or cash resources to any resulting collaborative effort.

Who Should Attend

The SFF/DMD technology is applicable for any metal end product application; thus, it is expected that attendees will be from all segments of industry. Specific topics that will be discussed will be applicable to users of injection mold tooling, short run manufacturers, as well as a broad array of repair and overhaul applications.

Workshop Background

This project is proposed by NCMS-member Optomec and is based upon the Laser Engineered Net ShapingTM (LENSTM) technology out of Sandia National Laboratories.

Agenda

12:00pm Lunch
1:30pm Introduction and Background
Kerry Barnett, NCMS
1:50pm SFF/DMD Overview and Video
David Keicher, Vice President of R&D, Optomec
2:30pm SFF/DMD for Injection Molding
Rich Plourde, Optomec
2:45pm Break
3:00pm SFF/DMD for Repair and Overhaul
Terry Feeley, President, Laser Fare
3:15pm SFF/DMD for Direct Manufacturing
Rich Plourde
3:30pm Questions and User Requirements
4:00pm NCMS Collaborative Project
Ken Johnson
4:30pm Adjourn

Contact: Ken Johnson, 734-995-4977

Volumetric Imaging Systems (VIS4D) – Demonstration

The goal of this workshop is to expose attendees to this new class of technologies known as Volumetric Imaging Systems (VIS4D). This will be done through hands-on participation by attendees via prototype equipment on-site.

Specific Objectives

Who Should Attend

Any organization interested in visualization technologies or current users of virtual reality technologies. Participants may also include commercializers of virtual reality technologies that would like to become exposed to a new suite of VR approaches and tools.

Workshop Background

This workshop is a continuation of the VIS4D project formation activities within NCMS. Following this morning session will be an afternoon session designed for organizations interested in pursuing further development and beta testing in this area.

Agenda

9:00am Project Background
Ken Johnson, Executive Director, Technologies Research Corporation
9:20am Global Virtual Reality Technology Overview
Bob Andrews, President, Ethereal Technologies
10:00am Volumetric Imaging Technology Overview
Mats Johansson, President, EON Reality
10:30am Break
10:45am VIS4D and Autosterescopic Demonstrations
On Site
12:00pm Lunch

Contact: Jeff Ceo, 734-995-4936

Volumetric Imaging Systems (VIS4D) – Program

A new wave of optically based visualization technologies are making their way from Europe to the United States. This family of technologies, championed by the University of Strathclyde in Glasgow, Scotland, and Ethereal Technologies of the U.S., represents a quantum leap over existing virtual reality, or visualization technologies. This workshop is designed to lay the foundation for a collaborative program in which these technologies will be taken forward to commercialization. Participants of this effort will not only have early access via currently existing beta systems, but will also drive the technology toward their specific needs and applications. For a full description of these new technologies as well as beta demonstrations, attendees are encouraged to participate in the morning demonstration session.

Specific Objectives

Project Resources Required

Project participants will be required to provide cash and/or cost share to move the technology development forward. Project participants will receive beta VIS4D units in return for their cash contributions. Certain companies may have valuable background technology that would be considered on a cost-share only basis.

Who Should Attend

Any organization interested in visualization technologies or current users of virtual reality technologies. Participants may also include commercializers of virtual reality technologies that would like to become exposed to a new suite of VR approaches and tools.

Background

This workshop is a continuation of the VIS4D project formation activities within NCMS. This session is designed for organizations interested in pursuing further development and beta testing in this area.

Agenda

12:00pm Lunch
1:30pm Project Introduction
Jeff Ceo, NCMS
1:45pm VIS4D Technology Overview
Bob Andrews, President, Ethereal Technologies
2:00pm Research Project Overview
Bob Andrews
2:30pm Participants Roles and Responsibilities
Ken Johnson
3:00pm Break
3:15pm Project Deliverables
Bob Andrews
3:45pm Project Formation Next Steps
Ken Johnson
4:15pm VIS4D and Autosterescopic Demonstrations
On site
5:00pm Adjourn

Contact: Jeff Ceo, 734-995-4936

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