IMPACT Project Call Worth $11.7M in Funding for Casting, Forging

The National Center for Defense Manufacturing and Machining (NCDMM) and America Makes have announced a new directed project call funded by the Office of the Under Secretary of Defense, Research and Engineering Manufacturing Technology Office (OUSD (R&E)) and the Air Force Research Laboratory (AFRL) worth a total of $11.7 million.

The objective of the “Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis (IMPACT)” project call is to demonstrate productivity and yield benefits for casting and forging manufacturing via additive manufacturing (AM) technologies, execute techno-economic analysis for metal powder AM, and to bridge component sourcing gaps with AM parts for casting and forging applications. The project call is also seeking innovative solutions for robotic AM process planning for continuous fiber-reinforced composite structures.

AM is of significant interest to the U.S. manufacturing base as the technology enables shorter lead times, mass customization, energy reduction, complex shapes and production of parts on demand providing benefits to both new acquisitions and legacy systems. “This project call addresses the needs of a broad cross section of our nation’s supply chain, including the casting and forging supply chain,” says Brandon Ribic, Ph.D., America Makes technology director. “We are thrilled for the opportunity to deliver longer term strategic investments to scaling AM technologies.”

America Makes strives to accelerate the development and deployment of innovative, cost-effective, energy-efficient AM and 3D printed technologies to meet defense and/or commercial needs. The proposed projects should be applicable to Technology Readiness Level (TRL) 4-7 and Manufacturing Readiness Level (MRL) 4-7 at the onset of the proposed project.

The request for proposal (RFP) includes 10 topic areas of focus. The number of anticipated awards and maximum funding will vary depending on the topic area being addressed.

Demonstrating Lead Time, Productivity and Yield Improvements for Casting and Forging Manufacturing Operations Using AM Technologies

• Topic Area 1 - Develop/disseminate leading practices and accelerate the adoption of 3D-printed molds/cores for sand castings.
• Topic Area 2 - Mature AM ceramic technology and promote adoption for rapid, low- volume production of investment castings for defense applications.
• Topic Area 3 - Develop and disseminate tools/frameworks to improve die (die casting) life with AM printed cooling channels.
• Topic Area 4 - Mature and promote methods to add high wear layers and complex geometric features to forgings.
• Topic Area 5 - Pilot the industrialization of AM preforms to expedite the forging process for low-volume forged components.
• Topic Area 6 - Develop and disseminate leading DED and cold spray practices to promote the adoption of die repair for forging applications.
• Topic Area 7 - AM for casting and forging innovations relevant to DoD acquisition or sustainment programs.

Disseminating the Value Proposition of Bridging Component Sourcing Gaps with AM Parts for Critical Casting and Forging Production

• Topic Area 8 - Techno-economic analysis and manufacturing readiness assessments to address bridging component sourcing gaps with AM parts for critical casting and forging production.
   

Identifying and Disseminating the Impact of Strategic R&D to Scale Powder Bed AM Technology

• Topic Area 9 - Powder AM techno-economic analysis.
   

Advancing AM Processing for Continuous Fiber Reinforced Composites

• Topic Area 10 - Innovations in robotic AM process planning.

To be eligible, the deadline for lead proposer to complete fully executed membership agreement with America Makes for Topics 1-8 is due by Wednesday, June 14; and for Topics 9-10 by Friday, June 23. Submission deadlines are Wednesday, June 28 by 5 p.m. ET for Topics 1-8; and  Friday, July 7 by 5 p.m. ET for Topics 9-10. For full details and guidelines, visit Project Call For Applied Research Projects – May 2023.