Convergent Manufacturing Platform - A Future of Additive, Subtractive, and Transformative Manufacturing: A Workshop

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A convergent manufacturing platform is defined as a system that synergistically combines heterogeneous materials and processes (e.g., additive, subtractive, and transformative) in one platform. The platform is equipped with unprecedented modularity, flexibility, connectivity, reconfigurability, portability, and customization capabilities. The result is one manufacturing platform that is easily reconfigured to output new functional devices and complex components for systems. This manufacturing system also converges the integration of physical components and digital models along with sensor networks for process monitoring and production.

The National Materials and Manufacturing Board of the National Academies of Sciences, Engineering, and Medicine hosted a 3-day workshop event to explore research and development (R&D) opportunities and challenges for convergent manufacturing. Sponsored by the U.S. Department of Defense, the three workshops in the series were held virtually on November 15, 2021; November 19, 2021; and November 22, 2021. The workshop series focused on the following three overarching topics: (1) key areas for R&D investments that will enable the readiness and commercial development of convergent manufacturing; (2) application areas for convergent manufacturing, with an emphasis on future Army and related civilian applications; and (3) approaches for the design of a convergent manufacturing platform.

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84 pages · 7 x 10 · paperback
ISBN Paperback: 0-309-68588-5
ISBN Ebook: 0-309-68606-7
DOI: https://doi.org/10.17226/26524

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National Academies of Sciences, Engineering, and Medicine. 2022. Convergent Manufacturing: A Future of Additive, Subtractive, and Transformative Manufacturing: Proceedings of a Workshop. Washington, DC: The National Academies Press.

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Thomas R. Kurfess

THOMAS KURFESS [NAE] Co-Chair, is the Chief Manufacturing Officer at the Manufacturing Demonstration Facility at Oak Ridge National Laboratory. Previously he was the BMW Chair in Manufacturing and a Professor in the Campbell Graduate Engineering Center at Clemson University. His current research focuses on the control of precision grinding systems that involve the development and implementation of adaptive controllers for precision grinding operations, including bore grinding, through feed centerless grinding, and surface grinding. Ultrarigid machine tools with open architecture controls are employed. The results of this work are used in a number of industrial environments. His project on precision measurement involves the use of coordinate measurement machines to verify part geometry in three dimensions. Currently, the metrology systems developed in this project are being used in the verification of parts on actual production lines. Dr. Kurfess is a fellow of the American Society of Mechanical Engineers, and has received both the Presidential Faculty Fellowship and the Presidential Young Investigator Award from the National Science Foundation. He received his Ph.D. from the Massachusetts Institute of Technology and he is a member of the National Academy of Engineering.

Ajay P. Malshe

AJAY P. MALSHE [NAE] Co-Chair, is the R. Eugene and Susie E. Goodson Distinguished Professor of Mechanical Engineering at Purdue University. He received his Ph.D. from the University of Pune in 1992. He has 25 years of academic, and partly overlapping, 15 years of nanomanufacturing entrepreneurship and business executive experience. Dr. Malshe’s primary professional expertise/research interest are convergent smart manufacturing (Industry 4.0), bio-inspired designing, multifunctional materials and surface engineering, system integration and production, entrepreneurship, and leadership. Engineering application areas of his interest/expertise are nano and micro-manufacturing, the high-performance mechanical system used in extreme environments, heterogeneous electronic packaging, 3D printing and cellular agriculture for equity and equality, and in-space manufacturing. Dr. Malshe has more than 200 peer-reviewed publications and has delivered more than 100 keynote and invited talks across the U.S. and the world. He has built national and global collaborations with corporations, academic institutions, and national laboratories including the Department of Energy’s (DOE) Argonne National Laboratory, Sandia National Laboratories, Oak Ridge National Laboratory, and the Army Research Laboratory. Dr. Malshe has more than 20 allowed patents with more than 65% resulting in engineered products commercialized and launched across multiple industrial sectors worldwide used by Fortune 500 companies in the energy, electric vehicle, heavy-duty transportation, high-performance extreme vehicles, strategic applications, and retail. Dr. Malshe has received more than 40 national and international recognitions and awards including member of the National Academy of Engineering (NAE; Section-8) and fellow of the International Academy of Production Engineering (CIRP), the American Society of Materials (ASM), the American Society of Mechanical Engineering (ASME), and the U.K.’s Institute of Physics (IoP). He has served and is serving on multiple key national and international committees for professional organizations including NAE. Dr. Malshe has trained more than 60 graduate and post-doctoral students and more than 1,250 undergraduate students and mentored young professional engineers in multiple universities and industries. He has also worked extensively with high school students and teachers to advance student learning success.

Craig Arnold

CRAIG ARNOLD is Professor of Mechanical and Aerospace Engineering, and Director of the Princeton Institute for the Science and Technology of Materials at Princeton University. His research interests focus on laser processing and transport in materials, with a particular emphasis on shaping laser-material interactions. His research has applications in energy, optoelectronics, and sensing. Examples of his work include the research and development of optical trap assisted direct-write nanopatterning (Trap and Zap), the tunable acoustic gradient index of refraction (TAG) lens for high-speed varifocal imaging and materials processing, laser direct-write printing for complex materials in biological and energy applications, and solution based printing methods of chalcogenide glass for mid-infrared photonic applications. Dr. Arnold is a recipient of the ONR Young Investigators Award and NSF Career Award. He received his Ph.D. in Physics from Harvard University in 2000.

Maria C. Baker

MARIA CHRISTINA BAKER is the Director of Additive Manufacturing for PPG industries. She joined PPG in 2012 as an R&D Chemist for the Aerospace Transparency business before transitioning to management roles including Global Materials Technology Manager in 2016. Prior to joining PPG, Christina was the co-founder of Fibron Technologies, a functional nanomaterial technology start-up company spin-out from UCLA, in 2008. In her role as director of operations she scaled-up nanoparticle synthesis with international investment partners, secured government and corporate investments, and led product commercialization. Originally from Atlanta, Georgia, Christina earned a bachelor of science in chemistry from the Georgia Institute of Technology and went on to complete her PhD in inorganic and materials chemistry at UCLA. In her current role she is leading strategy development and commercialization of PPG’s Ambient Reactive Extrusion (ARE) Additive Manufacturing technology.

Jian Cao

JIAN CAO is the Cardiss Collins Professor and the founding Director of NIMSI, the university research center on manufacturing science and innovation at Northwestern University. Cao considers manufacturing as an integration platform and specializes in innovative classical manufacturing processes and systems, particularly dieless double-sided incremental forming process and laser processes. Cao is an elected Fellow of the American Association for the Advancement of Science (AAAS), ASME, CIRP, and SME. Her major research awards include the ASME Milton C. Shaw Manufacturing Research Medal, SME Gold Medal, DoD Vannevar Bush Faculty Fellowship, ASME and Pi Tau Sigma Charles Russ Richards Memorial Award, and SME Frederick W. Taylor Research Medal. Prof. Cao is the Editor-in-Chief of the Journal of Materials Processing Technology. She served as President of the SME North America Manufacturing Research Institute, Chair of ASME Manufacturing Engineering Division, and a program director at NSF. Cao is a Board member of mHUB, Chicago's first innovation center focused on physical product development and smart manufacturing. She was an invited speaker at the workshops on additive manufacturing organized by the National Academy in 2018.

Sandra DeVincent Wolf

SANDRA DeVINCENT WOLF is the Senior Director of Research Partnerships at the College of Engineering, the Executive Director for the Next Manufacturing Center and the Executive Director for the Manufacturing Futures Institute at the Carnegie Mellon University. She has 15 years of research, development, engineering and management experience in advanced materials and manufacturing working in national laboratories, a start-up manufacturing company, and large corporations. Her technical work experience is followed by over ten years in executive management of nonprofits where she was responsible for leading initiatives from conception through implementation and assessment, internal and external communications, strategic planning and operational implementation, program management, corporate and government relations, education and outreach, and staff/volunteer engagement and development. Wolf joined the College of Engineering at Carnegie Mellon University in 2015. She is Senior Director of Research Partnerships and is responsible for facilitating research partnerships and the growth of new initiatives, centers and institutes, and industrial consortia across the College of Engineering especially as they apply to materials and manufacturing. Wolf is also the Executive Director of the CMU NextManufacturing Center for additive manufacturing research and education where she leads the activities and partnerships of the Center and its Consortium. She is additionally the Executive Director of the CMU Manufacturing Futures Institute where she works to identify, connect, leverage and accelerate research in manufacturing across campus to support innovation that will accelerate the path of discovery to commercialization to increase US competitiveness and drive economic development in the Pittsburgh region. Wolf is a member of the National Center for Manufacturing Sciences (NCMS) Advanced Manufacturing, Materials and Processes Program (AMMP) Technical Advisory Board, the America Makes Executive Committee and Governance Board, the SWPA Additive Manufacturing Working Group, the Pittsburgh Chapter of Women in 3D Printing, and the Pittsburgh Chapter of ASM International. Wolf holds the SB in Materials Science and Engineering from MIT. She earned an MS and PhD in the same field from Case Western Reserve University while she was a NASA Fellow in residence at the NASA Glenn Research Center. Wolf was recently awarded the CMU College of Engineering’s Inspirational Leadership Award.

Cambre Kelly

CAMBRE KELLY is Vice President of Research and Technology at Restor3d, Inc. Dr. Kelly is also a biomedical engineer, medical device entrepreneur, and additive manufacturing enthusiast. As co-founder of restor3d, she leads advanced development projects leveraging additive manufacturing and other technologies to improve human health. Previously, she worked at other early and mid-stage Medical Technology companies developing and commercializing innovative products using shape memory polymers and novel processing methods. Dr. Kelly holds a Ph.D. in Biomedical Engineering from Duke University, and a Bachelor’s degree in Biomedical Engineering from the Georgia Institute of Technology. She is a member of the ASTM subcommittee for additive manufacturing of medical devices as well as the Women in 3D Printing organization. Dr. Kelly is an inventor on numerous patents and has commercialized multiple medical device products which have impacted thousands of patients.

Francisco Medina

FRANCISCO MEDINA is an Associate Professor at the University Of Texas at El Paso, in the Department of Mechanical Engineering. He is also Director of Technology and Engagement at the W.M. Keck Center for 3D Innovation and Executive Consultant to HTL Japan. He has over twenty years of experience in AM and has educated over one thousand scientists and engineers in metals AM technology, processes, and advanced applications. He has published and contributed to over 120 peer-reviewed journals and conference proceedings. Additionally, he has been awarded thirteen additive manufacturing patents, with several other patents pending. In his past position, Dr. Medina was Technology Leader for Additive Manufacturing (AM) and the Director of the Additive Manufacturing Consortium (AMC) at EWI. As Technology Leader, he established the vision and goals for additive manufacturing technology at EWI and represented EWI nationally/internationally to help grow the EWI brand. Previous to EWI, Dr. Medina was a senior specialist in materials development at Arcam, stationed at Oak Ridge National Laboratory, where he managed Arcam’s relationships and R&D activities in North America. He would work with companies such as Honeywell Aerospace, Pratt and Whitney, and GE to produce and qualify AM materials. Throughout his career, his research interests have centered around additive manufacturing, with a heavy emphasis on the acceleration and advancement of the manufacturing readiness of metal AM technology. Specifically, he has focused his attention on new rapid AM alloy development, new AM strategies for material processing, material qualification, low-cost powder manufacturing, and AM education. Dr. Medina is the former chair of the SME Additive Manufacturing Community. His professional affiliations have include ASTM International, SME, MRS, SAE, MTS and is currently chair of ASTM F42.05.

Amy Peterson

AMY PETERSON is an Associate Professor of Plastics Engineering at University of Massachusetts Lowell with expertise in interfacial phenomena and additive manufacturing (AM). Her research group studies processing-structure-property relationships in polymers and polymer composites, with a focus on interfacial phenomena in multilayered systems. She has been a NSF IGERT and Graduate Research Fellow, and she was an Alexander von Humboldt Postdoctoral Fellow at the Max Planck Institute of Colloids and Interfaces 2011-2013 and Assistant Professor of Chemical Engineering at Worcester Polytechnic Institute 2013-2018. Her expertise is related to Polyelectrolytes, Composites, Polymer Synthesis, FTIR Spectroscopy, Mechanical Testing, Surface Analysis, and Rheology. Her education is a Ph.D. from Drexel University in Chemical Engineering (2011), and a B.S. from Drexel University in Chemical Engineering (2007).

Sudarsan Rachuri

SUDARSAN RACHURI is a Technology Manager in the Advanced Manufacturing Office, EERE, and DOE. He is the Federal Program Manager for the CESMII and an international expert in Smart Manufacturing. Prior to joining DOE, he was the program manager at National Institute of Standards and Technology (NIST) where he was an industrial engineer with the Life Cycle Engineering Group in the systems integration division. His primary objectives were to develop and transfer knowledge to industry about information models for sustainable manufacturing, green products, assembly representation, system level analysis, and tolerance representation. Prior to that he was a research professor at George Washington University and worked in the CAD/CAE/PLM software industry. Dr. Rachuri is the Editor-in-Chief of ASTM Smart and Sustainable Manufacturing Systems journal (www.astm.org/ssms). Rachuri is the founding member and was the vice chair of the ASTM subcommittee on sustainable manufacturing (E60.13) and a member of ASTM Smart Manufacturing Advisory Committee. Rachuri is the founding member and the Chair of the standards committee on ASME V&V 50 Verification and Validation of Computational Modeling for Advanced Manufacturing. Dr. Rachuri was a member of many ISO and ASME standards committees. Dr. Rachuri is a Fellow of ASME and AAAS (American Association for the Advancement of Science). Dr. Rachuri received the 2016 ASTM International President’s Leadership Award. Dr. Rachuri won first prize in the 2017 World Standards Day (WSD) Paper Competition, awarded by The Society for Standards Professionals. Dr. Sudarsan Rachuri was recently honored with the Excellence in Research Award by the American Society of Mechanical Engineers (ASME) Computers and Information in Engineering (CIE) Division.

Christopher Saldana

CHRISTOPHER SALDANA is the Ring family Professor in the George W. Woodruff School of Mechanical Engineering at the Georgia Institute of Technology. Dr. Saldana’s research expertise is in mechanics, materials and non-destructive evaluation. His research interests are on developing process qualification and process design tools for hybrid additive/subtractive manufacturing and digitally-enabled manufacturing. He has received his PhD and MS degrees in Industrial Engineering from Purdue University in 2006 and 2010, respectively, and received a BS in Industrial and Systems Engineering from Virginia Tech in 2004. His work in the manufacturing domain has resulted in 100+ archived publications and proceedings and has been recognized by several awards, including the NSF CAREER award, the R&D100 Award, the US Air Force Summer Faculty Fellowship, the US Small Business Administration Tibbetts Award, the Society of Manufacturing Engineers Robert J. Hocken Outstanding Young Manufacturing Engineer Award and Research Affiliate of the International Academy for Production Engineering (CIRP). Dr. Saldana serves as an associate editor for IISE Transactions Design and Manufacturing and on the editorial boards of Manufacturing Letters, Computer Aided Design and Applications and ASTM Journal of Smart and Sustainable Manufacturing. He is also a past participant on the National Academies 2020 meeting on Commercial Aviation Supply Chain Resilience.

Erik B. Svedberg

ERIK SVEDBERG is a senior program officer of the National Materials and Manufacturing Board at the National Academies of Science, Engineering and Medicine a position he has held since 2008. In this role, he works with experts from across the nation to develop, negotiate, and oversee scientific and technical advisory studies for federal agencies related to questions of materials science, manufacturing and engineering design. His previous and current activities at the National Academies includes work as a Study Director for; Materials Needs and R&D Strategy for Future Aerospace Propulsion Systems; Corrosion Research Grand Challenges; Opportunities in Protection Materials; Optics and Photonics, Essential Technologies for Our Nation; Review of the National Nanotechnology Initiative; Airport Passenger Screening; Frontiers of Materials Research, A decadal Survey; Participation by DOD in its Manufacturing USA Institutes; and High Performance Bolting Technology for Offshore Oil and Gas Operations. As well as overseeing workshops such as: Big Data in Materials Research and Development; Limited Affordable Low-Volume Manufacturing; Materials and Manufacturing Capabilities for Sustaining Defense Systems; New and Novel Processes that are on the Verge of Industrial Modernization; and Emerging Needs in Quantum-Enabled Systems. Dr. Svedberg has a decade of industry experience with both small and large companies in the materials science area and has been a guest researcher at NIST for several years. He has been awarded and overseen five research grants and has published over 80 scientific articles, been granted two patents and is cited over 1,600 times with an h-index of 22. His Ph.D. and masters are in materials science and he is a fellow of the American Association for the Advancement of Science (AAAS), the American Vacuum Society (AVS), and the Washington Academy of Science (WAS) including being their 2019 leadership in material science award recipient.

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Convergent Manufacturing Platform - A Future of Additive, Subtractive, and Transformative Manufacturing: A Workshop

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Convergent Manufacturing Platform - A Future of Additive, Subtractive, and Transformative Manufacturing: A Workshop

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Featured publication

Convergent Manufacturing: A Future of Additive, Subtractive, and Transformative Manufacturing: Proceedings of a Workshop

Description

Contributors

Committee

Sponsors

Staff

Parent projects

National Materials and Manufacturing Board

Major units and sub-units

Contact

Contact us

Provide feedback

More like this

National Forum on Nature-Based Solutions

Future pathways for the BGC Argo program: A Workshop

Prevention of and Response to Sexual Harassment in Higher Education: Tools for Department Chairs and Principal Investigators: A Workshop

Transit Cooperative Research Program

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Improving Command Climate, Unit Cohesion, and Warfighter Readiness