Tuesday June 13, 2023

From Digitization to Sustainability - Challenges and Opportunities for Future Manufacturing

Thomas Bergs

Univ. Prof. Dr.-Ing., Aachen

Abstract: In recent years, hardly any other development had such an impact on production engineering as digitization. As such, the utilization of data as well as the consistent and comprehensive connectivity within growing IIoT environments play a key role for various innovations in manufacturing. In addition to digitization, the second trend topic rises the question, how we can ensure "sustainability" in our industrial value chains by radical minimizing energy - and resource consumption. Both topics, digitization and sustainability will therefore have a huge impact on the future transformation of manufacturing. Here, the digital twin (DT) will be the central vehicle, aggregating, structuring, and utilizing the available data and information for holistic optimization over the entire life-cycle, from design, manufacturing, usage and recovery of real products.

This presentation will introduce the concept of digital twins within a typical manufacturing environment and deepens the understanding of the interaction between data- and model-driven approaches based on specific and representative use cases. These aspects are then put into the context of “sustainability” and it will be presented how digital twins within the production and manufacturing domain can be used as a basis for life cycle assessments as well as for the transformation from a linear to a sustainable circular economy.

Biosketch: Thomas Bergs is Professor at the Chair of Manufacturing Technology at the Laboratory for Machine Tools and Production Engineering WZL of the RWTH Aachen University and as Director of the Process Technology Division at the Fraunhofer Institute for Production Technology IPT. He is also a member of the Board of Directors of both production engineering institutes.

Tuesday June 13, 2023

The Urgent Need To Accelerate The Adoption Of Smart Manufacturing In The US

John Dyck

Chief Executive Officer, CESMII

Abstract: As we transition from one manufacturing era to another, it’s clear that legacy behaviors, business models and technology architectures must make way for new ones. The mission of The Smart Manufacturing Institute to enhance U.S. manufacturing productivity through a collaborative ecosystem of partners, an interoperable technology standard and continuous improvement in workforce development and education will help break down those barriers.

Biosketch: John Dyck is the Chief Executive Officer of CESMII - Clean Energy Smart Manufacturing Innovation Institute. CESMII is a Manufacturing USA Institute chartered with transforming the U.S. manufacturing market and increasing global competitiveness through the democratization of Smart Manufacturing technologies, knowledge, and business practices. John brings a highly pragmatic perspective to CESMII, and a crisp focus on outcomes that will benefit the Nation’s energy and economic security by sharing existing resources and co-investing to accelerate development and commercial deployment of innovative technologies. He was recognized by the Society of Manufacturing Engineering (SME) in 2020 as one of ‘30 Leaders Transforming Manufacturing in the USA’. Prior to joining CESMII, John held senior leadership positions in large corporations like GE and Rockwell Automation, and was effective in raising VC funding and building a successful software startup called Activplant.

Tuesday June 13, 2023

(NAMRC Track Keynote)

Advanced Manufacturing – Enabling Innovation at the Speed of Thought

Thomas R. Kurfess

HUSCO/Ramirez Distinguished Chair, Georgia Tech

Abstract: It has been said that having a good idea is not nearly as important to success as having a good business plan. There is some truth to this statement. However, regardless of the idea or business plan, if one cannot rapidly scale a product to mass production in a cost-effective manner, the ability to make an impact on society or to launch a successful product is substantially jeopardized at best. This talk presents some of the technical concepts and business models that will enable new technologies and capabilities in the manufacturing sector to be rapidly deployed throughout the industrial base. The insight will be presented into next-generation resilient hyper-connected production operations and business models that favor local and point-of-assembly manufacturing. Such operations will leverage readily available tools such as ChatGPT to advance manufacturing capabilities in a global manner. The talk will conclude with a discussion of how rapidly advancing technological innovations such as AR/VR and AI/ML will be propagated throughout the manufacturing enterprise via flexible cloud/fog operations, ensuring a state-of-the-art manufacturing economy. This will provide opportunities for businesses of all sizes and democratize advanced manufacturing technologies. Such capabilities will enable the rapid scaling of new concepts and products into manufacturing operations, enabling industry to innovate at the speed of thought.

Biosketch: Thomas R. Kurfess is the Chief Manufacturing Officer of the Georgia Institute of Technology and the Executive Director of the Georgia Tech Manufacturing Institute. He is also the HUSCO/Ramirez Distinguished Chair in Fluid Power and Motion Control and Professor of Mechanical Engineering at Georgia Tech. During 2019-2021 he served as the Chief Manufacturing Officer, and the Founding Director for the Manufacturing Science Division at Oak Ridge National Laboratory. During 2012-2013 served as the Assistant Director for Advanced Manufacturing at the Office of Science and Technology Policy in the Executive Office of the President of the United States of America, where he was responsible for coordinating Federal advanced manufacturing R&D. He was President of SME in 2018, and currently serves on the Board of Governors of the ASME. His research focuses on the design and development of advanced manufacturing systems targeting secure digital manufacturing, additive and subtractive processes, and large-scale production enterprises. He is an elected member of the National Academy of Engineering and is a Fellow of ASME, AAAS, and SME.

Tuesday June 13, 2023

(LEM&P Luncheon Keynote)

On the path towards a more efficient single laser SLM machine using in-situ and ex-situ X-ray imaging

Fred M. Carter III

Head of Research and Development, DMG MORI

Abstract: Many manufacturers of Selective Laser Melting (SLM) machines are turning towards multi-laser systems as a method to improve productivity and reduce overall Cost Per Part (CPP). While there is merit to this approach there are also some drawbacks including increased optical complexity, calibration burden, alignment issues, and unbalanced toolpath strategies. As additive manufacturing has gone from prototyping and a growing manufacturing method to an impactful process used in many critical industries such as medical and aerospace, the developments that help improve CPP are of increasing focus.

There are many limitations to the achievable productivity of a single laser SLM system, some of these include laser beam diameter, laser power, layer thickness, laser beam profile, and laser speed. This work describes a new approach leveraging a programmable laser technology enabling a hybrid toolpath workflow that uses different laser profiles within a single optical processing head. In-situ X-ray imaging work has been performed to understand the impact of non-Guassian energy profiles on melt pool dynamics, spatter generation, and coaxial monitoring signature. Part scale X-ray Computed Tomography (XCT) has been performed to rapidly evaluate the processing domain for this new paradigm. The results show significant changes in melt pool dynamics, enlarged processing domain, and improved processing time while maintaining near identical surface finish, density, and accuracy.

Biosketch: Fred M. Carter III is the Head of Research and Development at DMG MORI Additive Solutions Inc. leading a multi-disciplinary team of development engineers focused on delivering the next generation of Additive Manufacturing machine tools. During his professional and academic tenure, he has worked on a range of metal additive manufacturing technologies, developments, and applications in terms of fluid process modeling, monitoring, process control, mechanical and material characterization. He has made many contributions to the field of advanced additive manufacturing with many creative works published in academic journals. He recently received the outstanding paper award at NAMRC 2022.

Tuesday June 13, 2023

Concurrent Engineering of Materials, Manufacturing, and Design in Terms of Materials Genome

Zi-Kui Liu

Dorothy Pate Enright Professor, Penn State

Abstract: Design is a process to determine optimal combinations of ingredients and processing parameters for desired performances of a product.  The ingredients for materials design are their chemical compositions, and processing parameters are temperature, pressure/stress, and electric/magnetic fields with the outcomes being the phases and their morphologies, i.e., microstructures, which dictate the performances of materials.  In the history of human civilization, those optimal combinations were obtained through extended periods of trial-and-error experimentations such as the tin content in bronze and blacksmith procedures.  Human knowledge has been accumulated through apprenticeships, books, journals, and the latest digitization as the core of the 4th industry revolution.  The digitization of knowledge on phases and their properties in last century can be broadly categorized as bottom up from quantum mechanics in terms of the density functional theory and top down from phenomenological CALPHAD modeling in terms of free energy of individual phases.  In this presentation, author’s experiences and perspectives on these two approaches and their integrations in terms of zentropy theory and the theory of cross phenomena through integrating quantum, statistical, and irreversible thermodynamics will be discussed.

Biosketch: Dr. Zi-Kui Liu is the Dorothy Pate Enright Professor in the department of Materials Science and Engineering at The Pennsylvania State University. He obtained his BS from Central South University (China), MS from University of Science and Technology Beijing (China), PhD from Royal Institute of Technology (KTH, Sweden).  He was a research associate at University of Wisconsin-Madison and a senior research scientist at Questek Innovation, LLC.  He has been at the Pennsylvania State University since 1999, coined the term “Materials Genome®” in 2002, and served as the 100th President of ASM International in 2020.  Dr. Liu is Fellow of ASM International and TMS. His current research activities are centered on (1) DFT-based first-principles calculations and deep neural network machine learning for prediction and modeling of materials properties through integration of quantum, statistical, and irreversible thermodynamics, and (2) their applications for designing and tailoring materials chemistry, processing, and performances.  He published over 600 papers in peer-reviewed journals and was the lead author of a textbook titled “Computational Thermodynamics of Materials” published by Cambridge University Press.

Tuesday June 13, 2023

The Future of Automation in Smart Manufacturing

Mathias Hakenberg

Senior Key Expert, Siemens

Abstract: Automation has been a key enabler of productivity increases in manufacturing since the beginning of the industrial revolution. For high volume production Automation is very efficient, but we still struggle to exploit its full benefits for smaller lot sizes. The availability of computing power on the shop floor offers new possibilities to increase the level of autonomy in automation and extend its applicability towards new tasks. The first part of this keynote will highlight advances in automation, that become feasible through image processing, statistical analysis, and optimization. Developing these technologies into tools for the real world requires thoroughness and vigor. Therefore, the second part of this keynote is dedicated to bridging the gap between research and industrial practice. The latter of these is characterized by inconsistent or missing data and a heterogeneity of systems.

Biosketch: Dr. Mathias Hakenberg is a Senior Key Expert at Siemens Technology in Princeton. He is the lead developer for the Receding Horizon Planner technology for production planning and fleet management. Before joining Siemens in 2017 he was the chief engineer for ‘Industrial automation and control’ at the Institute of Automatic Control at RWTH Aachen University, Germany. He got his Ph.D. at the faculty of mechanical engineering at RWTH Aachen University in 2013.

Wednesday June 14, 2023

Expanding U.S. Advanced Manufacturing Opportunities

Michael F. Molnar

Director, Advanced Manufacturing National Program Office

Abstract: Manufacturing is receiving federal attention at a level not seen for decades. As global economies recover from COVID-induced supply chain disruptions, policymakers are focusing on ensuring reliable access to materials, domestic manufacturing capacity, and skilled workers. Advanced manufacturing plays a critical role in these efforts and the Manufacturing USA® program, in conjunction with the Manufacturing Extension Partnership program, is helping to lead the way.  Across a range of sectors – biomanufacturing, microelectronics, digital controls and automation, clean energy manufacturing, and advanced materials – Manufacturing USA institutes are bringing together researchers from industry, universities, and national labs to create and transition innovative technologies into scalable, cost-effective, and high-performing production capabilities while preparing the technology-ready workforce needed to win in the global arena. During this presentation, updates will be shared about significant new program initiatives, including new Manufacturing USA institutes, the National Science Foundation’s Innovation Engine program, the Department of Commerce Technology Hubs, and implementation of the $50 billion Commerce-led CHIPS program.  

Biosketch: Mike Molnar is the founding director of the Advanced Manufacturing National Program Office, the interagency team responsible for the Manufacturing USA program.  Mike also leads the NIST Office of Advanced Manufacturing and serves as co-chair of the National Science and Technology Council, Subcommittee on Advanced Manufacturing – the team responsible for the National Strategic Plan for Advanced Manufacturing. Prior to joining federal service in 2011 Mike had a successful industry career, including 25 years leading manufacturing and technology development at Cummins, a U.S. based global company that designs, manufactures, and distributes engines and power generation products. Midcareer he served as the first Manufacturing Policy Fellow in the White House Office of Science and Technology Policy.  He earned a Bachelor’s in Mechanical Engineering and Master’s in Manufacturing Systems Engineering from the University of Wisconsin, and an Executive MBA from the University of Notre Dame.  He is a licensed Professional Engineer, a member of the Senior Executive Service, and was elected a Fellow of SME and a Fellow and Honorary Member of ASME.

Wednesday June 14, 2023

(NAMRC Track Keynote)

Sustainable Manufacturing: Today and Tomorrow

Shaw C. Feng

Mechanical Engineer, NIST

Abstract: With combined pressures of raw material price increases, global climate change concerns, public emphasized social responsibilities, and quick advancement in using artificial intelligence techniques, the number of manufacturing companies looking to operate sustainably is rapidly increasing. Sustainable manufacturing has become a common practice to save energy and materials and reduce emissions. Reuse, recycle, and remanufacturing are quickly becoming a sustainability goal in manufacturing industry. Likewise, the means for measuring sustainability in processes and products is gaining more public attention. Many standards for sustainable manufacturing have been developed in ASTM and ISO. Sustainability metrics can provide crucial guidance for decision-making in managing the product development process within a company or a supply chain. Recently, machine Learning and artificial intelligence are used as new methods to make manufacturing more sustainable by learning from the best sustainable manufacturing practices. This talk will review the current state of sustainable manufacturing and present a currently being developed measurement infrastructure that is designed to enable manufacturing companies to measure sustainability in multiple dimensions, such as environmental stewardship, social well-being, economic growth, and performance management while providing an open platform for information sharing and smooth communications. Techniques of machine learning to improve sustainability will also be introduced for advancing sustainability manufacturing beyond Industry 4.0.

Biosketch: Shaw C. Feng is working on sustainable manufacturing indicators and disassembly for reuse, recycle, and remanufacturing in the Systems Integration Division in the Engineering Laboratory at NIST. Shaw Feng has been leading research and development efforts in metrology of mechanical parts, process planning, design for eco-friendly manufacturing, disassembly, and sustainability performance metrics.

His research work is focused on manufacturing metrology, specifically in the following fields: advanced manufacturing (AM), dimensional metrology and quality, manufacturing process performance measurement, and tolerances for three-dimensional (3D) models. Shaw Feng’s standardization work includes AM data registration, inspection planning rules as part of the Quality Information Framework standard, key performance indicators for sustainable manufacturing, and 3D tolerances in Product Data Exchange standard. Shaw has received awards from both ASTM E60 Sustainability and Digital Metrology Standardization Consortium for his outstanding leadership and significant contributions. Shaw also received three U.S. Department of Commerce Bronze Medals. Shaw has numerous publications in additive manufacturing, quality information framework, sustainable manufacturing, process planning, and product lifecycle engineering. Recently, Shaw received the SME 2021 Eli Whitney Productivity Award for the impact made on cost savings in manufacturing industries.

Wednesday June 14, 2023

(MED Luncheon Keynote)

Sustainable Manufacturing: Origins and Future Directions

John W. Sutherland

Professor and Fehsenfeld Family Head, Purdue

Abstract: Over the last 60 years, driven by an increasing population and improved affluence that has been enabled by advances in manufacturing, there has been a dramatic global growth in resource consumption and concomitant waste production. This has, in turn, motivated increasing attention to the environment and sustainability that is now impacting all aspects of society. This presentation will describe the origins of the environmental movement and the emergence of “sustainable manufacturing,” which is focused on reducing the environmental impact of manufacturing processes and systems, and the design of products that result in minimum environmental impact across the life cycle. Some personal reflections on my own journey will be provided. Thoughts on future research directions will be offered, including actions that the ASME community should pursue to ensure a sustainable future. Since this presentation is associated with the awards luncheon, the speaker will share his connections with some of the namesakes for these awards.

Biosketch: Dr. John W. Sutherland is Professor and Fehsenfeld Family Head of Environmental and Ecological Engineering (EEE) at Purdue University. He has led the development of the department into one of the largest environmental engineering programs in the U.S. He is one of the world’s leading authorities on the application of sustainability principles to industrial issues. He has published more than 400 papers in various journals and conference proceedings and is co-author of the textbook: Statistical Quality Design and Control: Contemporary Concepts and Methods. His recognitions include an SME Outstanding Young Manufacturing Engineer Award, Presidential Early Career Award for Scientists and Engineers, SAE Teetor Educational Award, SME Education Award, SAE John Connor Environmental Award, ASME Ennor Manufacturing Technology Medal, SME Gold Medal, and Frederick George Pohland Medal from AEESP/AAEES.  He is a Fellow of SME, ASME, CIRP, and AAAS. He was elected to the National Academy of Engineering (NAE) in 2023. Sutherland received his B.S., M.S., and Ph.D. degrees from the University of Illinois at Urbana-Champaign.

Wednesday June 14, 2023

(NAMRC Track Keynote)

Lessons From Rensselaer's 'Teaching Factory’: A Two-decade Journey in Manufacturing Education

Samuel Chiappone

Director of Manufacturing Innovation, RPI

Abstract: Rensselaer's Manufacturing Innovation Learning Laboratory (MILL) has a two-decade-long history in successfully deploying the 'Teaching factory' model for manufacturing education. The MILL's flagship course involves a two-semester long, hands-on experience for the students where they are required to (1) Design a product that uses all of MILL's diverse manufacturing capabilities; (2) Establish both manufacturing and assembly pathways for their product; (3) Design and manufacture appropriate fixtures and tooling; (4) Realize the production-run for 300-400 units of their product and (5) Document their work in a technical data package. This keynote talk will highlight the cornerstones of this teaching factory model that includes the continuous design of appropriate curriculum, manufacturing infrastructure investment decisions, and engagement of industry stakeholders. The talk will also showcase lessons from leveraging CESMII's capabilities to provide a more 21st-century-relevant manufacturing education. Finally, the talk will discuss the MILL's efforts in engaging with STEM outreach through community colleges, middle/high schools, and minority outreach programs in the upstate New York ecosystem. These engagements are critical to maintaining a thriving local ecosystem that promotes the cause of manufacturing education.

Biosketch: Samuel Chiappone is the Director of Manufacturing Innovation for the School of Engineering (SOE) at RPI. As the director, Sam works with administration and faculty to provide the strategic vision that guides the direction of the manufacturing classes and facilities within SOE. Sam ensures manufacturing programs align with the SOE vision, Accreditation Board for Engineering and Technology requirements, and current industry practices. He is an instructor or part of a teaching team for various manufacturing classes at the graduate and undergraduate levels. Sam is the past chairperson of the Society of Manufacturing Engineers CH20 and currently serves as an advisor for Rensselaer’s Student Chapter of SME, S141. Sam is also a past University Representative on the Haas Technical Education Council.

Wednesday June 14, 2023

DFM With Knowledge Embedded In Manufacturing Data

Changsheng Guo

Associate Director, Raytheon Technologies Research Center

Abstract: Implementing Design for Manufacturing (DFM) is challenging for parts such as jet engine compressor rotors and turbine components, where advanced designs with more complex geometry, advanced materials, and tighter tolerance requirements impose greater manufacturing challenges. The growing adoption of industry 4.0 and availability of detailed manufacturing data are creating a real opportunity for transforming the product development and implementing co-designing with manufacturing. There is also an urgent need to establish and adopt industry standard to facilitate efficient manufacturing data exchanges. This presentation will outline the industry needs, the challenges, and the potential use cases for manufacturing data. The discussion will focus on how the industry can use digital thread to capture and link all production data to part designs, how to automatically extract manufacturing knowledges and manufacturing capabilities at part feature level and use the extracted knowledge to develop products with good producibility.

Biosketch: Dr. Changsheng Guo is an Associate Director of Advanced Manufacturing at the Raytheon Technologies Research Center leading projects on developing manufacturing models and software tools. Dr. Guo’s recent work has been focused on digital thread and co-design with manufacturing. He has more than 80 published papers, co-authored one book, and 50 patents. Changsheng received his Ph.D. in mechanical engineering and MBA from University of Massachusetts, a MS from Northeastern University in China. He is a Fellow of the International Academy for Production Engineering (CIRP) and a Fellow of SME. Changsheng received numerous awards such as the prestigious F.W. Taylor Medal of CIRP and the ASME Blackall Award.

Wednesday June 14, 2023

Future of Flight Manufacturing at GE Aerospace

Vinod Kumar

Chief Engineer, GE Aerospace

Abstract: Aerospace manufacturing, like many other industry sectors, continues to face multitude of challenges and disruptions in its supply chain. Yet, to meet customer demands and maintain resiliency, there is constant need to deploy solutions that increase productivity, capture efficiencies, and cut costs. At GE Aerospace, we address these challenges by building solutions on a strong foundation of Lean, Technology and Digital with a strong emphasis on innovation. Lean with a continuous improvement mindset significantly boosts both throughput and productivity, maximizes utilization while maintaining superior product quality. Technology that seamlessly integrates novel manufacturing processes, digital inspection, and sensor-enabled automation enables optimal production of complex geometries. Digital transformation through model-based manufacturing, digital thread, process optimization, and advanced data analytics unlocks hidden value as well as rapidly advances production capability. With commitment to revolutionary propulsion capabilities and decarbonization breakthroughs in our next generation of engines, GE Aerospace continues to invent the future of flight that is enabled by technological advancements in manufacturing and production.

Biosketch: Dr. Vinod Kumar is the Chief Engineer Manufacturing for GE Aerospace Supply Chain leading initiatives to accelerate the global supply chain for GE Aerospace by providing advanced manufacturing, technology, and automation solutions for factories worldwide. Vinod leads a central team of experts and engineers who are responsible for multigenerational strategies on new product manufacturing, production readiness, manufacturing technology maturation, and technical talent development. His organization is responsible for engaging in industry standards and ensure regulatory compliance as key contributor to industry and government agencies and committees. Prior to this role, Vinod has held multiple leadership roles in GE Global Research leading organizations on Manufacturing, Materials, and Inspection. Vinod holds a doctorate in mechanical engineering from the University of Michigan, Ann Arbor. He has authored 15 publications and has 5 patents. Vinod is a certified Six Sigma Black Belt.

Thursday June 15, 2023

A Digital Twin Framework for Materials-Aware Manufacturing Process Design

Wei Chen

Wilson-Cook Professor, Northwestern

Abstract: Concurrent materials, geometry and manufacturing process optimization involves many computational challenges such as high-dimensionality associated with location dependency, material heterogeneity, multi-modal information, and nonlinear material behaviors such as large deformations and plasticity. The recent growth of using physics-based machine learning creates opportunities for incorporating data-driven methodologies with physical models into design. Furthermore, digital twin is an emerging technology in the era of Industry 4.0 that holds promises for real time optimization of manufacturing processes and quality control. We will present in this talk a digital twin framework that integrates materials modeling, part-scale manufacturing simulation and mechanics analysis, as well as state-of-the-art data science techniques to achieve off-line surrogate modeling and model uncertainty quantification and on-line predictive model control. To support materials-aware product and process design, techniques of microstructure characterization and reconstruction, machine learning of materials laws, differentiable simulation based optimization, and deep-learning based computer vision metrology will be introduced.

Biosketch: Dr. Wei Chen is the Wilson-Cook Professor in Engineering Design and Chair of Department of Mechanical Engineering at Northwestern University. Directing the Integrated DEsign Automation Laboratory (IDEAL-, her current research involves the use of statistical inference, machine learning, and uncertainty quantification techniques for design of emerging materials systems including microstructural materials, metamaterials and programmable materials. She serves as the Design Thrust lead for the newly funded NSF Engineering Research Center (ERC) on Hybrid Autonomous Manufacturing, Moving from Evolution to Revolution (HAMMER), where she works on digital twin systems for concurrent materials and manufacturing process design. Dr. Chen is an elected member of the National Academy of Engineering (NAE) and currently serves as the President of the International Society of Structural and Multidisciplinary Design (ISSMO). She served as Editor-in-chief of the ASME Journal of Mechanical Design and the Chair of the ASME Design Engineering Division (DED). Dr. Chen is the recipient of the 2022 Engineering Science Medal from the Society of Engineering Science (SES), ASME Pi Tau Sigma Charles Russ Richards Memorial Award (2021), ASME Design Automation Award (2015), Intelligent Optimal Design Prize (2005), ASME Pi Tau Sigma Gold Medal achievement award (1998), and the NSF Faculty Career Award (1996). She received her Ph.D. from the Georgia Institute of Technology in 1995.

Thursday June 15, 2023

Additive Manufacturing in Industry 4.0: Disrupting the Aerospace and Defense Industry

Melissa Orme

Vice President, Boeing Additive Manufacturing

Abstract: Additive Manufacturing is an emerging technology that has the potential to significantly disrupt the Aerospace and Defense industry by creating innovative design solutions to difficult engineering problems that increase a vehicles performance, lower cost, reduce schedule, and enhance sustainability trades. Because Additive Manufacturing is a digital process, the end-to-end value stream can be more readily integrated into the digital thread, where extracted data from each process in the value stream is archived in a cloud-based repository that is easily accessible for engineering analytics such as the creation of data driven models and machine learning algorithms to drive quality and scale. This talk will provide case studies illustrating positive trades in performance, cost, quality, schedule, sustainability, and digital integration, and will discuss opportunities and challenges on the path forward.

Biosketch: Melissa is a renowned pioneer, innovator and leader in the developing field of Additive Manufacturing, where her seminal work in additive manufacturing spans three decades and has resulted in 15 US patents. Melissa has a rich and diverse professional background, having begun her career in academia where she rose to the rank of Full Professor of Mechanical and Aerospace Engineering at the University of California Irvine. There, she established globally recognized research laboratories in the field that is now termed ‘Additive Manufacturing,’ where she developed methods for controlled electrostatically charged and deflected molten metal droplet deposition for precision manufacturing, direct writing of electronic components, and precise powder production. Subsequently, she transitioned from academia to high tech startups where she served as the Chief Technology Officer of Morf3D, a company that is focused on producing and delivering flight qualified additively manufactured hardware to the aerospace industry. From Morf3D she was recruited by Boeing to lead Additive Manufacturing across all business units.

In the capacity of Vice President of Additive Manufacturing at The Boeing Company, Melissa leads a highly innovative team that drives advanced engineering solutions to complex design problems for commercial airplanes such as the 787 Dreamliner; space and launch vehicles such as Artemis SLS rocket; satellites such as the O3b constellation; vertical lift programs such as the Chinook helicopter; fighter airplanes such as the F/A-15 and F/A-18; and autonomous vehicles such as the MQ-25 refueling drone. Insertions of Additive Manufacturing into these and other flight vehicles has been demonstrated to enhance quality and performance while simultaneously saving millions of dollars. Additionally, Melissa oversees Boeing research, both internal and external, focused on Additive Manufacturing including the development of new processes; materials; manufacturing digital transformation for industry 4.0; the creation of the digital thread; machine learning and data analytics.

Melissa has been a leader in additive manufacturing since the early days when she was an outlier in her academic department, advocating for adoption of manufacturing processes of the future. Today she leads a team of highly creative engineers, some of whom have never designed for traditional manufacturing, and have adopted and regularly implement additive manufacturing as a standard manufacturing technology in order to solve complex engineering problems on Boeing products, reducing cost and improving performance.

Thursday June 15, 2023

Intelligent Digital Twins: Driving 21st Century Manufacturing Transformation

Michael Grieves

Executive Director, Digital Twin Institute

Abstract: Digital Twins have been integrally connected to manufacturing from their inception. Manufacturing is the product phase where there are two major and distinct uses of digital twins: the use of digital twins of manufacturing equipment and processes for the efficient and effective production of products and the creation and testing of the as-built digital twins instances that will stay connected to their physical counterparts for the rest of the physical product’s life. Dr. Grieves will discuss the transformation of manufacturing enabled by digital twins and the possibilities that artificial intelligence will provide for intelligent digital twins.

Biosketch: Dr. Michael Grieves is an internationally renowned expert on digital twins, a concept he originated, and Product lifecycle Management (PLM) a discipline he wrote the seminal book for. Dr. Grieves has over five decades of executive, board, and technical experience in both global and entrepreneurial technology and manufacturing companies. He has consulted and done research at some of the global organizations (NASA, Boeing, GM, Unilever) and has served as a senior executive and board member at both Fortune 1000 companies and entrepreneurial organizations. Academically, he has had appointments and has done research and/or taught at the University of Michigan, Purdue University, and University of Iowa. Dr. Grieves has a BS Computer Engineering from Michigan State, and MBA from Oakland University, and his doctorate from Case Western Reserve University.

Thursday June 15, 2023

(NAMRI/SME Founder’s Lecture)

How Did We Get Here, and What Are We Going to Do?

Scott Smith

Section Head for Precision Manufacturing and Machining, ORNL

Abstract: Manufacturing and manufacturing innovation are important, and they always have been. Manufacturing is the fundamental mechanism of wealth creation. Manufacturing innovation even improves the productivity of other wealth creation mechanisms like farming and mining by creating the necessary tools for those sectors. A distinguishing characteristic of being human has been our ability to manufacture things that people need and want. Manufacturing is crucial to the economy, to our health and welfare, and to national security. Innovation in manufacturing has brought into existence a world where today even relatively poor people can afford things that would have been unthinkable luxuries, even for the richest people hundreds of years ago. Manufacturing innovation is deflationary – it increases the buying power of existing wealth. The positive impact of manufacturing innovation on our quality of life is undeniable.

The US has been a traditional manufacturing powerhouse, but is that still true? The extent of our dependency was clearly shown in during the recent pandemic and supply chain shortages. Why then, did the US let manufacturing go? How did we get in a position where we are not self-sufficient, but dependent? More importantly, what are we going to do about it?

Biosketch: Scott Smith is the Section Head for Precision Manufacturing and Machining at Oak Ridge National Laboratory. Prior to joining ORNL in 2019, Smith was Professor and Chair of Mechanical Engineering at the University of North Carolina at Charlotte. During 2012-13 he served as the Assistant Director for Technology at the US Advanced Manufacturing National Program Office in Washington DC. His research areas include high-speed machining, process optimization, and machine dynamics. He has taught numerous industrial short courses.

Smith is a Fellow of the International Academy for Production Engineering (CIRP), and he is a Fellow of both ASME and SME. Smith served as the Chair of the Manufacturing Engineering Division of ASME, and as President of the North American Manufacturing Research Institute of SME. He is author of more than 100 technical papers, and he is co-author of the books Machining Dynamics: Frequency Response to Improved Productivity and Mechanical Vibrations: Modeling and Measurement. He holds 14 patents.

Smith has received numerous awards including the ASME/SME M. Eugene Merchant Manufacturing Medal, the ASME William T. Ennor Manufacturing Technology Award, the ASME Blackall Machine Tool and Gage Award, the NAMRI/SME S.M. Wu Research Implementation Award, the SME Education Award, the AMT Charles F. Carter Advancing Manufacturing Award, the American Helicopter Society Pinckney Award, a Federal Laboratory Consortium Technology Transfer Impact Award, two R&D 100 Awards, the University of Florida MAE Outstanding Alumnus Award, and the NAMRI/SME Lifetime Service Award.

Thursday June 15, 2023

NSF New Directorate for Technology, Innovation and Partnerships (TIP)

Erwin Gianchandani

Assistant Director, NSF/TIP

Abstract: The new NSF Directorate for Technology, Innovation and Partnerships, TIP, advances use-inspired and translational research in all fields of science and engineering, giving rise to new industries and engaging all Americans — regardless of background or location — in the pursuit of new, high-wage jobs in science, technology, engineering and math (STEM). TIP harnesses the nation's vast and diverse talent pool to advance critical and emerging technologies, address pressing societal and economic challenges, and accelerate the translation of research results from lab to market and society. TIP improves U.S. competitiveness, growing the U.S. economy and training a diverse workforce for future, high-wage jobs.

An overview of TIP’s mission, programs, proposal review, and challenges will be given in this talk.

Biosketch: Dr. Erwin Gianchandani is the U.S. National Science Foundation’s assistant director for Technology, Innovation and Partnerships (TIP), leading the newly established TIP Directorate. Prior to becoming the assistant director for TIP, he served as the senior advisor for Translation, Innovation and Partnerships, where he helped develop plans for the new TIP directorate in collaboration with colleagues at NSF, other government agencies, industry, and academia. During the previous six years, Gianchandani was the NSF deputy assistant director for Computer and Information Science and Engineering (CISE), twice serving as acting assistant director. Before joining NSF in 2012, Gianchandani was the inaugural director of the Computing Community Consortium, providing leadership to the computing research community in identifying and pursuing bold, high-impact research directions such as health information technology and sustainable computing. Gianchandani holds a Ph.D. in biomedical engineering from the University of Virginia. In 2021, Gianchandani received the Distinguished Presidential Rank Award, awarded to members of the Federal Government’s Senior Executive Service for sustained extraordinary accomplishment.

Thursday June 15, 2023

(Banquet Keynote)

The Creation, Development & Implementation of a National Supply Chain Tool

John W. Kennedy

Chief Executive Officer - Emeritus, NJMEP

Abstract: This talk will provide insight into the development status of a National Supply Chain tool being driven forward by the NIST-MEP National Network to ensure the nation has a deeper understanding of domestic manufacturing capabilities and ensure the United States can quickly act in time of disaster. The COVID crisis shined a light on the need for visibility and transparency regarding the nation's manufacturing capabilities. Federal and State governments need to understand what is, or what is not, in the domestic supply chain. Not only will this tool be able to help pull the nation out of a crisis, but it will provide a way for the federal government to source more products and services from United States manufacturers and distributors. Find out what progress is being made, expect timelines, and intended outcomes while emphasizing the harsh realities of the nation's current supply chain shortcomings.  

Biosketch: John Kennedy is the CEO of the New Jersey Manufacturing Extension Program (NJMEP). John is first and foremost a ‘Jersey Boy’, as he has always been proud of his home State and what it actually brings to our country…including significant Manufacturing, Engineering, Science, and R&D capabilities. As an Engineer and NJ Business Owner, John was focused on (both) Engineering & Manufacturing and enjoyed success through working with many incredible individuals. From Coleman Equipment to Sandvik to Barnett Industries to The Multitech Group…all part of my Manufacturing evolution through the Material Handling, Power Plants, and DoD workloads. When John came to NJMEP in 2012, he found a place where he could support a critical Industry that means all the difference to our independence as a Country, while keeping New Jersey at the forefront of technology. NJMEP is his ultimate ‘fit’ as a professional. John is a proud Eagle Scout and National Distinguished Eagle. NJ Manufacturing…it is our time again!