Senior Manager Future Engineering
Derek is a Senior Engineer for the adidas Future team focusing on computational engineering and additive manufacturing. He has spent the past 7 years working in the sporting goods industry with the adidas Group. His area of expertise is modeling of dynamic impact simulations, compressible structures, and optimization. Derek has a B.S. and a M.S in Mechanical engineering from the University of Southern California.
Space Technology Mission Directorate
National Aeronautics and Space Administration (NASA)
John Vickers is currently the NASA principal technologist in the area of advanced materials and manufacturing. He also serves as the Associate Director of the Materials and Processes Laboratory at NASA’s Marshall Space Flight Center and as the Manager of the NASA National Center for Advanced Manufacturing. He has over 30 years of experience in materials and manufacturing -- research and development, engineering, and production operations for propulsion, spacecraft, and scientific systems.
As principal technologist, he leads the nationwide NASA team to develop advanced manufacturing technology strategies to achieve the goals of NASA’s missions. In this role he represents the Agency supporting the President’s National Manufacturing Initiative and the Interagency Advanced Manufacturing National Program Office, which includes participation by the National Institute of Standards and Technology (NIST), the Department of Defense, the Department of Energy, NASA, the National Science Foundation, the Department of Education, and other agencies. He also he leads the NASA Technology Roadmap effort for “Materials, Structures, Mechanisms and Manufacturing.”
NASA’s Additive Manufacturing Development Materials Science to Technology Infusion - Connecting the Digital Dots
Advanced manufacturing is a technology area that is critical to all of the NASA missions in exploration, science, aeronautics, and technology. NASA has deep roots in manufacturing technology and innovation, and today these advancements are helping us in our mission to understand the universe and move from development to full implementation of the nation’s journey to Mars.
Manufacturing can many times be the enabler of innovation and additive manufacturing has become a crucial part of the NASA technology portfolio. Additive manufacturing offers significant potential to make our NASA missions more capable, more affordable, with better quality and can dramatically improve aerospace technological capabilities for the Nation. However, today NASA does not have the standards or engineering practices in place for the certification of additively manufactured components for human-rated spaceflight hardware.
NASA is developing “A Digital Twin for Additive Manufacturing” - connecting the digital dots from materials science to technology infusion, from physics-based materials and process models integrating across the engineering design, development, and testing practices. NASA’s focus for additive manufacturing is to bridge the gap between research and commercialization. Researchers from multiple NASA Centers working together with industry and academia are collaborating to develop a new set of predictive computational engineering, materials, and processes tools for additive manufacturing that closely mirror the physical processes and resulting material microstructure and properties. Results of this work presents a disruptive opportunity for NASA to accelerate design and certification of additively manufactured hardware.
Troy Hartwig, PE
Staff Engineer, Simulation and Modeling Center of Excellence Leader
Kansas City National Security Campus
Troy has a Bachelor of Science Degree in Mechanical Engineering from Missouri S&T and a Master of Science Degree in Mechanical Engineering from Purdue University. He is a Honeywell certified Black Belt, has his Professional Engineering License. Troy worked in the automotive industry for 6 years and then worked as an experimentalist in environmental testing for 14 years at Honeywell. Troy now leads the Simulation and Modeling Center of Excellence at the Kansas City National Security Campus.
Digital Manufacturing at the Kansas City National Security Campus
With the advent of additive manufacturing and advanced simulation technology, Digital Manufacturing at the Kansas City Nation Security Campus has come to mean much more than computer aided design and computer controlled machining. Digital manufacturing encompasses all the tools needed to get a brilliant idea into a user’s hands as fast, effectively and affordably as possible. We break the digital manufacturing process into 5 segments, “Think It”, “Simulate It”, “Print It”, “Validate It”, and finally “Use It”. We begin with changing how we think about design and production constraints, and are developing the tools to transform to a model based enterprise. We apply physics based analysis and simulation tools to optimize the design, confirm functional performance requirements, and develop the required manufacturing processes. Parts can then be fabricated with additive manufacturing technologies over a broad design spaced including metals and polymers, with a vision for using simulation to optimize material and build parameters to ensure printed parts meet the highest standards for quality. Validation is performed with digital tools such as coordinate measuring machines, computed tomography, or laser surface scanning. Finally, items are put into use, not just on display.
Honeywell Federal Manufacturing & Technologies is operated for the United States Department of Energy under Contract Number - DE-NA-0002839
Jerry Feldmiller, Sr. Principal Engineer
Senior Principal Engineering Lead of Additive Manufacturing for Orbital ATK’s (OA) Launch Vehicle Division
Mr. Feldmiller is the Sr. Principal Engineering Lead of Additive Manufacturing for Orbital ATK’s (OA) Launch Vehicle Division. He has over 29 years of experience in mechanical design, analysis and test of launch vehicles. He has a B.S. in Mechanical Engineering. He has been instrumental in developing Orbital’s use of Additive Manufacturing technology with the acquisition of multiple FDM machines, and led the effort to qualify an Additive Manufacturing polymer material that is suitable for launch vehicle environments. This effort allowed additively manufactured secondary structure components to be flown on the maiden Antares mission to resupply the International Space Station. Since then, multiple vehicles have flown AM parts. He is actively seeking new materials to improve strength to weight ratio, shock and RF attenuation, and other material properties that will enable more AM parts to be used on OA launch vehicles.
The importance of industry participation with AM companies in shaping future hardware, software, and materials development
In selecting an AM machine, industry typically reviews the features that the companies publish and designs parts around the build envelope, material capabilities, environmental considerations. Having industry involved up front with these developments via alpha, beta, and other pre beta programs is a win-win for both companies. AM companies and industry should actively seek to understand the AM road map and actively plan 1, 5, and 10 year goals and realize that constant need to update the plan often due to the rapidly changing AM landscape. This presentation focuses on the importance for industry involvement in many facets of additive manufacturing including user groups, university research and capstone projects, technical seminars, hands on workshops with local and national labs, membership in AM innovation institutes, and attending trade shows.
Timothy W. Simpson, Ph.D.
Paul Morrow Professor of Engineering Design and Manufacturing
The Pennsylvania State University, University Park, Pennsylvania 16802 USA
Dr. Simpson is the Paul Morrow Professor of Engineering Design and Manufacturing at Penn State with affiliate appointments in Architecture and Information Sciences & Technology. He also serves as the co-Director of CIMP-3D (www.cimp-3d.org) and helps manage an additive manufacturing research portfolio that exceeds $8M/year. He has been PI or Co-PI on over $30M in funding for his own research in additive manufacturing and 3D printing, product family and product platform design, and design innovation and entrepreneurship. He has published over 300 peer-reviewed papers and 2 edited textbooks, and he is currently co-authoring a new textbook on Design for Additive Manufacturing. He is a recipient of the ASME Ben C. Sparks Award, the ASEE Fred Merryfield Design Award, the SAE Ralph R. Teetor Award, and a NSF Career Award. He has received awards for outstanding research and teaching at Penn State, including the 2007 Penn State President’s Award for Excellence in Academic Integration. He is a Fellow in ASME and an Associate Fellow in AIAA. He chairs the ASME Design Engineering Division (DED) Executive Committee and serves on the ASME Design, Manufacturing, and Materials Segment Leadership Team. He helped ASME launch the Innovative Additive Manufacturing 3D (IAM3D) Design Challenge in 2014 and the 2015 and 2016 ASME Additive Manufacturing and 3D Printing Conference & Expo. He received his Ph.D. and M.S. degrees in Mechanical Engineering from Georgia Tech and his B.S. in Mechanical Engineering from Cornell.
Design for Additive Manufacturing: Challenges & Research Opportunities
Additive manufacturing provides engineers with unprecedented design and material freedom. Thanks to additive manufacturing (AM) technology, engineers can consolidate assemblies into a single integrated component, lightweight parts using topology optimization and lattice structures, and functionally-grade structures and components made from multiple materials. While many advocate that “complexity is free” when it comes to AM, understanding the design, material, and process limitations associated with AM is important when producing end-use parts. This talk will discuss the challenges associated with part substitution, consolidation, and optimization for AM, with an emphasis on laser-based powder bed fusion systems. Several examples will be presented to illustrate the challenges associated with design workflow, part selection, and support structures. These examples are drawn from the activities in Penn State’s Center for Innovative Materials Processing through Direct Digital Deposition (CIMP-3D), which serves as the DARPA Open Manufacturing Program’s Additive Manufacturing Demonstration Facility (MDF). CIMP-3D’s mission is three-fold: (1) advance enabling technologies required to successfully implement AM technology for critical components and structures; (2) provide technical assistance to industry through selection, demonstration, and validation of AM technology as an “honest broker”; and (3) promote the potential of AM technology through training, education, outreach, and dissemination of information. CIMP-3D also provides Penn State’s interface to America Makes, the National Additive Manufacturing Innovation Institute (NAMII). Efforts to educate the next generation workforce and (re)training the current workforce to use AM effectively will also be discussed.
Carnegie Mellon University
Department of Mechanical Engineering
Dr. Jack L. Beuth is Professor of Mechanical Engineering at Carnegie Mellon University. Jack Beuth received his Ph.D. in Engineering Sciences from Harvard in 1992. He has been a researcher in the field of additive manufacturing for over 20 years. Dr. Beuth’s modeling research in additive manufacturing has led to the development of “process map” approaches for mapping out the role of principal process variables on process characteristics such as melt pool geometry, microstructure, porosity and build rate. Dr. Beuth’s research is allowing unique insights into process control, expansion of process operating ranges, identification of tests needed to characterize a process, and unique comparisons of AM processes operating in very different regions of processing space.
Additive Manufacturing Process Design
A current issue in metal-based additive manufacturing is achieving consistent, desired process outcomes in manufactured parts through “design” of the additive process. When process outcomes such as strength, fatigue resistance, or precision need to meet certain specifications, these specifications can be met by changes in process variables. However, the changes required to achieve a better part may not be intuitive, particularly because process variable changes can simultaneously improve some outcomes while decreasing others. In this work, an approach is demonstrated to quantify the tradeoffs between multiple process outcomes throughout the design space of process variables. User input for each process outcome is then considered and the best combination of process variables is found to achieve a user’s desired outcome.
Additive Manufacturing Challenges for Industry
The NextManufacturing Center at Carnegie Mellon is focused on industry collaboration in AM research, education and workforce training. As part of its work, the center has met with over 70 industry groups over the past 2 years and currently has a 15 member consortium supporting center activities. Based on conversations with our collaborators, this talk will define what we see are the principal technical challenges and opportunities for industry as it considers and applies AM for prototyping, tooling and manufacturing. This includes the need for expertise in navigating multiple inter-related design spaces for AM needed to fully compete in additive processing. A vision for advances in AM over the next 5 years will be presented, which forms the basis for a wide range of industrially significant AM research projects.
Dr. Jacob Rome
The Aerospace Corporation
Dr. Jacob Rome is a structural analyst at The Aerospace Corporation focusing on composite and AM parts for space applications. For the past 15 years, Dr. Rome has evaluated new designs and discrepant components for a wide range of space programs. Dr. Rome has also published and presented more than 20 conference papers on these and related topics. He earned his B.S. in Mechanical Engineering from The University of Michigan, and earned M.S. and Ph.D degrees from the University of California, San Diego.
Process Simulation for Developing and Qualifying AM Parts for Space Applications
How can process simulation facilitate the design, manufacture and production of metallic AM components? The steps required to qualify an additive manufacturing (AM) part generally have direct analogs with other manufacturing methods. Therefore, the guidelines for AM parts will be similar to existing guidelines currently used in the space industry for composite or metallic parts. Qualifying a component requires tests and analyses to establish the design, material, and manufacturing process baseline. Process simulation can be used to facilitate each of these steps and to aid in the evaluation of parts through its entire life cycle. This includes the initial design and subsequent iterations, material development, the creation of a material build plan, qualification of production hardware and evaluation of as-built parts. This talk describes an approach to design for additive manufacturing and the incorporation of AM simulation.
Materials Measurement Laboratory
National Institute of Standards and Technology
Dr. Lyle Levine works in the Materials Measurement Laboratory of the National Institute of Standards and Technology (NIST) in Gaithersburg, MD, where he leads the multidisciplinary Additive Manufacturing of Metals Project that uses world-leading measurement capabilities to guide and validate high-fidelity microstructure evolution models. To help industry, Dr. Levine recently founded AM-Bench, an additive manufacturing benchmark test series with active participation from over 40 different organizations around the world. Dr. Levine has a broad scientific background with numerous diverse interests such as developing new synchrotron X-ray microbeam diffraction and small-angle scattering methods for studying material microstructures, percolation theory descriptions of dislocation behavior during plastic deformation of metals, density functional theory simulations of atomic-scale wire deformation, as well as additive manufacturing. Dr. Levine received his B.S. in physics from Caltech, and his Ph.D. in physics from Washington University in St. Louis. He has edited three books, published more than 130 technical papers, and has given about 120 plenary, keynote and other invited lectures since joining NIST. Dr. Levine is a recipient of NIST’s highest honor for innovations in measurement science, the Allen V. Astin Measurement Science Award, and the U.S. Department of Commerce Silver Medal, the department’s second highest honor.
Additive Manufacturing of Metals: Finding and Slaying the Dragons
Additive Manufacturing (AM) has been widely hailed as a new manufacturing paradigm. Here, the digital revolution meets digital manufacturing in a marriage that foreshadows a bright new future of design and production on demand. Topology-optimized parts, functionally-graded materials, limitless customization - the grandiose vision of additive manufacturing promises it all. But what problems lurk in the details? What challenges must be faced? Where are the dragons and how can they be slain?
NIST researchers and our many collaborators are working hard to find these dragons and help industry to overcome them. Many innovative approaches are being followed, including the development of world-leading metrology testbeds for AM, DOE/NIST work on generation-after-next exascale modeling for AM, and the Additive Manufacturing Benchmark Test Series (AM-Bench). Here, I will concentrate on AM-Bench, where the most rigorous and quantitative AM measurements ever conducted will be used as validation tests for your AM simulations. Over 40 organizations worldwide, including numerous companies, universities, DOE and DOD laboratories, NASA centers, and institutes have expressed support for this endeavor and are participating in our advisory committee. At last, AM simulation companies will have rigorous measurement results for testing and validating their codes. AM builders will have proof that these codes work as advertised. And end users will get better parts at an affordable price. I will describe our current thoughts on AM-Bench and its timeline. For now, keep the week of June 18, 2018 open, because all interested parties from academia, industry and national laboratories are invited to visit NIST and participate in the first AM-Bench conference, where measurements and simulations will be compared, and where discussions will be held on what worked, what didn’t work, and how we can slay the dragons that were found.
Global CAE-ACE Leader
Pieter Volgers is the DuPont Global CAE-ACE leader, driving the direction of DuPont’s CAE (particularly FEA) capability developments. He not only directs and links the various members based in the different sites around the globe, but is also actively involved in specific activities. He has developed the concept and initial implementation for DuPont’s model for thermoplastic composite materials, worked on the hyper-elastic-plastic modelling for Hytrel® and is now focusing on unreinforced engineering polymer behaviour, with Delrin® as the research base – specifically driven by gear design. A further area of his responsibilities from 2017 is that of medical device applications.
Pieter has a background is aerospace engineering, and after having worked in aerospace R&D, his particular focus has often been material modelling of composites and polymers, ranging from structural components to blister packaging film.
DuPont’s Vision for the Thermoplastic AM landscape: Breaking Down Barriers for Innovative Concepts and Validation
One of the main limitations for the development of new designs and concepts using thermoplastic polymers, is the inherent cost for prototyping, due to the need for molding tools. Continued advancements in additive manufacturing, particularly 3D printing, open the door to utilize more performant materials, such as engineering thermoplastic polymers. This, in turn, brings the promise of new, fast prototyping options for these materials.
In this contribution, potential advantages for fast prototyping with engineering thermoplastic polymers are demonstrated, along with a material supplier perspective on the requirements on simulation methods for processing and material property prediction. Harnessing all advantages would allow the performance of any given prototype to be linked to the predicted part performance as manufactured. Examples of such development accelerators will also be presented.
Zhichao (Charlie) Li
Zhichao (Charlie) Li is the Vice President at DANTE Solutions, Inc. located in Cleveland, Ohio. Dr. Li got his bachelor and master degrees on materials engineering from Harbin Institute of Technology in China, his doctoral degree from Wright State University, and joined with DANTE in 2002. His area of expertise is design optimization, finite element modeling, heat treatment process modeling and development, and fatigue life characterization and analysis.
Heat Treatment Process Modeling of Steel Components
Author: Zhichao (Charlie) Li, and B. Lynn Ferguson
Heat treatment processes are utilized for changing material properties, which is often required for improved service performance or further manufacturing processes. Quenching hardening is one common process to increase the hardness and strength of steel components, and these properties are critical to contact and bending fatigue life. The material behavior while phase transformation occurs is highly nonlinear because the material is in plastic deformation field even without external load. DANTE is a set of user subroutines linking to Abaqus/Standard including phase transformation models and multiphase mechanical models for carburization, quench hardening and tempering processes. The modeling results include volume fractions of phases, hardness, residual stresses and distortion. The implementation of these material models is demonstrated by examples of low pressure carburization, oil quench, plug/press quench, induction hardening, and a simplified additive manufacturing process.
Dr. Mike Vasquez is a 3D Printing expert specializing in pushing the boundaries of advanced 3D printing technology. He is the Founder of 3Degrees, a Chicago-based consulting company focused on helping organizations maximize their investment in the technology. He has worked side-by-side with some of the top machine manufacturers, material producers and end users in the industry, consulting with them to identify novel applications, test new materials, and develop tools to maximize efficiency and boost ROI. He completed his PhD in Additive Manufacturing at Loughborough University and received both his Bachelors and Masters from MIT in Materials Science and Engineering.
Smart Planning for Additive Manufacturing Adoption
There is little doubt that 3D Printing combined with advanced simulation tools present opportunities that are numerous and extensive. From light weighting to component reduction the ability to reduce cost and cut time to market are certainly achievable using the technology. However, the path to get to that level of adoption is often circuitous and requires smart planning across multiple stakeholders and groups. This talk will discuss best practices when it comes to assessing where your company is in that process and steps that can be taken to move your agenda forward considering facility design, software integration and adherence to standards.
Yu-Ping Yang, Ph.D.
Edison Welding Institute
Dr. Yu-Ping Yang is a Principal Engineer in EWI Structural Integrity and Modeling group. His main area of expertise is computational modeling of thermal related processes to predict temperature, microstructure, residual stress, and distortion in large and complicated structures. He has extensive experience in finite-element analysis of welded structures including static, dynamic, creep, and fatigue simulation. He also has strong capabilities in welding and thermal forming software development, and in-depth knowledge in the mitigation of weld residual stress, distortion, and cracking. Prior to joining EWI, Yu-Ping worked at Battelle Memorial Institute as a Principal Research Scientist, and he worked as a Postdoctoral Researcher at Missouri University of Science and Technology. He has developed a number of finite-element thermomechanical modeling procedures and tools to simulate manufacturing processes in many government and industrial projects. Yu-Ping is the recipient of the 2009 Sossenheimer Award for welding software development from the International Institute of Welding and the 2013 Elmer L. Hann Award from the Society of Naval Architects and Marine Engineers. He has authored approximately 100 publications in journals and conference proceedings.
Knowledge and Lessons Learned from Weld Modeling and How We Apply them to AM Process Simulation
Additive manufacturing (AM) processes for metals are extensions of welding processes. There are many similarities between AM processes and welding processes. The heat sources which include laser beam, electron beam, and electric arc that are used in welding processes are also adapted into AM processes. The materials in both welding and AM processes experience rapid heating, melting, and rapid cooling to induce material microstructure changes, residual stress, and distortion which impacts on the mechanical performance and dimension accuracy of end products. However, AM process brings more unique challenges than welding in both processes and numerical simulation.
Weld modeling technologies have been developed for more than 30 years. Heat source models have been proposed and implemented to model arc welding, laser-beam welding, and electron beam welding to predict temperature history. Metallurgical models have been developed to simulate microstructural evolution during the welding process and predict hardness in the weld and heat-affected zone (HAZ) by inputting the predicted temperature history. Mechanical models have been used to predict residual stress and distortion by inputting temperature history and microstructure evaluation. This presentation introduces the knowledge and lesson learned from welding simulation and demonstrates how to apply them in simulating AM process to predict temperature, microstructure phases, hardness, residual stress, and distortion using ABAQUS commercial software.
To predict temperature history during AM processes, Goldak double-ellipsoidal heat-source model used for weld heat-source modeling was extended to model laser-based AM processes, laser power bed fusion (L-PBF), and directed energy deposition, to calculate laser heat flux for a given location and time. To reduce the computational time during modeling L-PBF, a line-heating method was developed by integrating the Goldak heat-source model in the time taken to heat a line. In addition, the lump-pass modeling method used in welding simulation was extended to model AM processes, which results in a layer-heating method to model laser scanning of stripes with hatching and layer rotation and a square-heating method to model the chessboard heating pattern in L-PBF.
To predict microstructure evolution and hardness in AM processes, Ashby microstructure model used in welding simulation was extended to model AM processes. The microstructure and hardness of AISI 4140 steel built with L-PBF were predicted by inputting predicting the temperature history and chemical composition. Experimental measured hardness was used to validate the model prediction. It was found that tempering effect has to be modeled in order to correctly predict the hardness.
To predict residual stress and distortion induced by AM processes, mechanical models used in welding simulation was extended to model AM processes. The knowledge learned in welding simulation to model material-property changes from solid to liquid was used to simulate material-property changes from power to solid in AM processes. By comparing the modeled predicted distortion with experimental measurement, it was found that the layer-heating method is an effective modeling technique for the prediction of distortion in L-PBF production parts.
Vijay Jagdale, Ph.D.
Dr. Jagdale is a Staff Engineer in the UTRC’s Solid Mechanics group in the Physical Sciences department. Dr. Jagdales’ research areas include computational mechanics, finite element analysis, multidisciplinary design optimization, topology optimization, experimental mechanics and manufacturing process modeling. He has researched metallic and composite material systems. Dr. Jagdale is currently working on process development, physics-based process models and project management related to additively manufactured components utilizing different material systems including Nickel superalloys, Al alloys, Copper and Steel. Dr. Jagdale is leading a project on additively manufactured conformal heat exchanger from America Makes and co-lead another project with GE and Honeywell from America Makes on Development of Distortion Prediction & Compensation Methods for Metal Powder-Bed AM. Dr. Jagdale has over 15 peer reviewed journal and conference papers. He is a member of AIAA, ASME, SEM, ASM and a regular invited reviewer of articles in optimization and additive manufacturing journals.
Brad Rothenberg is the co-founder & CEO of nTopology Inc., a startup developing design software for industrial additive manufacturing. Brad has been working with 3D printing for 10 years & has a background in computational geometry in architecture. Brad received his B. Arch at Pratt institute in 2009.
More intelligent design tools
Both parametric & generative are terms used to signify intelligent tools in CAD. Initially, tools in CAD were built to replicate existing ways of doing things -- sometimes even borrowing from other industries (like lofting from the shipbuilding industry). As new manufacturing methods have emerged, like additive, the existing techniques make it difficult (if not impossible) to take advantage of all of the amazing things that these advanced processes allow for. The current argument has always been additive manufacturing allows for far more complex structures than what we could have built in the past, so design tools need to represent this complexity. While this is true, additive cannot build "anything" & there also still are a number of constraints. It is just that the constraints are different. Allowing CAD to understand constraints is the first step towards more intelligent design tools. These constraints can be mechanical: like interfaces to other parts, structural: like load cases, & they can be based on the manufacturing process: like no large horizontal spans. However, the knowledge of the constraints are not enough to design an object. Additionally, rule sets are needed that represent a structural system or typology in combination with constraints allow for more intelligent design tools. Parametric technology is still incredibly useful to allow for the constant changes within the design process while the actual tools, or operations are generative.
Head of Software Research
Blake Courter had dedicated his career to innovation in computer-aided engineering. Blake started his career at PTC, where he created new CAD tools to assist with conceptual design and components to solve interoperability problems. In 2003, Blake founded SpaceClaim, whose direct modeling paradigm heralded a new generation of mechanical CAD. In 2013, Blake joined GrabCAD to transform engineering data management an interactive, enjoyable team experience and to democratize CAD throughout engineering organizations. At Stratasys, Blake serves as Head of Software Research, where he is building a new generation of tools for functional additive manufacturing. In 2016, Blake received the Peter Marks Pioneer Award from the CAD society, which acknowledges visionary leaders in the engineering software industry. Blake holds a BS in Mechanical Engineering and a certificate in Materials Science from Princeton University.
Group Software Director/AM Business Development Manager - Americas
Stephen Anderson PhD CEng MBCS MInstP is the Group Software Director at Renishaw plc. Joining in 2000 as Internet Development Manager and switching into Group Engineering in 2007 he has over 17 years' systems software experience and has delivered much of the Group's Software portfolio across its Industrial Metrology, Healthcare and Additive Manufacturing businesses; from probing solutions to neurosurgical planning and including Renishaw's own AM build preparation software QuantAM as well as its InfiniAM machine and part status monitoring packages. In 2015 he partnered with 3DS to provide an integrated Delmia QuantAM integration with Simulia build simulation based on QuantAM outputs.
In 2017 Stephen will be transferring to take up a new role as AM Business Development Manager - America where he will be responsible for all aspects of Renishaw's AM product line in the US.
Director, Materials Strategy and PLM Integration
Arthur has developed, implemented and marketed materials information systems for over twenty years, working with three generations of materials software technology. His first company, Matsel Systems Ltd (a subsidiary of Elsevier Science Publishers), offered desktop and online materials selection software in the days before the Internet! Arthur then held a variety of positions at MSC Software, latterly as Director in Simulation Data Management. Joining Granta in 2006, he now helps to steer Granta's strategic initiatives focused on new technologies and products for integration with CAD, CAE, and PLM, and for applying materials data to optimize product design while minimizing product risk and cost. He has a BSc in Mechanical Engineering from Glasgow University and a PhD in composite materials from the University of Liverpool.
AM Informatics – optimizing Additive Manufacturing through effective use of materials and process information
Additive manufacturing promises to transform manufacturing, but only if we understand the effect of process parameters on materials in order to control part performance, consistency, and quality. A pre-requisite is a strategy to capture and mine material and process information.
AM programs generate vast amounts of data on material properties, process parameters, tests, simulation, and qualification of parts. This raises many questions: what data to retain, how to use it, and what is best practice? How to audit processes? Which parameters or relationships are critical? Can we avoid investing in parts that don’t get certified, or repeating work for certification purposes?
At Granta, we aim to answer these questions. The GRANTA MI™ materials information management system can capture, manage, and analyze complete AM process information on powders, builds, machine parameters, and parts. Collating data and sharing it between collaborating materials scientists, machine manufacturers, and process simulation experts is particularly important for AM. Full auditability and comparison between physical data and simulation data (e.g., for and from Abaqus) supports in-depth study of the parameters affecting part quality.
Such “AM Informatics” is part of a wider trend to digitalize supply chains, manufacturing processes, parts, and in-service data. Data is captured throughout the product lifecycle and analyzed for opportunities to drive down tooling costs and lead times, or to support innovation. The phrase “Digital Thread” is commonly used to describe this process. AM is ideal for Digital Thread initiatives: shortening development times, enhancing reproducibility, and improving part quality in support of qualification objectives.
Najib Baig Product Manager, Materials Innovation
Arthur Fairfull, Senior Consultant, Materials Strategy & PLM Integration
Granta Design Limited
62 Clifton Road
Arthur Dubois is an Engineer at Joby Aviation, an aerospace startup based in Santa Cruz, CA. At Joby, he is in charge of aircraft structural and thermal analysis and composite optimization. Arthur is a longtime Abaqus user, and he has been transitioning to the 3DEXPERIENCE platform over the last year. He holds a Mechanical Engineering Degree from McGill University and a Master in Aerospace Engineering from Stanford University. In his free time, you may find him on a basketball court or hiking in the Santa Cruz Mountains.
Expert Level Engineer
Daniel Fradl is an Expert Level Engineer at HP, Inc. HP, Inc builds printers, from small home printers to multi-ton industrial printers and AM printers, along with PCs and tablets. As part of a larger modelling and simulation team, he leads the structural analysis section of the team, working on printers and printing devices. For the last two years, Daniel has been primarily focused on predicting the thermal history of HP’s new line of AM printers which use Multi-Jet Fusion techniques. Daniel has been using SIMULIA Abaqus to simulate this thermal process. Daniel is publishing a technical paper at this year’s Science in the Age of Experience conference: “Finite Element Simulation of the Multi Jet Fusion (MJF™) Process using Abaqus”.
U.S. Army RDECOM-ARDEC
Pasquale Carlucci has been a Mechanical Engineer at the U.S. Army Armament, Research, Development and Engineering Center at Picatinny Arsenal, since July 2006. His duties include acting as the technical team lead on multiple developmental projects and is responsible for the design and analysis of electro-mechanical packaging of gun launched projectiles. He has worked to develop and implement new simulation capabilities, and is currently working to establish a practical workflow for modeling additive manufacturing processes. Pasquale has also served as a technical mentor and teacher for new engineers, providing guidance and training when necessary.
His primary duties include conducting dynamic, quasi-static, heat transfer and coupled FEA analyses to determine the survivability and performance of projectiles during gun launch and impact. These FEA results are used as an integral part of the design process.
Pasquale received his Bachelor's Degree in Mechanical Engineering from Brooklyn Polytechnic in 1995 and his Master's degree in Mechanical Engineering from Stevens Institute of Technology in 2001.
Bill Bihlman founded Aerolytics – a management consultancy – in 2012. The firm’s focus is materials, manufacturing and supply chain for aerospace. He started his career in 1995 with Raytheon Aircraft, eventually serving as Project Engineer. Subsequently, he was Senior Consultant with AeroStrategy. He led multiple engagements and two major intellectual property initiatives, including the well-published Aerospace Raw Materials model. Bill is a regular conference speaker both domestically and internationally, including Europe, Middle East and Asia. He is currently a PhD student in Industrial Engineering at Purdue University. He holds a BS and MS in Mechanical Engineering from Purdue University, and an MBA and MPA from Cornell University, and is a licensed pilot.