America Makes announces $6.6 million IMPACT 2.0 project call winners

January 17, 2025

America Makes, based in Youngstown, Ohio, and the National Center for Defense Manufacturing and Machining (NCDMM) have announced the winners of the $6.6 million Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis 2.0 (IMPACT 2.0) project call.

Funded by the US Office of the Secretary of Defense Manufacturing Technology Program (OSD ManTech), the project call consisted of two areas of focus and aimed to demonstrate lead time, productivity, and yield improvements for casting and forging manufacturing operations using Additive Manufacturing technologies.

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The winners and related topic areas are as follows:

Part A (Topics 1-3)

  • Topic 1Mature and Promote Methods to Add Functional Surfaces and Complex Geometric Features to Forgings
    • Team Lead: RTX Technology Research Center (RTRC)
    • Project Team: Collins Aerospace; University of Pittsburgh; Camarc, LLC
  • Topic 2 (1): Disseminate Leading Practices and Promote the Adoption of 3D-printed Sand Molds/Cores
    • Team Lead: Honeywell Aerospace
    • Project Team: Lightspeed Concept, Inc; American Foundry Society
  • Topic 2 (2):
    • Team Lead: Youngstown Business Incubator
    • Project Team: University of Northern Iowa 4.0 Center; The Ohio State University Center for Design and Manufacturing Excellence; The University of Tennessee Knoxville; The Boeing Company; HA International, LLC; Humtown Additive; Defense & Energy Systems, LLC; M&P Gravity Works, LLC; 3D Systems; Mathews Additive
  • Topic 3: Techno-Economic Analysis Tool for Selection of Metal Part Manufacturing Processes
    • Team Lead: The University of Arizona Investment Casting Institute
    • Project Team: PADT; 3Degrees

Part B – Rapid Casting Demonstration Challenge

  • Team Lead: Skuld, LLC | Project Team: University of Tennessee Knoxville; 3Degrees; Foundry Casting Systems; Metallurgical Solutions, Inc.; American Testing
  • Team Lead: DDM Systems, Inc. | Project Team: Department of The Air Force Sustainment Center; 76th Commodities Maintenance Group; Oklahoma City Air Logistics Complex; Tinker Air Force Base
  • Team Lead: Renaissance Services, Inc. | Project Team: UNEW; Aspen Technology, LLC; HTC (castings); A-Labs; Product Development & Analysis, LLC; The Ohio State University Center for Design and Manufacturing Excellence; Value Tool & Engineering

“For nearly two decades, challenges related to capability and capacity have significantly impacted the US casting and forging industry, creating obstacles in sourcing essential components for critical military equipment and support platforms,” explained John Martin, Research Director at America Makes.

“Addressing these challenges is crucial for defence and economic stability. While many Additive Manufacturing technologies can enhance casting operations and have proven effective across other sectors of the supply chain, augmenting and scaling these capabilities while testing them in real-world demand situations is essential.

“The IMPACT 2.0 project call is designed to pinpoint the strengths and limitations of these integrated manufacturing approaches,” Martin continued. “This initiative will empower our members and project teams to research, develop, and execute cutting-edge solutions in the casting and forging sector, a strategic move to mitigate supply chain risks that pose a threat to both the nation’s defence and economy.”

www.americamakes.us

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