America Makes announces winners of 2022 project call awards

January 9, 2023

America Makes, Youngstown, Ohio, USA, has announced the winners of the 2022 Rapid Innovation Call (RIC) and the Steel (HY-80) Wire-Arc Additive Heat Treatment (SWAAHT) project calls, totalling $1.75 million in funding. Winning proposals were said to address the evolving challenges of the US domestic supply chain and offer progressive solutions.

“America Makes continues to support the transformation of the Additive Manufacturing (AM) ecosystem in the United States through innovative, coordinated AM technology development, and education workforce and development,” stated Dr Brandon Ribic, America Makes Technology Director. “We are thrilled to offer these funding opportunities to our members and partner with industry experts who are driven to advance AM on a national level.”

Funded by America Makes via the US Air Force Research Laboratory (AFRL), the 2022 RIC focused on promoting and accelerating the development & development of innovative, cost-effective, energy-efficient Additive Manufacturing to meet defence and/or commercial needs.

Four awardees were announced on December 16, 2022, each presented with the maximum federal funding of $100,000. This call centered on addressing the needs of the membership in five topic domains and aligns with various requirements spanning the design, process, materials, value chain and AM genome swimlanes.

The following are the RIC award winners and related topics/projects:

  • Topic 3: Process-Structure-Property Relationships for Directed Energy Deposition (DED)
    Winner: Edison Welding Institute (EWI) Project: Process, Thermal, Structure, Property Model for Ti64 Built with DED-LB
  • Topic 4: Effects of Defects — Production of Higher Criticality Parts Accelerator
    Winner: Penn State University (PSU) Project: Effect of Defects on Ti-6Al-4V Powder Bed Fusion Additive Manufacturing Components
  • Topic 5: AM Machine Qualification – Measurement Methods and Characterisation
    Winner: Colorado School of Mines Project: Measurement of Process Gas Flow and Delivered Laser Power Impact Toward AM Machine Qualification
  • Topic 5: AM Machine Qualification – Measurement Methods and Characterisation
    Winner: University of Dayton Research Institute (UDRI) Project: Rapid Print Characterisation for Machine Qualification and Equivalency

The projects are expected to be completed in June 2023 with data made available to America Makes members.

Winning proposals of the SWAAHT project call are expected to work to inform and build acquisition and sustainment frameworks that the metal AM community can leverage when producing steel DED and heat treatment practices at scale. Driven by the National Center for Defense Manufacturing and Machining (NCDMM), AFRL, and the Office of Naval Research (ONR), America Makes awarded approximately $600,000 in funding with $395,000 in matching funds from the winning project teams for a total of $1.350 million.

Announced on December 23, 2022, proposals were based on metal AM projects that aim to develop an understanding and set of tools (experimental and computational models) specific to the selection of feedstocks, AM build parameters, and post-build heat treatments applied to the DED of high-strength structural steel shapes. MIL-100S-1 DED HY-80 casting alternatives are the targeted use case examined in these studies. Winning teams can advance to phase two of the project and receive a maximum of $750,000 in (incremental) funding if phase one objectives are met.

The following are the SWAAHT award winners and related projects:

  • Project: Development and Transition of HY80 Steel for Qualification to NAVSEA WIRE-DED Tech Pub
    Winner: Worcester Polytechnic Institute (WPI)
  • Project: Additive Manufacturing Casting Replacement Optimisation (AMCRO) – Heat Treating and Chemistry
    Winner: Penn State University (PSU)

The SWAAHT projects are expected to be completed in May 2025 with data made available to America Makes members.

“We congratulate the winning project teams and are thrilled to see collaboration between the US Navy, industry, and academia,” concluded Dr. Ribic.

2022 Winter Metal AM

In the latest issue of Metal AM magazine

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Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • What happens when you take the powder out of AM? Charting the rise of wire-based DED with WAAM3D
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  • NanoAL: Alloy development on an open parameter PBF-LB machine, from installation through to Rapid Alloy Screening
  • Using the Six Sigma method to optimise metal powder spreading in PBF-LB
  • Insights from R&D to part production: How CT analysis can advance metal Binder Jetting
  • Corrosion and wear resistence of materials processed by beam-based AM technologies

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