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Anticipating the Broad Implications of Additive Manufacturing on Workforce Development and Education
Darrell Wallace, Ph.D. Deputy Director, Workforce and Educational Outreach National Additive Manufacturing Innovation Institute (NAMII) [email protected]
NSF Workshop on Frontiers of Additive Manufacturing
Research and Education July 12, 2013
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Why Teach Additive Manufacturing?
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Why Teach Additive Manufacturing?
Empower people to build what they dream.
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Developing Workforce and Education Framework
• Who should we teach / train?
• What should we teach / train?
• How should we teach / train?
• Challenges and opportunities?
To begin to answer these, we must understand how AM fundamentally changes the manufacturing and education environments.
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Reimagining Manufacturing
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Rethinking the Problem
Barriers to broader adoption of AM:
–Cost
–Confidence
• Solutions to these challenges are different for AM than for traditional processes.
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Traditional Model for Manufacturing
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Tooling
Engineering Design
Supply Chain
Production
Business
Warehousing
Distribution
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Disruptive Technology will Change the Downstream Model
• Warehousing
• Distribution
• Tooling
• Stock Losses / Risk
• Carrying costs
• EOQ / amortization schedules
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New Models for Manufacturing: “Traditional” Manufacturers
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= Distributed / Regional Manufacturing Centers
Engineering Design
Business
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Additive Manufacturing Changes Who Can be a “Manufacturer”
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Affordable
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=
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Accessible
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≈
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Which is the “Consumer” Product?
Milling Machine
Boutique Coffee Maker
Ability to directly control process parameters (speeds, temperatures)
Limited only by machine capabilities
Pre-set configurations
Ability to directly customize cycle (time/temperature / toolpath)
Unlimited Pre-set configurations
Raw Materials and tools Best available based on price and properties
Limited selection, OEM packaged, expensive
Flexibility to innovate High Low
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Which is the “Consumer” Product?
<$2000 “Hobby” 3D Printer
>$50,000 “Commercial” 3D Printer
Ability to directly control process parameters (speeds, temperatures)
Limited only by machine capabilities
Pre-set configurations
Ability to directly customize cycle (time/temperature / toolpath)
Unlimited Pre-set configurations
Raw Materials and tools Best available based on price and properties.
Limited selection, OEM packaged, expensive
Flexibility to innovate High Low
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Innovation from the Grass Roots • Materials
• Software
• Toolpaths
• Equipment
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Component printed with Laywoo-D3 composite wood filament
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Familiar Trajectory
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IBM System 370 1972
1 MIPS
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Intel 286 1982
2.66 MIPS
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Accelerated 2011
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2012
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Reduces the barriers to entry • Low cost for prototyping
• Production parts do not require capital investment
• Innovations are not limited to technology firms
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The Individual Manufacturing Entrepreneur
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Design Make Ship
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Designs as Apps
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Design Make
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Who do we Teach / Train?
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“Workforce”– Traditional View
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Tooling
Engineering Design
Supply Chain
Production
Business
Warehousing
Distribution
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Traditional View of “Workforce”
– Non-Degree
– Labor
– Technichians / Technologists
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“Workforce” Impacted by AM
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Tooling
Engineering Design
Supply Chain
Production
Business
Warehousing
Distribution
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A Broader Look at “Workforce” • Broadened Age Range:
– K-Gray
– Non-Degree through Ph.D.
• Broad disciplines:
– Labor
– STEM
– Creative
– Entrepreneurial
– Business Enterprise
Traditional view in Manufacturing
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Identified Focus Areas for Workforce and Education
• General Awareness
– Public, K-12
• Workforce (non-degree through graduate curricula)
– AM Foundational Understanding
– AM Technology / Process and Materials
– AM Inputs
– Design for AM
– Quality Assurance for AM
– AM Enterprise (Business and Economics)
• Advanced AM Research / Education
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Identified Target Groups for Education and Workforce Development
• Public
– General public • The curious
• The contentious
• Government
– Poltical leaders
– Economic development agencies
• Individual entrepreneurs / Makers
• K-12
– Students
– Faculty
– Administrators
– Parents
• Technical / non-Degree
– Students
– Faculty
– Administrators
• 2- and 4-year Degree Programs
– Students
– Faculty
– Administrators
• Graduate Degrees / R&D
– Students
– Faculty
• Industry by Role
– Floor Labor • Operators
• Technicians
– Engineering and Design • Manufacturing Engineers
• Designers / Design Engineers
– Business and Administration • Management
• Finance
• Inventory Management
• Transportation and Logistics
• Legal
• Industry by Segment
– Manufacturers • Component suppliers
• OEM manufacturers / integrators
– Material Suppliers
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Evolution of Job Market Job market and technology adoption are closely related
– Demand for technicians / operators will depend on viability of AM in manufacturing enterprise
– Viability of AM will depend on proper training of designers, engineers, executives, finance, logistics, etc.
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What do we Teach / Train?
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Additive Manufacturing as an Integrated System
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What do we Teach? • What we can teach effectively today:
– AM Processes
– Multidisciplinary teaming
• Topics that depend on further development:
– AM design communication
– Costing and enterprise-level design decisions
– AM design methodologies
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AM Processes • Essential for manufacturing professionals to
understand in the context of traditional manufacturing processes.
– Capabilities and limitations
– Differentiation between various AM processes (not “Catch All”)
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A Unique Bottleneck in Human History
• Papyrus
• Phonetic alphabet
• Gutenberg press
• 3-View orthographic projections
• Tolerances
• Geometric Dimensioning and Tolerancing
• Digital models (still evolving)
• Design and communication tools for AM
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Everything I Needed to Know about AM Design Communication … I learned from an Igloo
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Igloo Language
• Layer-wise construction technique
• Requires specialized language to describe
– English language: “snow”
– Inuit language: 15 lexemes with 1000+ inflected forms to describe “snow” (several of the lexemes are important for the igloos)
• Building the structure properly requires the right combination of types of snow.
– Inuits use precise language to unambiguously describe
– Other languages fumble around with modifiers: “new-fallen snow, hard-packed crust, sticky snow” etc. 36
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Chain of Design Communication • Design
– Specifications
– acceptable tolerances around nominal
• Manufacturing
– produce parts and assemblies within tolerance
• Validation
– Based on unambiguous specifications
– Based on measuring outcomes against specifications
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In a Different Context
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“Color” as a Design Parameter • Traditional design parameters are discrete /
quantized, seldom continuously varying.
• Complex contours are already a challenge for traditional design communication tools.
• Characteristics that vary in through-body gradients are much more difficult to specify / satisfy / verify.
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“Color” of Parts – 3D Gradients Some things we can currently control:
• Material composition
• Micro/Macro structure
– Microstructure
– Gross anisotropy (build orientation)
– Local anisotropy (tool path)
– E-materials (multi-material deposition patterns)
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How do we Specify / Verify?
• What is the language to communicate the “color” parameters of our parts?
• What is our ability to measure and verify
– gradated properties
– Internal geometric features
Are our designs hampered by communication?
We can make designs that we can’t effectively communicate.
How, therefore, do we teach it? 41
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Teaching Additive Manufacturing • Teaching and learning depend on effective
communication
– Present concepts
– Manipulate concepts
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DFAM (Design for Additive) • Design for Manufacturing and Assembly
(DFMA) rules have evolved to be generally applied across traditional manufacturing processes.
• AM disrupts key assumptions.
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How do we Teach / Train?
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Evolving Curriculum in Parallel with Technology
• Technology is available at all levels of education
• Not yet well understood or broadly adopted in industry
• Technology and pricing will likely change dramatically over a short time period
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AM Curriculum Development and Credentials
• AM processes developing at a faster pace than curricular programs can keep up.
• NAMII will support shared, current resources
• Aligning degree, course, certificate, and certification program content with nationally recognized consensus materials will foster broader credential recognition.
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Challenge and Opportunity • 83% of US manufacturers report an overall
shortage of qualified employees
• 59-milion K-12 Students
– Attracting just 1% more to pursue careers in STEM / manufacturing would have tremendous impacts
• Total number of 3D printers sold worldwide to-date numbers only in tens of thousands.
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Leveling the Playing Field
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• Anyone with an idea can be a manufacturer
• Same technology will be used across broad ranges demographics
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Experiential Learning • Empower students at all levels to create the
tools that allow them to learn
• Open-ended, multi-disciplinary challenges
• AM as a classroom resource to be used whenever applicable
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Growing the Pie • Opens up opportunities for the largest
untapped populations
– Hands-on experimentation at all levels of education attracts kids who are kinesthetic learners
– Low barriers to innovation and entrepreneurship
– Cost of technology is approachable
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Inspiring Ingenuity
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2013 First Robotics National Championship • Students make what they can’t buy • On-site parts hospital
• Philosophy of empowerment and self-reliance
• Demonstration of “cloud sourcing” - more than 2300 parts in 2 weeks
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Empower Everyone The best solution to any problem lies outside of your organization.
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Easton LaChappelle, 15 year old inventor of a 3D printed prosthetic arm that can be controlled by nerve and brain impulses for less than $250.
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Conclusion • The opportunities offered by AM are revolutionary.
• Dissemination of the technology to the many potential users will democratize manufacturing and spur innovation.
• Many of the biggest challenges are tied to the rapid rate of evolution.
• The ability to educate our students, workers, and enterprises about this technology is best served by a thriving, dynamic, and connected community of technology experts, manufacturers, and educators.
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