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WhatgavetheU.S.itsprosperityandinfluence?

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World-leadingandenduringindustries!Afewexamples:• Steel• Automobiles• Aerospace• Nuclear• Telecommunications• Petrochemical• Pharmaceuticals• Internet

• Semiconductors• Machinetools• SolarCells• Lithium-ionbatteries

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ArtificialIntelligence?

Detroit

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Processinnovation:Assemblyline1924ModelT,Dearborn,MI

1920’s– 1950’sDetroitWealthiestcityintheworld

Detroittoday– urbandecayandworldclassskills

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Detroitfromabove… Heartofautomation:N-SalongI-75,E-WalongI-90BuffalotoChicago

Hundredsofinterconnectedsuppliers!!

Ohioexample– Hondaassembly(Accord,Acura,etc.)

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About600NorthAmericanSuppliers

Over$20B/yr spendinN.America

Over$10B/yr inOhioalone

LastinglegacyofHenryFord…

HondaSupplierMap

Old-SchoolProcessInnovation(ChinesePorcelain)

BlackPotteryCauldron HemuduCultureNeolithicPeriod(ca.5000-3000B.C.).Thesecookingcauldronsfrombuilt-uplayersofclayflakes,whichweredecoratedwithanoverlappingropepattern.Theywereplacedoveropenfires.

CollectionofPalaceMuseum,Beijing.Paintedpotterypotwithdragonandphoenixrelief,aswellastaotie designsforthelughandles.WesternHanDynasty,206-8B.C.

HandynastydevelopedPorcelain!!~1200° Cfiring>500yearsbeforeEurope!

MingDynasty:GoldfishVase,reignoftheJiajingEmperor(1521–67);Porcelain;Paris,MuséeGuimet261101

Porcelainwares,suchasthosesimilartotheseYongle-eraporcelainflasks,wereoftenpresentedastradegoodsduringthe15th-centuryChinesemaritimeexpeditions.(BritishMuseum)

HanDynastyKiln

Typesof“Innovation”• ScientificDiscoveryn (ideas)

• USleadstheworld!• ProvidesNobelPrizesandideas.

• ProductInnovation• Examples:iPhone,Dysonvacuum,IKEAfurnishings,TeslaS• Canbefast

• PracticeInnovation• Practicesthatinvolvenewthinkingoralgorithms• Examples:Uber,Lean,AmazonPrime,Crowdsourcing,FedEx.• Canbefast

• (Physical)ProcessInnovation• Maturationofenablingphysicalprocesses;newhardwareisinvolved.• Examplesmaking:steel,aluminum,tires,glass,semiconductors,ornewwaysofmining,suchasfracking.

• Frustratinglyslow… Butprovidessustainedadvantages

Weneedscience,andtoputitintoproduction.

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ProcessandProductInnovationintheiPhone

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Ideas Factories&Jobs

Greatdiscussiononthis:MforesightManufacturingProsperity,athttp://mforesight.org/download-reports/ MForesightsummit:June18@HamiltonHotel,Sens.Rubio&PetersKeynote!

Inforgraphics from:http://comparecamp.com/how-where-iphone-is-made-comparison-of-apples-manufacturing-process/

Anothergreatevent…

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Processinnovationispreciousandmakesclusters• Newprocessesbuildpersistentclustereconomies

• Detroità Automotive• Akronà Elastomers/polymers• Wichita,KSà Airframecomponents• Seattle,WAà Airframes• Detroità Automotive• Rochester,NYà Optics• MinneapolisàMedicalImplants• Warsaw,INà Orthopedicimplants• FortWayne,INà Electromagnetsandwires• Corning,NYà Ceramics• Toledo,OHà Glass• Shenzhen,Chinaà Electronicsystems

• Newprocessesteachnewskills,andacultureofdoing

• “Innovatehere,buildthere”doesnotwork!

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Incentives(becomedifferentineachcountry)

• Government – Employment,infrastructure,development.

• Universities – Happy&successfulstudents,facultyanddonors.

• Companies – Lucrativemarkets,lowcostproduction,sourcesofinnovation.

• Legislators – Happyconstituents(includingcompanies).

• MadeinChina2025 isverydifferentthananAmericancourseofaction.Innovationandentrepreneurshipareareasoffocus.

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AnewwaytomakestructuralpartsStuffdoesmatter– materialsandprocessingisabigpartofoureconomyandaccountsforabout1/3ofthegreenhousegasweproduce.

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MetamorphicManufacturing• AnopportunitytodosomethingestablishnewprocessesintheUS.

• Treatsneedsforcomponents(aerospace,heavyindustry,medical,etc.)withcompletelynewandsimplerproductionpaths.

• Hassimilarpotentialtoadditivemanufacturing.

• Allowssustainableproductionofcomponentswheretheyareneeded.

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Germananonymous,circa1606

ShortTutorial:Howdowemakethingsnow…

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1. Take somethingfromnature(tree,rock,etc.)2. Cutormachine somethingtosize3. Solidifyorcurealiquidinamold4. Buildsomethingfromsmallparts(add)5. Form toshapewithdies(sheet,forge,etc.)

Examplecold-forgedparts

Openandcloseddiehotforgings

Castmetalproducts• Easywaytocomplexshape• Verylittlewaste• Surprisinglevelsofinnovation• Oftenpoorpropertiesvs.wrought

ClosedDieForgingAwesomeproperties

Canbeexpensive

Longtimeandbig$tofirstpart

DigitalManufacturing• Partdescriptionisstoredonacomputer• Equipmentmakesthepartwithoutdiesormolds• Flexible,rapidproductchanges,shortlots.• Potentiallysustainable• Manufacturingcanbeatpointofneed.

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CNCMachining1st WaveDigitalManufacturing

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Subtractive/RemovalMIT - starting in ~1949

AdditiveManufacturing(a.k.a.3-Dprinting)2nd WaveofDigitalManufacturing

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NSF, etc., start early 1980’s

Federalspendingofhundredsof$MspentonAdditivesincethe1990’s

3rd Wave-- MetamorphicManufacturing(Manual)• Changeshape• ChangeProperties

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S –sensors

A –actuator

C –computation

R –robotics

T –thermal

Metamorphic Manufacturing Study• Overarching Goal of Study: jump start the

development, emergence, and growth of this potentially disruptive technology

• Identifies MM value proposition, foundational underlying technologies, fundamental science and engineering challenges/needs

• Develops recommendations and detailed action plans

• All intended to help community achieve above goal, and make quantifiable progress within next 3 years

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v Expertiseinvariedareas:metals,forging,manufacturing(includingadditive),welding,deformation,robotics,machines…

• Glenn Daehn (Team Chair) – Ohio State University

• John Allison – University of Michigan

• Elizabeth Bilitz - Finkl Steel

• David Bourne - Carnegie Mellon University

• Jian Cao - Northwestern University

• Kester Clarke - Colorado School of Mines

• Johnnie J. DeLoach Jr. – Office of Naval Research

• Ed Herderick – OSU Center for Design & Man. Excellence

• John Lewandowski - Case Western Reserve University

• Tony Schmitz – University of North Carolina

• Howard Sizek – Air Force Research Laboratory

• A. Erman Tekkaya –Tech. Univ. of Dortmund

The Study Team

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Keystudyquestion:Whatwouldbethebenefitsandchallengesindevelopingarobustandgeneralcapabilityforthedigitalreshapingofmetal?

Whatstepsareneededtoactualizesuchavision?

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Foundationalideas

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Roboticmetalforming

Opendieforging

TeamHoneyBadger,ofOhioStateUniversity.Alex Koenig,Bhuvi Nirudhoddi andBrianThurstonSee:RoboticBlacksmithing.com fordetails.

LIFTPrize– $25kofferedforasingleprogrammablesystemthatcanshape2of3targetparts.

Proof of Concept; The LIFT Prize–

FundamentalElements

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S –sensors

A –actuator

C –computation

R –robotics

T –thermal

T

S

A

R

C

SensorsThermalActuatorsRoboticsComputation

RoboticBlacksmith

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Reportoutcome:ValueProposition

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3 value categories

Actionsrecommended1. Launch Computational-MM benchmarking & modeling

efforts2. Build prototype MM process suites & exemplar parts3. Characterize critical-to-quality property drivers for MM

materials.4. Develop MM internship program5. Foster small organization-led industry-based MM

projects6. Formulate & address some grand challenge problems7. Create desktop prototype machine

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Exampleclosed-dieforgedparts

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ExampleforgingimagesfromConsolidatedIndustries:http://www.consolindustries.com/products-military-forgings.php

The3wavesofdigitalmanufacturing

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Technology 1-Subtractive 2- Additive 3- MetamorphicMachine • • •ToolPath • • •Material StateControl • •FormingStrategy •Sense,Compute,Control •

ComparingAdditiveandMetamorphicManufacturing

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Additive Metamorphic• Widerrangeofmaterials• Lessenergyconsumed• Scalestolargersizes• Bettermaterialsproperties• Integrateswithotherprocesses• Challenges:awareness,training,tools,

algorithms.

PracticalProblemBiggerproblemthanusuallyhandledinUniversityenvironment.

Precommercial.

Needsmanydisciplines:Materials,Robotics,Computation,Metrology,ArtificialIntelligence,Equipmenthosting,etc.,etc.

Needsanunusualstructureandsupport.

Usefultofindawaytodoithere.

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TechnicalcaseSubtractà AddàMorph.(shapeandproperties)

BasedonfastadvancingdisciplinesRoboticsIntegratedComputationalMaterialsEngineeringArtificialIntelligenceSensorsControl

Canscalenaturallytolargesizes

Providesexceptionalmaterialsproperties;extendabletogradedchemistry

Naturallyprovidesapathforqualificationandcertification

IsanopportunityfortheUSA.Helpsbalanceoftrade.Cementthishereby:FastinnovationSkilledworkforce(motivatedbycreativeopportunity)Uniqueandaccessibleequipment

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ConcludingRemarks…• D-Dayremindstobeselfrelianttomakewhatweneedinacrisis…• Thisprocessinnovationprovidesinfrastructureandskills;hardtomove.• MetamorphicManufacturing(roboticblacksmithing)offersanopportunitytoinvestonthegroundfloorforanewtechnology.Thiscanprovide:

• Skills• Capabilities• Jobs• Competitiveadvantages

• Dosupportmanufacturingtechnology.Weneedtokeepparitywithrivalcountries.

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