YOUNGSTOWN, Ohio – America Makes and the National Center for Defense Manufacturing and Machining this week announced the winners of a $6.6 million project call.

The project call, Improvements in Manufacturing Productivity via Additive Capabilities and Techno-Economic Analysis 2.0 (IMPACT 2.0), is funded by the Office of the Secretary of Defense Manufacturing Technology Program.

It consists of two areas of focus and aims to demonstrate lead time, productivity and yield improvements for casting and forging manufacturing operations using additive manufacturing technologies.

The goal of the project is to further establish data-driven methods for applying the best attributes of novel additive manufacturing metal materials.

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

“Addressing these challenges is crucial for defense 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,” Martin said. 

The project call “is designed to pinpoint the strengths and limitations of these integrated manufacturing approaches,” Martin said. “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 defense and economy.”

Here are the award winners and related topic areas:

Topic 1: Mature and Promote Methods to Add Functional Surfaces and Complex Geometric Features to Forgings

  • Team Lead: RTX Technology Research Center.
  • Project Team: Collins Aerospace, University of Pittsburgh, Camarc LLC.

Topic 2: 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.
  • 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 Co., 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.