Forging Future Fleet Readiness: Lessons from History and the Promise of Additive Manufacturing

In "Freedom's Forge," author Arthur Herman details the remarkable industrial mobilization effort undertaken by the United States during World War II, particularly in the context of government contracting and war production. One example that illustrates the concept of marginal utility in government contracting is the case of the Ford Motor Company.

During World War II, Ford Motor Company made a significant contribution to the war effort by transitioning its production lines from civilian automobiles to military vehicles and equipment. Henry Ford's vision and belief in the potential for mass production played a crucial role in this transformation. Ford believed that by allocating substantial resources to wartime production, the company could achieve significant gains in terms of both profits and patriotic contribution.

Applying the concept of marginal utility, we can see that companies like Ford, which perceived the opportunity for great benefit, were willing to allocate the most resources and mobilize rapidly to capitalize on this opportunity. In the eyes of government contracting, Ford's commitment to wartime production represented a high level of marginal utility, as the company was able to produce vast quantities of essential military equipment, such as trucks, jeeps, and aircraft engines, thereby greatly contributing to the overall war effort.

How can the lessons learned from historical industrial mobilization efforts, coupled with advancements in additive manufacturing for naval readiness, address the complex geopolitical tensions facing the world today?

Fast forward to today, the demand for additive manufacturing in war production efforts for fleet readiness and availability in the US Navy presents a modern-day parallel to the industrial mobilization efforts of World War II. Additive manufacturing, including 3D printing, offers significant advantages in terms of flexibility, speed, and cost-effectiveness in producing complex parts and components for naval vessels.

Drawing lessons from World War I and World War II, where industrial mobilization played a critical role in supporting military operations, we can develop strategies to leverage additive manufacturing technology to enhance fleet readiness and availability in the US Navy. Key lessons include:

1. Government-Industry Collaboration: Foster close collaboration between government agencies, such as the Department of Defense and the Navy, and private sector companies involved in additive manufacturing. This partnership can help align priorities, streamline procurement processes, and facilitate technology transfer to accelerate the adoption of additive manufacturing in naval production.
2. Investment in Research and Development: Allocate resources towards research and development initiatives aimed at advancing additive manufacturing technologies, materials, and processes tailored to the unique requirements of naval applications. Emphasize the development of certified and qualified additive manufacturing techniques to ensure the reliability and performance of printed parts in maritime environments.
3. Workforce Training and Education: Invest in workforce training and education programs to build a skilled workforce capable of leveraging additive manufacturing technologies effectively. Provide training opportunities for naval personnel and industry professionals to enhance their proficiency in design, simulation, and manufacturing utilizing additive techniques.
4. Supply Chain Resilience: Strengthen the resilience of the additive manufacturing supply chain by diversifying sourcing options, enhancing domestic production capabilities, and mitigating potential vulnerabilities, such as reliance on foreign suppliers for critical materials or components.

By applying these lessons learned from past conflicts and leveraging the potential of additive manufacturing technology, the US Navy can enhance its fleet readiness and availability while bolstering national defense capabilities in the face of evolving threats and challenges.

How do you envision training programs addressing the multifaceted needs of additive manufacturing personnel?

Training requirements for operating additive manufacturing machinery typically encompass a blend of technical knowledge, hands-on skills, and safety protocols. Key aspects of training may include:

1. Machine Operation: Personnel must undergo comprehensive training to understand the operation of specific additive manufacturing machines, including setup, calibration, maintenance, and troubleshooting procedures.
2. Software Proficiency: Proficiency in computer-aided design (CAD) software is essential for creating and modifying digital models that serve as the basis for additive manufacturing processes. Training programs may focus on CAD software functionality, design optimization techniques, and file preparation for printing.
3. Material Handling and Preparation: Training in material handling protocols is crucial for ensuring the proper storage, handling, and processing of raw materials, including powders, filaments, and resins. This training emphasizes safety practices to minimize risks associated with material handling and exposure.
4. Quality Assurance: Quality control and assurance procedures are integral to additive manufacturing operations, requiring personnel to be trained in inspection techniques, dimensional accuracy assessment, and defect identification. Training programs may cover quality management systems, metrology tools, and adherence to industry standards.
5. Safety Training: Given the potentially hazardous nature of additive manufacturing processes, comprehensive safety training is paramount to mitigate risks associated with high temperatures, chemical exposure, and machine operation. Training modules typically cover personal protective equipment (PPE), emergency response protocols, and safe work practices in additive manufacturing environments.

By equipping personnel with the necessary knowledge and skills through targeted training programs, additive manufacturing companies can enhance operational efficiency, ensure product quality, and promote a culture of safety within the workplace.

What equipment holds the key to unlocking advanced manufacturing capabilities, catering to the evolving demands of government customers, and ensuring the highest return on investment in today's dynamic industrial landscape?

Additive manufacturing relies on a variety of machinery and equipment tailored to different printing processes and materials, along with traditional fabrication tools. Some of the key types of machinery and tools used in additive manufacturing and fabrication processes include:

• 3D Printers: These machines form the core of additive manufacturing operations, utilizing various technologies such as selective laser sintering (SLS), fused deposition modeling (FDM), stereolithography (SLA), and electron beam melting (EBM) to build objects layer by layer from digital designs.
• Powder Bed Fusion Systems: Commonly employed for metal additive manufacturing, powder bed fusion systems utilize lasers or electron beams to selectively melt layers of metal powder, enabling the production of complex metal parts with high precision and resolution.
• Material Extrusion Systems: Material extrusion, also known as fused filament fabrication (FFF), involves depositing thermoplastic filaments through a heated nozzle to create layers that fuse together to form 3D objects. These systems are widely used for prototyping, tooling, and low-volume production.
• Digital Light Processing (DLP) Printers: DLP printers utilize photopolymerization to cure liquid resin into solid layers, offering high-speed printing capabilities and exceptional surface finish quality suitable for applications in jewelry, dentistry, and rapid prototyping.

In addition to additive manufacturing equipment, traditional fabrication tools play a crucial role in the production process. These tools include:

• Plasma Cutters: Utilized for cutting through electrically conductive materials such as steel, aluminum, and copper, plasma cutters employ a high-velocity jet of ionized gas to melt and sever the material.
• Press Brakes: Press brakes are used to bend and fold sheet metal into desired shapes and angles. They exert force on the material through a punch and die system, allowing for precise and repeatable bending operations.
• Bending Tools: These tools, including manual or powered bending machines, are used to deform sheet metal or other materials into curved or angular shapes. They are essential for fabricating components with complex geometries.
• CNC (Computer Numerical Control) Machines: CNC machines, such as milling machines and lathes, are automated tools controlled by pre-programmed instructions. They are used for precision machining operations, including cutting, drilling, and shaping various materials.

By integrating both additive manufacturing technologies and traditional fabrication tools, manufacturers can leverage the strengths of each approach to produce high-quality parts and components efficiently and cost-effectively.