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America Makes

NIST Polymer Workshop:

Additive Manufacturing Roadmapping Overview

Rob Gorham

America Makes

Director of Operations
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Complementary Technology

Additional technologies (i.e. IT) and tools 

required for a mature 3DP capability

Talent (People)

Competencies, skills, 

talent infrastructures and 

workforce planning

Process

Integrated set of process and 

activities designed to achieve 

an outcome

Governance

Clear roles, decision 

rights, and policies

Insights

Decision flows, 

information and 

analytics

Mission

Purpose of a capability, how it will 

operate, and what it will deliver

Technology

Roadmap

Creating capabilities

Technology 

Roadmap

(Today)
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 America Makes has released v2.0 of the 

Technology Roadmap using a systems 

engineering-based methodology

 America Makes has partnered with Deloitte on 

a shared vision for growing from technology 

development to capability development

 Execute a continuous Systems Engineeringbased approach to roadmap development, 

anchored by in-person workshops featuring a 

suite of enhanced facilitation techniques

America Makes Roadmapping Approach
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Swimlane Critical Technology Element Impact Focus

Bio-Inspired Design & Manufacturing

Cost & Energy Driver Driver Analysiss

Design Aides/Apps

Additive Mfg Tech Data Packages

Next-Gen Materials

Powder/Material Characterization

Multi-Material Delivery & Deposition

Next-Gen Machines

Process Temperature Gradient Control

Digital Thread Integration

Advanced Sensing & Detection Methods

Intelligent Machine Control Methods

Rapid Inspection (Post Build)

Repair Technologies

Standards/Schemas/Protocols

Benchmark Validation Use Cases

Physics-Based Modeling & Simulation

Model-Assisted Property Prediction

Design

Material

Process

Value Chain

AM Genome

Complexity Exploitation, 3D Graded Materials, MultiMaterial Integration, Model-Based Development, 

Product Customization

Standard Feedstock Materials, Benchmark Property 

Data, Microstructure Relationships, Process Window 

Definition, Processing Guidelines & Specifications

Faster Build Speeds, Improved Surface Quality, Larger 

Part Envelopes, Improved Detail Capability

Material Costs, Processing Costs, Quality Control Costs, 

Productivity Costs, Energy Efficiency Costs

Concurrent Methods, Computational Tools, Experimental 

Tools, Modular Open Simulations, Open Multi-Scale 

Data
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Additive Manufacturing Technology Roadmap 

Level 1
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The Design focus area of the Roadmap is aimed 

at driving technological advancements in new 

and novel non-proprietary design methods and 

tools required to enable a culture change and 

break the cycle of designing additive 

manufacturing parts like cast or machined parts. 

The technical focus for this area includes:

• Complexity exploitation

• 3D functionally graded materials

• Multi-material integration

• Model-based inspection

• Product individualization and customization

Design Overview
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2013 2014 2015 2016 2017

DESIGN Level 2

Maturation Needs

Ti-64 DMLS Production Cost Modeling

Cost & Energy Driver Analysis/Modeling

Bio-Inspired Design & Manufacturing

America Makes Technology Roadmap 

Level 2

Ti-64 EBM Production Cost Modeling

Cradle-to-Cradle Life Cycle Energy Use Modeling

Product/Process Family Energy Use Modeling

Product & Process Design Aides/Apps

Cellular FEA Topology Models for DMLS Ti-64

Efficient Structural Analysis Algorithms for Cellular Structures

FDM ULTEM 9085 Tooling Design Guidelines

SLS CFR ESD PEKK Topology Optimization Guidelines

Integrated AM and Secondary Machining Support Guidelines

FDM ULTEM 9085 Part Design and Build Path Guidelines

Project Call 3 – Summer 2015 Focus Area

Rule-Based DFM Methods & Algorithms

CAD Linkable Expert Design Advisors

Design Specification Query Algorithms

Automatic Generation of Process/Material/Machine Compliance

2018 2019 2020

Design Advisors that Recommend Rapid Qual/Cert Approaches
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Material Overview

The Material focus area of the Roadmap is 

aimed at building the body of knowledge for 

benchmark additive manufacturing property 

characterization data and eliminating variability 

in “as-built” material properties.

The technical focus for this area necessitates 

the development of:

• Standardized feedstock materials

• Benchmark material property data

• Process-property-structure relationships

• Process window boundary definition

• Post-processing guidelines and specifications
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2013 2014 2015 2016 2017 2018 2019 2020

EBM Ti-64 & Co-Cr PV Process Maps

“Non Ad Hoc” Additive Manufacturing Tech Data Packages

DMLS Ti-64 & Co-Cr PV Process Maps

LENS Ti-64 & IN718 Process Window Characterization

EB-DED Ti-64 Microstructure for Ultrasonic NDI

Project Call 3 – Summer 2015 Focus Area

Material Property Characterization

FDM ULTEM 9085 B-Basis Allowable Data

SLS CFR ESD PEKK B-Basis Design Allowable Data

EBM Ti-64 & Co-Cr Wire Feedstock Effects on Microstructure

DMLS Ti-64 & Co-Cr Powder Feedstock Effects on Microstructure

SLS PEKK Characterization

SLS Cu Characterization

EBM Ti-64 & Co-Cr Feedstock to Property Relationships

DMLS Ti-64 & Co-Cr Feedstock to Property Relationships

EBM Ti-64 B-Basis Allowable Development

Project Call 3 – Summer 2015 Focus Area

Next-Gen Materials

SLS CFR ESD PEKK Recyclability Guidelines

Low Cost Recycled Al Material Specifications

Forging Tool Wear Resistant Coating Guidelines

Biocompatible/Bioabsorbable Binder-Jet Fe-Mn

Project Call 3 – Summer 2015 Focus Area Material Recyclability Indices

MATERIAL Level 2

Maturation Needs

America Makes Technology Roadmap 

Level 2
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The Process focus area of the Roadmap is 

aimed at driving technological advancements 

that enable faster, more accurate, and higher 

detail resolution additive manufacturing 

machines with larger build volumes and 

improved “as-built” part quality. 

The technical focus for this area includes:

• Build speed

• Accuracy

• Detail capability

• Surface quality

• Maximum part size

Process Overview
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2013 2014 2015 2016 2017 2018 2019 2020

Multi-Material Delivery & Deposition

Project Call 3 – Summer 2015 Focus Area

3D-Gradient Material Deposition Control

Next-Gen Machines

Modular LENS Machine Tool Retrofit Systems

Low Cost Recycled Aluminum Desktop Printer

Micro-Induction Sintering Test Bed

High-Throughput LHW Ni & Ti Processing

Hybrid AM and Subtractive Systems

Project Call 3 – Summer 2015 Focus Area

Open Source PLC Architectures

Process Temperature Gradient Control Systems

Project Call 3 – Summer 2015 Focus Area

Real-Time Processing Temperature Analysis Methodologies

PROCESS Level 2 

Maturation Needs

America Makes Technology Roadmap 

Level 2
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The Value Chain focus area of the Roadmap is 

aimed at driving technological advancements 

that enable step change improvements in endto-end value chain cost and time to market for 

additive manufacturing produced products.

The technical focus for this area includes:

• Processing costs

• Feedstock material costs

• Quality control costs

• Labor productivity costs

• Energy efficiency costs

Value Chain Overview
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IR Imaging for Laser PBF Thermoplastics

2013 2014 2015 2016 2017 2018 2019 2020

Advanced Sensing & Detection Methods

In-Situ Laser PBF Defect Monitoring Sensor Test Bed

Layer-by-Layer 3D Quality Certificates

3D Visualization Methods for Thermal Imaging Data

Multi-Sensor Thermal Imaging Systems for EBM & LENS Processes

Digital Thread Integration

MBE Methods for Integrated AM & Secondary Machining Real-Time "As-Designed" vs. "As-Built" Toler. Comparisons

Intelligent Machine Control Methods

Process Map Microstructure Control Algorithms

Distortion Compensation Control Algorithms

Integrated AM & Secondary Machining Control

Thermal Imaging Control of Laser PBF Thermoplastics

Model-Based Closed Loop Feedback Control Algorithms 

Rapid Inspection Technologies

In-Situ QA Methods for Superalloy Laser PBF

NDE Post-Build Inspection of Laser PBF

Ti & Ni Alloy X-Ray CT NDI Procedures

Repair Technologies

H13 Die Cast Tooling Repair & Rejuvenation Guidelines

Laser Powder Directed Energy Part Repair Methods

Standards/Schemas/Protocols

NIST Round Robin Protocols Open Laser PBF Control Protocols

EB-DED Ti-64 Ultrasonic NDI Protocols

Industry Specific Qual/Cert Protocols

Third Party Data Capture Templates

Data Repository Card Catalog & Pedigrees Shared Data Repository Schemas

Project Call 3 – Summer 2015 Focus Area

Project Call 3 – Summer 2015 Focus Area

Project Call 3 – Summer 2015 Focus Area

VALUE CHAIN Level 2 

Maturation Needs

America Makes Technology Roadmap 

Level 2
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The Additive Manufacturing Genome focus area 

of the Roadmap is aimed at accelerating 

technological advancements that enable step 

change improvements in the time and cost 

required to design, develop, and qualify new 

materials for additive manufacturing. 

The technical focus for this area includes:

• Computer-aided materials development

• Modular open simulation frameworks

• Access to open transparent material property 

data

• Multi-scale data management 

• Sharing efficient material property 

characterization method

AM Genome Overview
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EBM Al Process Modeling

2013 2014 2015 2016 2017 2018 2019 2020

Benchmark Validation Use Cases

Ti & Ni Alloy X-Ray CT NDI Reference Test Coupons

EB-DED Ti-64 Ultrasonic NDI Test Coupons

Model-Assisted Property Prediction

ICME & Data Repository Statistical Model Links

Physics-Based Modeling & Simulation

Laser PBF Al Process Modeling

DMLS Numerical Simulation Methods

LENS Ti-64 ABAQUS FEA Set-Up Scripts

Laser PBF Ni, Co, and Ti Distortion Modeling

Project Call 3 – Summer 2015 Focus Area

Project Call 3 – Summer 2015 Focus Area

Project Call 3 – Summer 2015 Focus Area

AM GENOME Level 2

Maturation Needs

America Makes Technology Roadmap 

Level 2
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Title Lead Organization Lead Investigator NCDMM Project 

Manager

Total Funding

3D Printing Multi-Functionality: Additive Manufacturing 

for Aerospace Applications

University of Texas-El Paso Ryan Wicker Randy Gilmore $2,369,652.45

3D Printing Skills Development America Makes Mike Hripko $164,002.11

3D Printing Process Migration (Plastic  Metal) and 

Materials 

Lehigh University Alparslan Oztekin John Wilczynski $228,176.96

A Design Guidance System for Additive 

Manufacturing

Georgia Institute of 

Technology

David Rosen John Kimball $2,083,929.00

A Low Cost Industrial Multi3D Systems for 3D 

Electronics Manufacturing

University of Texas-El Paso David Espalin Randy Gilmore $2,408,935.00

Closed Loop Process Control for Powder Bed Fusion 

Thermoplastics

University of Texas-Austin Scott Fish Ed Nemeth $675,000.00

Digital Threading of Additive Manufacturing Boeing David Dietrich Brian Schmidt $2,071,111.00

Economic Production of Next Generation Orthopedic

Materials through Powder Reuse in Additive 

Manufacturing 

University of Notre Dame Steven Schmid Jim Fisher $1,975,086.00

Fused Deposition Modeling (FDM) of Complex 

Composites Tooling 

Northrup Grumman 

Corporation

Pedro Gonzalez Rob Gorham $697,902.12

America Makes Projects: Polymers
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Title Lead Organization Lead Investigator NCDMM Project 

Manager

Total Funding

Integrated Design Tool Development for High 

Potential Additive Manufacturing Applications

University of Pittsburgh Albert To Ed Nemeth $2,883,517.00

Maturation of FDM Component Manufacturing RP+M Tom Santelle Rob Gorham $1,933,542.33

Maturation of High Temperature Laser Sintering (LS) 

Technologies and Infrastructure for Air and Space 

Vehicles 

Northrop Grumman

Corporation

Pedro Gonzalez Rob Gorham $2,597,478.45

Maturing Additive Manufacturing for Low Cost 

Sustainment

University of Dayton Research 

Institute

Brian Rice Dave Siddle $11,860,512.00

Multidisciplinary Design Analysis for Seamless 

Additive Manufacturing Design, Analysis, Build, and 

Redesign Workflows

Raytheon Jeff Shubrooks Bill Walch $2,768,966.00

Optimizing SLS Processing Parameters for Polymer

Nanocomposites

Lehigh University Ray Pearson John Wilczynski $162,117.04

Sparse-Build Rapid Tooling by Fused Deposition 

Modeling for Composite Manufacturing and 

Hydroforming 

Missouri Science & 

Technology

Ming Leu Rob Gorham $479,192.79

America Makes Projects: Polymers 

Cont. 
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America Works

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