Statistical and
Data-Driven Methods for
Additive Manufacturing
Qualification

______

Robert Pool, Rapporteur

Board on Mathematical Sciences
and Analytics

National Materials and
Manufacturing Board

Division on Engineering and
Physical Sciences

Proceedings of a Workshop

NATIONAL ACADEMIES PRESS 500 Fifth Street, NW Washington, DC 20001

This activity was supported by contracts between the National Academy of Sciences and the Department of Energy and the National Science Foundation. Any opinions, findings, conclusions, or recommendations expressed in this publication do not necessarily reflect the views of any organization or agency that provided support for the project.

International Standard Book Number-13: 978-0-309-72562-0
International Standard Book Number-10: 0-309-72562-3
Digital Object Identifier: https://doi.org/10.17226/27939

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Suggested citation: National Academies of Sciences, Engineering, and Medicine. 2024. Statistical and Data-Driven Methods for Additive Manufacturing Qualification: Proceedings of a Workshop. Washington, DC: The National Academies Press. https://doi.org/10.17226/27939.

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PLANNING COMMITTEE FOR STATISTICAL AND DATA-DRIVEN METHODS FOR ADDITIVE MANUFACTURING QUALIFICATION—FUTURE DIRECTIONS AND OPPORTUNITIES IN MATERIALS AND MODELS: A WORKSHOP

THOMAS R. KURFESS (NAE), Georgia Institute of Technology, Chair

WEI CHEN (NAE), Northwestern University

TERESA CLEMENT, Raytheon

MARIA EMELIANENKO, George Mason University

ERIC FODRAN, Northrop Grumman Corporation

MIKE HALEY, Autodesk, Inc.

ADE MAKINDE, VulcanForms, Inc.

RALPH G. NUZZO (NAS), University of Illinois at Urbana-Champaign (emeritus)

ADRIAN S. ONAS, Webb Institute of Naval Architecture

MELISSA ORME (NAE), The Boeing Company

ALYSON G. WILSON, North Carolina State University

Staff

BRITTANY SEGUNDO, Workshop Director

AMISHA JINANDRA, Senior Research Analyst

SAMANTHA KORETSKY, Research Associate

MICHELLE SCHWALBE, Board Director

ERIK SVEDBERG, Scholar

BOARD ON MATHEMATICAL SCIENCES AND ANALYTICS

MARK L. GREEN, University of California, Los Angeles, Co-Chair

KAREN E. WILLCOX (NAE), The University of Texas at Austin, Co-Chair

HÉLÈNE BARCELO, Mathematical Sciences Research Institute

BONNIE BERGER (NAS), Massachusetts Institute of Technology

RUSSEL E. CAFLISCH (NAS), New York University

A. ROBERT CALDERBANK (NAE), Duke University

DUANE COOPER, Morehouse College

RONALD D. FRICKER, JR., Virginia Polytechnic Institute and State University

SKIP GARIBALDI, Institute for Defense Analyses

JULIE IVY, University of Michigan

LYDIA E. KAVRAKI (NAM), Rice University

TAMARA G. KOLDA (NAE), MathSci.ai

PETROS KOUMOUTSAKOS (NAE), Harvard University

RACHEL KUSKE, Georgia Institute of Technology

YANN A. LECUN (NAS/NAE), Facebook

JILL C. PIPHER, Brown University

AARTI SINGH, Carnegie Mellon University

BRANI VIDAKOVIC, Texas A&M University

JUDY WALKER, University of Nebraska–Lincoln

Staff

MICHELLE K. SCHWALBE, Director

SAMANTHA KORETSKY, Research Associate

HEATHER LOZOWSKI, Senior Finance Business Partner

JOE PALMER, Senior Project Assistant

BLAKE REICHMUTH, Associate Program Officer

BRITTANY SEGUNDO, Program Officer

NATIONAL MATERIALS AND MANUFACTURING BOARD

THERESA KOTANCHEK (NAE), Evolved Analytics, LLC, Chair

JOHN KLIER (NAE), University of Massachusetts Amherst, Vice Chair

KEVIN R. ANDERSON (NAE), Brunswick Corporation

CRAIG ARNOLD, Princeton University

FELICIA J. BENTON-JOHNSON, Georgia Institute of Technology

WILLIAM B. BONVILLIAN, Massachusetts Institute of Technology

JIAN CAO (NAE), Northwestern University

ELLIOT L. CHAIKOF (NAM), Harvard Medical School

JULIE A. CHRISTODOULOU, Office of Naval Research (retired)

JULIA GREER, California Technical Institute

SATYANDRA K. GUPTA, University of Southern California

BRADLEY A. JAMES, Exponent, Inc.

THOMAS R. KURFESS (NAE), Georgia Institute of Technology

MICHAEL MAHER, Maher & Associates LLC

RAMULU MAMIDALA, University of Washington

Y. SHIRLEY MENG, University of Chicago

OMKARAM NALAMASU (NAE), Applied Materials, Inc.

MATTHEW J. ZALUZEC (NAE), University of Florida

Staff

MICHELLE K. SCHWALBE, Director

BRYSTOL ENGLISH, Senior Program Officer

AMISHA JINANDRA, Senior Research Analyst

HEATHER LOZOWSKI, Senior Finance Business Partner

JOE PALMER, Senior Project Assistant

ERIK SVEDBERG, Scholar

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Reviewers

This Proceedings of a Workshop was reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise. The purpose of this independent review is to provide candid and critical comments that will assist the National Academies of Sciences, Engineering, and Medicine in making each published proceedings as sound as possible and to ensure that it meets the institutional standards for quality, objectivity, evidence, and responsiveness to the charge. The review comments and draft manuscript remain confidential to protect the integrity of the process.

We thank the following individuals for their review of this proceedings:

Although the reviewers listed above provided many constructive comments and suggestions, they were not asked to endorse the content of the proceedings, nor did they see the final draft before its release. The review of this proceedings was overseen by AJAY P. MALSHE, Purdue University. He was responsible for making certain that an independent examination of this proceedings was carried out in accordance with standards of the National Academies and that all review comments were carefully considered. Responsibility for the final content rests entirely with the rapporteur and the National Academies.

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Contents

1 INTRODUCTION

2 DATA, STATISTICS, AND ANALYTICS FOR ADDITIVE MANUFACTURING IN THE NATIONAL LABORATORIES

Manufacturing Issues

Materials Design

Examples of Projects at Lawrence Livermore National Laboratory

What Is Happening Outside the National Laboratories?

Discussion

3 ENHANCING DIMENSIONAL ACCURACY AND STABILITY WITH DIGITAL INTEGRATION

4 DIMENSIONAL ACCURACY, PART QUALITY, AND PROCESS STABILITY IN ADDITIVE MANUFACTURING

In-Process Quality Improvement

Additively Manufactured Metal Parts for Extreme Environments

A Perspective on Additive Manufacturing

Discussion

5 DIMENSIONAL ACCURACY, PART QUALITY, AND PROCESS STABILITY IN POST-ADDITIVE PROCESSES

Quality Control in Additive Manufacturing

Integrated Computational Materials Engineering

Metrology Techniques for Additive Manufacturing

Additively Manufactured Parts as Preforms for the Post-Additive Process

Discussion

6 RECAP OF DAY 1

7 A PRIMER ON STATISTICS, DATA ANALYTICS, AND ARTIFICIAL INTELLIGENCE

8 STATISTICS, DATA ANALYTICS, AND ARTIFICIAL INTELLIGENCE FOR AUTOMATED MACHINE CALIBRATION AND TOOLPATH CORRECTION

Hydrogel Infusion Additive Manufacturing

Using Gaussian Processes to Optimize Design for Additive Manufacturing

Software for the Design and Control of Defects and Microstructure

Understanding, Optimizing, and Controlling Advanced Manufacturing Processes Using Data Science

Discussion

9 OVERVIEW OF MEASUREMENT AND METROLOGY

10 MEASUREMENTS AND CALIBRATION FOR STATISTICS, DATA ANALYTICS, AND ARTIFICIAL INTELLIGENCE

The Additive Manufacturing Benchmark Series

Setting Up Workflows for Additive Manufacturing

Handling Data for Use by Artificial Intelligence

Operando Synchrotron Experiments to Study Additive Manufacturing

Discussion

11 RECAP OF DAY 2

12 BARRIERS TO THE RAPID ADVANCE OF ADDITIVE MANUFACTURING MATERIAL QUALIFICATION AND PART CERTIFICATION

Barriers to Rapid Qualification and Certification of Additively Manufactured Parts by the U.S. Air Force

Automated Metrology and Part Quality Prediction

Using Machine Learning for Additive Manufacturing

Discussion

13 KEY THEMES FROM THE WORKSHOP

Enhancing Dimensional Accuracy and Stability

Statistics, Data Analytics, Artificial Intelligence, and Machine Learning

Additive Manufacturing Material Qualification and Part Certification

Gaps and Opportunities

APPENDIXES

A Public Meeting Agenda

B Biographical Information for Workshop Planning Committee Members and Speakers

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