October 16, 2018 | International, Naval

How the Office of Naval Research hopes to revolutionize manufacturing

WASHINGTON — The Office of Naval Research awarded Lockheed Martin Oct. 1 a two-year, $5.8 million contract to explore how machine learning and artificial intelligence can make complex 3-D printing more reliable and save hours of tedious post-production inspections.

In today's factories, 3-D printing parts requires persistent monitoring by specialists to ensure intricate parts are produced without impurities and imperfections that can compromise the integrity of the part overall. To improve this laborious process, the Navy is tasking Lockheed Martin with developing multi-axis robots that use lasers to deposit material and oversee the printing of parts.

Lockheed Martin has multiple partners on the contract including Carnegie Mellon University, Iowa State University, Colorado School of Mines, America Makes, GKN and Wolf Robotics and Oak Ridge National Laboratory.

The contract covers what Glynn Adams, a senior engineer with Lockheed Martin, describes as the pre-flight model of the program's development. Initial work will focus on developing computer models that can predict the microstructures and mechanical properties of 3-D printed materials to generate simulation data to train with. Adams said the Carnegie Mellon team will look at variables such as, “the spot size of the laser beam, the rate of feed of the titanium wire [and]the total amount energy density input into the material while it is being manufactured.” This information helps the team predict the microstructure, or organizational structure of a material on a very small scale, that influences the physical properties of the additive manufactured part.

This data will then be shared with Iowa State, who will plug the information into a model that predicts the mechanical properties of the printed component. By taking temperature and spot size measurements, the team can also ensure they are, “accurately controlling energy density, the power of both the laser and the hot wire that goes into the process,” Adams said..

“All of that is happening before you actually try to do any kind of machine learning or artificial neural networks with the robot itself. That's just to try to train the models to the point where we have confidence in the models,” Adams said.

Sounds easy, right?

But one key problem could come in cleaning up the data and removing excess noise from the measurements.

“Thermal measurements are pretty easy and not data intensive, but when you start looking at optical measurements you can collect just an enormous amount of data that is difficult to manage,” Adams explained. Lockheed Martin wants to learn how shrink the size of that dataset without sacrificing key parameters. The Colorado School of Mines and America Makes will tackle the problem of compressing and manipulating this data to extract the key information needed to train the algorithms.

After this work has been completed, the algorithms then will be sent to Oak Ridge National Laboratory, where robots will begin producing 3-D titanium parts and learn how to reliably construct geometrically and structurally sound parts. This portion of the program will confront challenges from the additive manufacturing and AI components of the project.

On the additive manufacturing side, the team will work with new manufacturing process, “trying to understand exactly what the primary, secondary and tertiary interactions are between all those different process parameters,” Adams said. “If you think about it, as you are building the part depending on the geometric complexity, now those interactions change based on the path the robot has to take to manufacture that part. One of the biggest challenges is going to be to understand exactly which of those parameters are the primary, which are the tertiary and to what level of control we need to be able to manipulate or control those process parameters in order to generate the confidence in the parts that we want.”

At the same time, researchers also will tackle AI machine learning challenges. Like with other AI programs, it's crucial the algorithm is learning the right information, the right way. The models will give the algorithms a good starting point, but Adams said this will be an iterative process that depends on the algorithm's ability to self-correct. “At some point, there are some inaccuracies that could come into that model,” Adams explained. “So now, the system itself has to understand it may be getting into a regime that is not going to produce the mechanical properties or microstructures that you want, and be able to self-correct to make certain that instead of going into that regime it goes into a regime that produces the geometric part that you want.”

With a complete algorithm that can be trusted to produce structurally sound 3-D printed parts, time-consuming post-production inspections will become a thing of the past. Instead of nondestructive inspections and evaluations, if you “have enough control on the process, enough in situ measurements, enough models to show that that process and the robot performed exactly as you thought it would, and produced a part that you know what its capabilities are going to be, you can immediately deploy that part,” said Adams. “That's the end game, that's what we're trying to get to, is to build the quality into the part instead of inspecting it in afterwards."

Confidence in 3-D printed parts could have dramatic consequences for soldiers are across the services. As opposed to waiting for replacement parts, service members could readily search a database of components, find the part they need and have a replacement they can trust in hours rather than days or weeks. “When you can trust a robotic system to make a quality part, that opens the door to who can build usable parts and where you build them,” said Zach Loftus, Lockheed Martin Fellow for additive manufacturing. “Think about sustainment and how a maintainer can print a replacement part at sea, or a mechanic print a replacement part for a truck deep in the desert. This takes 3-D printing to the next, big step of deployment.”

https://www.c4isrnet.com/industry/2018/10/15/how-the-office-of-naval-research-hopes-to-revolutionize-manufacturing

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November 7, 2018 | International, Aerospace, Naval, Land, C4ISR, Security

Contract Awards by US Department of Defense - November 5, 2018
AIR FORCE Lockheed Martin Corp., Orlando, Florida, has been awarded a $350,000,000 increase to an indefinite-delivery/indefinite-quantity contract for Joint Air-to-Surface Standoff Missile (JASSM) production support. Contractor will provide lifecycle support for all efforts related to JASSM, Long Range Anti-Ship Missile, JASSM-Extended Range, and any JASSM variant in the areas of system upgrades, integration, production, sustainment, management and logistical support. Work will be performed in Orlando, Florida, and is expected to be completed by April 17, 2022. This award is the result of sole-source acquisition. No funds are being obligated at the time of award. Air Force Life Cycle Management Center, Eglin Air Force Base, Florida, is the contracting activity (FA8682-17-D-0002). General Atomics - Aeronautical Systems Inc., Poway, California, has been awarded a $263,403,355 firm-fixed-price contract for MQ-9 Reaper production. This contract provides for the production of the MQ-9 Reaper aircraft in the fiscal 2018 production configuration. Work will be performed at Poway, California, and is expected to be complete by Nov. 30, 2021. This award is the result of a sole-source acquisition. Fiscal 2017 and 2018 aircraft procurement funds in the amount of $263,403,355 are being obligated at the time of award. The Air Force Life Cycle Management Center, Wright-Patterson Air Force Base, Ohio, is the contracting activity (FA8620-19-F-2374). Raytheon Co., El Segundo, California, has been awarded an $11,532,469, competitive, cost-plus-fixed-fee contract for the research and development of Millimeter-Wave Digital Arrays (MIDAS) Defense Advanced Research Projects Activity program. The contractor will address the MIDAS program goals through innovations in digital tile architecture and integrated, scalable apertures with groundbreaking transmit and receive components. Work will be performed in El Segundo, California, and is expected to be completed by Nov. 4, 2020. Fiscal 2018 research and development funds in the amount of $2,928,098 are being obligated at the time of award. Air Force Research Laboratory, Wright Patterson Air Force Base, Ohio, is the contracting activity (FA8650-19-C-7993). DEFENSE LOGISTICS AGENCY Burlington Apparel Fabrics, Greensboro, North Carolina, has been awarded a maximum $40,632,816 firm-fixed-price, indefinite-delivery contract for blue wool cloth. This was a competitive acquisition with one response received. This is a one-year contract with four one-year option periods. The maximum dollar amount is for the life of the contract. Location of performance is North Carolina, with a Nov. 4, 2023, performance completion date. Using military service is Navy. Type of appropriation is fiscal 2019 through 2023 defense working capital funds. The contracting activity is the Defense Logistics Agency Troop Support, Philadelphia, Pennsylvania (SPE1C1-19-D-1112). Burlington Apparel Fabrics, Greensboro, North Carolina, has been awarded a maximum $40,563,765 firm-fixed-price, indefinite-delivery contract for blue poly/wool cloth. This was a competitive acquisition with one response received. This is a one-year contract with four one-year option periods. The maximum dollar amount is for the life of the contract. Location of performance is North Carolina, with a Nov. 4, 2023, performance completion date. Using military service is Army. Type of appropriation is fiscal 2019 through 2023 defense working capital funds. The contracting activity is the Defense Logistics Agency Troop Support, Philadelphia, Pennsylvania (SPE1C1-19-D-1100). Southeast Power Systems of Orlando,* Orlando, Florida, has been awarded a maximum $8,247,300 firm-fixed-price, indefinite-delivery/indefinite-quantity contract for diesel engine fuel pumps. This was a sole-source acquisition using justification 10 U.S. Code 2304(c)(1), as stated in Federal Acquisition Regulation 6.302-1. This is a three-year contract with no option periods. Location of performance is Florida, with a Nov. 4, 2021, performance completion date. Using military service is Army. Type of appropriation is fiscal 2019 through 2022 Army working capital funds. The contracting activity is the Defense Logistics Agency Land and Maritime, Warren, Michigan (SPRDL1-19-D-0016). NAVY Transoceanic Cable Ship Co. LLC, Baltimore, Maryland, is awarded a $35,952,500 firm-fixed-price contract for the time charter services of a cable-laying and repair ship. This contract contains options, which if exercised, would bring the contract value to $224,619,153. Work will be performed worldwide, and is expected to be completed Jan. 10, 2019. If options are exercised, work will continue through November 2023. Fiscal 2019 operations and maintenance (Navy) funds in the amount of approximately $42,000,000 will be obligated at the time of award and will expire at the end of the current fiscal year. This contract was competitively procured with proposals solicited via the Federal Business Opportunities website and Navy Commerce Online website. Two offers were received. The Navy's Military Sealift Command, Norfolk, Virginia, is the contracting activity (N32205-19-C-3506). ExxonMobil Marine Ltd., Spring, Texas, was awarded a $16,572,038 firm-fixed-price, indefinite-delivery/indefinite-quantity contract for worldwide delivery of lubricants and related support services to Military Sealift Command vessels, Navy ships, and other government-owned or government-chartered ships designated by the Military Sealift Command. This contract contains options, which if exercised, will bring the contract value to $86,602,374. Work will be performed worldwide and is expected to be completed by Nov. 3, 2019. If all options are exercised, work will continue through Nov. 4, 2023. Fiscal 2019 Navy working capital funds in the amount of $5,000 are obligated to cover the minimum-guarantee. Navy working capital funds will be obligated on individual delivery orders for the fiscal year when delivery orders are issued. This contract was competitively procured, with proposals solicited via the government-wide Point of Entry Federal Business Opportunities website, with four offers received in response to the solicitation. The Navy's Military Sealift Command, Norfolk, Virginia, is the contracting activity (N3220519D7000). (Awarded Nov. 2, 2018) General Dynamics Electric Boat Corp., Groton, Connecticut, is awarded a $13,888,444 cost-plus-fixed-fee modification to previously-awarded contract N00024-09-C-2104 for planning and execution of USS Indiana (SSN 789) post-delivery work period. Work includes long-lead-time material procurement, in preparation to accomplish the maintenance, repair, alterations, testing and other work on USS Indiana. Work will be performed in Groton, Connecticut, and is expected to be completed by April 2019. Fiscal 2018 shipbuilding and conversion (Navy) funding in the amount of $8,638,444 will be obligated at time of award and will not expire at the end of the current fiscal year. The Supervisor of Shipbuilding Conversion and Repair, Groton, Connecticut, is the contracting activity. The Boeing Co., St. Louis, Missouri, is awarded $12,106,016 for modification P00003 to a previously awarded cost-plus-incentive-fee contract (N00019-18-C-1022) in support of the Infrared Search and Track (IRST) Block II Phase 2 non-recurring engineering effort. This modification incorporates an engineering development model and upgrades two sets of IRST Block I system weapon replacement assemblies. Work will be performed in Orlando, Florida (73 percent); and St. Louis, Missouri (27 percent), and is expected to be completed in April 2022. Fiscal 2019 research, development, test and evaluation (Navy) funds in the amount of $6,500,000 will be obligated at time of award; none of which will expire at the end of the current fiscal year. The Naval Air Systems Command, Patuxent River, Maryland, is the contracting activity. *Small Business https://dod.defense.gov/News/Contracts/Contract-View/Article/1682676/
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September 18, 2019 | International, Aerospace, C4ISR

Virtual reality training — for pilots, maintainers and more — expands in 2020
By: Stephen Losey One of the top priorities of Lt. Gen. Brad Webb, the newly minted head of Air Education and Training Command, will be expanding the Air Force's experiment with virtual reality training. So far, the Air Force has had success with Pilot Training Next, which uses VR, biometrics and artificial intelligence to better teach aspiring pilots how to fly. Webb is eyeing similar technologies, under the name Learning Next, to improve other forms of technical training. This could include teaching airmen how to maintain aircraft, fly remotely piloted aircraft or perform other technical tasks. These programs allow students' education to proceed more at their own pace, since they are based on competency and are not tied to a timetable, Wright said. A student who already has the fundamentals down can skip the basics and go right to what he or she needs to learn. AETC is now in the process of broadening Pilot Training Next, which has been a demonstration, to the next phase of wider experimentation, Webb said. He and Maj. Gen. Craig Wills, commander of the 19th Air Force, are working on plans to expand Pilot Training Next. By next summer, Webb wants to have set up Pilot Training Next elements at several squadrons, though it wouldn't be across all undergraduate pilot training bases. A few classes after that, Webb expects, Pilot Training Next will be expanded to all UPT bases. The Pilot Training Next expansion will likely be done methodically, at one base first, Webb said, though he would not say which base AETC is looking at. “What has happened in our last couple of years with Pilot Training Next has been an explosion, out of the box, of innovation,” Webb said. “Make no mistake, the Air Force wants this inculcated as fast as we can go,” he said. AETC is already in the “nascent stages” of testing VR and other technology-enhanced training for maintenance and other technical training as part of Learning Next, Webb said. Maintenance Next is a particular priority and is happening on an experimental basis at Kelly Field at Joint Base San Antonio-Lackland in Texas, he said, and using VR for RPA training is also proceeding. As the VR pilot training shows, such programs can accelerate in a hurry, he said. Ethics Webb also wants to cultivate an “environment of excellence, professionalism, ethics and character development” during his time at AETC. Webb, who was previously commander of Air Force Special Operations Command, pointed to the ethical clouds that have fallen over parts of the special operations community in recent years. For example, the Navy relieved the entire senior leadership team of SEAL Team 7 earlier this month over what it described as leadership failures that resulted in a breakdown of good order and discipline while deployed. AFSOC took a hard look at itself, Webb said, to make sure it doesn't allow similar lapses to fester. “For a leader, you can never ... talk about core values enough,” Webb said. “If I had to look myself in the mirror from my last command, I can tell you my team knew our mission and vision of priorities backwards and forwards.” But while airmen at AFSOC understood Air Force core values, he acknowledged he didn't always articulate those values in his everyday “walk-around, talk-around” encounters. That can create problems if leaders assume airmen already know about the core values, he said. When a unit starts to feel the pressure from high operations tempos and a lack of resources, Webb said, that “get-'er-done” mentality can lead to bad decisions if airmen don't have a firm foundation of the Air Force core values. “If you don't have a firm foundation, you can go to a dark place with that ... ‘find a way to yes' mentality,” Webb said. “We've got to always talk about professionalism and ethics, and also always talk about our core values. That will be a capstone” of his time at AETC. Webb said he plans to continue with AETC's recent improvements in how special warfare airmen are recruited and trained, which included standing up the new Special Warfare Training Wing and the special warfare-focused 330th Recruiting Squadron. More work needs to be done to “normalize” and fine-tune those units, and more firmly fold them into AETC's everyday culture, he said. https://www.airforcetimes.com/news/your-air-force/2019/09/16/virtual-reality-training-for-pilots-maintainers-and-more-expands-in-2020/

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How the Office of Naval Research hopes to revolutionize manufacturing

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How Space Development Agency contractors are mitigating supply chain issues Early planning, as well as collaboration and problem solving from its prime contractors, has helped SDA lessen the impact of supply chain issues that have affected the space industry in recent years.

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