International Conference on Additive Manufacturing

Before additively manufactured parts can be used in safety-critical applications, a clear understanding of the entire process chain and feedstock-process-structure-property-performance relationships must be established. ICAM 2022 will be the largest ASTM International scientific conference and intended to provide a forum for the exchange of ideas and to transition the research to applications, focusing on the need for industry-specific standards and design principles as well as challenges with qualification and certification.

The first event, a May 2016 workshop, was sponsored by the committee on fatigue and fracture (E08) in San Antonio, Texas. The second event, a November 2017 symposium, was sponsored by E08 committee and the committee on additive manufacturing technologies (F42) in Atlanta, Georgia. The third event in November 2018, sponsored by the F42, E08, and E07 (nondestructive testing) committees, was held in the Washington, D.C. After the creation of ASTM International Additive Manufacturing Center of Excellence (AM CoE) in 2018 and the growth of the additive manufacturing industry, the 4th event, held in Washington, D.C. area in 2019, was led by the AM CoE and dozens of involved additional technical committees. In 2020, the ASTM AM CoE decided to offer this gathering as a major conference. The ASTM International Conference on Additive Manufacturing (ICAM 2020) included 19 symposia and 10 panels, held over 5 days with 5 parallel sessions. Due to the pandemic, the ICAM 2020 was organized virtually with over 300 presentations and close to 600 participants. ICAM 2021 grew to a hybrid event held in Anaheim, CA and online, in November 2021 with over 850 participants, including 26 symposia, 11 panel discussions, and 7 keynote addresses.

This year’s event, the ASTM International Conference on Additive Manufacturing (ASTM ICAM 2022), will have a broader scope related to standardization, qualification, and certification of AM products. This event will involve even more ASTM committees and external stakeholders, setting the stage to bring experts from around the world to exchange the latest developments in the field of additive and advanced manufacturing towards the 4th industrial revolution. We invite the entire community to join us for the exchange of ideas, to learn about the most recent advancements in the field, and to be a part of the journey for transitioning research to application through standardization.

Polymers form a significant portion of additively manufactured printed products. Challenges with implementing polymer based additive manufacturing include material and process standardization, unique test standards, lack of documented design, analysis, qualification and certification methods, and a limited trained workforce.

Organizers:

Rachael Andrulonis, WSU – NIAR, USA

Cindy Ashforth, FAA, USA

Carl Dekker, Met-L-Flo, USA

Jonathan Seppala, National Institute of Standards and Technology (NIST), USA

Additive manufacturing feedstocks are available for a broad range of material types and in various forms, including powder, wire, filament, inks, etc. New offerings are continuously introduced to the market with varied and unique characteristics. In some cases, all of the critical feedstock characteristics which significantly impact the quality of each process step are not fully understood quantitatively. Therefore, a proper understanding of AM feedstock characteristics and key variables contributing to their performance can be essential for production of AM parts with repeatable quality. New characterization methods, acceptance criteria, and standards are to be developed for the complete characterization of the feedstock materials.

Organizers:

Ben Ferrar, Carpenter Additive, USA

Edward Garboczi, National Institute of Standards and Technology (NIST), USA

Steven Hall, The MTC, UK

Tony Thornton, Micromeritics, USA

Frank Venskytis, Consultant, USA

Additive manufacturing enables modernization and more capable defense systems through the fabrication of highly optimized and complex parts. It also enables improved readiness by providing an alternative route to manufacturing hard to source spare parts and parts at the point of need, e.g. by battle damage repair or temporary spare parts manufactured onsite. Because of this, the defense industry has taken a lead in advancing and maturing this technology. However, the existing commercial standards, military standards, airworthiness standards, and certification practices may be difficult to apply or are not relevant to AM parts. Thus, new standards and practices need to be developed to facilitate broader and more rapid adoption.

Organizers:

Mark Benedict, U.S. Air Force, USA

Eric Fodran, Northrop Grumman, USA

Travis Mayberry, Raytheon, USA

Katherine Olson, U.S. Army, USA

Nam Phan, Naval Air Systems Command (NAVAIR), USA

Brandon Ribic, NCDMM, USA

Hector Sandoval, Lockheed Martin, USA

As AM technologies and processes mature, complex ceramic component geometries, with suitable structural and functional properties, can be realized. AM of ceramic components has already been leveraged for applications in many industries such as aerospace, defense, biomedical, dental and satellite components. As AM ceramics become more ubiquitous, many more applications will be developed and implemented.

Organizers:

Shawn Allan, Lithoz America, USA

Brandon Cox, Honeywell, USA

Jason Jones, Moog, USA

Sean Looi, Creatz3D, Singapore

Sadaf Sobhani, Cornell University, USA

Additive manufacturing has gained significant attention in many applications and particularly for the electronics industry. Broadly, the symposium will address three major sub-categories. The first is direct printing of electronics that leverage the complex geometries and mass customization offered by AM, such as patient-specific smart implants, spatially-efficient antennas, and low-volume specialty devices. The second involves printing of high-value complex components for use in the semiconductor industry, such as components with novel designs used in wafer chambers to improve yield and process efficiency. The third is high-volume consumer electronics components that are used in, for example, computers, phones or other electronic devices.

Organizers:

Shweta Agarwala, Aarhus University, Denmark

Masoud Mahjouri-Samani, Auburn University, USA

Jaim Nulman, Nano Dimension, USA

Alireza Sarraf, Divergent3D, USA

The automotive transportation/heavy machinery industry continues to advance the use of additive manufacturing through a wide variety of manufacturing technologies and materials. The transportation industry looks to AM to enable benefits through redesign of existing components as well as part consolidation, in order to improve cost, performance, and lead time. Successful implementations have focused on the ability of AM to enable low volume solutions, but high-volume production remains a challenge. Barriers to adoption include the cost of AM production tied to large capital investment and low AM build rates, the need for suitable and cost effective materials, and a lack of data and standards to facilitate adoption with confidence in quality assurance compounds these concerns.

Organizers:

Eric Johnson, John Deere, USA

Aaron Lalonde, U.S. Army, USA

Ante Lausic, General Motors, USA

Simon Pun, Divergent, USA

The aerospace industry is one of the primary sectors which leverages additive manufacturing to its fullest extent. Cost savings, weight reduction, functional improvements and schedule optimization are the key drivers, which can be achieved by redesigning many existing components, new design concepts and through part consolidation. New materials with superior or similar properties, capable process controls and process stability, and novel design methodologies are the key enablers. However, related standards, as well as qualification and certification (Q&C) practices may need to be reevaluated/updated for additively manufactured products.

Organizers:

Thomas Broderick, Air Force Research Laboratory (AFRL), USA

Jim Dobbs, Boeing, USA

Michael Gorelik, FAA, USA

Mikkel Pedersen, Oerlikon AM, Germany

Space flight is a unique industry which utilizes additive manufacturing to its fullest potential, often resulting in geometrically complex and integrated designs that only can be fulfilled by AM. Along with structural integrity, new materials, novel designs and advanced post processing techniques are key enablers. Yet, standards, qualification and certification practices require updates for AM products for space applications.

Organizers:

Faith Oehlerking, Beehive3D, USA

Rick Russell, NASA, USA

Kiley Versluys, Relativity Space, USA

John Vickers, NASA, USA

Additive manufacturing in construction has made the headlines in many news channels, both AM specific and mainstream, with different governments putting resources into R&D with the objective to improve efficiency through reduced manpower, cost, and lead time. Besides revolutionizing how structures are built on earth, as humanity once again looks to the stars, many also see AM as ideally suited for construction on the Moon and Mars. This symposium aims to explore the current state of the art in development of AM techniques for construction across the globe with a focus on what is realistic now and what is a future possibility.

Organizers:

Michael Fiske, NASA, USA

Giada Gasparini, University of Bologna, Italy

Ali Kazemian, Louisiana State University, USA

Stephan Mansour, MaRiTama, Canada

Sam Ruben, Mighty Buildings, USA

Timothy Wangler, ETH Zürich, Switzerland

The pace of AM technology diffusion and maturity varies across different industry verticals. As compared to the aerospace, automotive, and medical, the adoption of additive manufacturing in the energy, maritime, and oil & gas industries has been moderate and is still very nascent. However, these sectors are aggressively exploring the potential of using additive manufacturing to improve operational efficiency. Many stakeholders in energy, maritime, and oil & gas have already demonstrated the capability of using additive manufacturing to produce key components, which has triggered increased interest within these industries.

Organizers:

Ole Geisen, Siemens Energy, Germany

Matt Sanders, Stress Engineering, USA

Valeria Tirelli, AIDRO, Italy

Lakshmi Vendra, Baker Hughes, USA

The medical industry is one of the key sectors to take advantage of additive manufacturing technology. AM’s unique capability to design and rapidly fabricate complex geometries using a diverse array of materials has enabled the ever-growing adoption of this technology in biomedical applications. Despite the tremendous opportunities that AM offers in manufacturing patient-specific biomedical devices with custom and complex designs in orthopedic devices, the full potential of AM to serve the medical sector has not been fully explored. Advancements in regenerative medicine, medical device fabrication, and surgical planning is enabling a broader adoption of AM in the critical medical industry. In addition, special attention is required for standardization, qualification and certification protocols of these products.

Organizers:

Matthew Di Prima, FDA, USA

David Heard, Stryker Joint Replacement, USA

Eddie Kavanagh, Johnson & Johnson, Ireland

Guha Manogharan, Pennsylvania State University, USA

Michael Roach, University of Mississippi Medical Center, USA

Utilizing the freedom of design enabled by techniques such as topology optimization and generative design approaches is one key success factor in making the most out of additive manufacturing. Design optimization, stress analysis, thermal modeling, microstructural evolution, and understanding the material-process-microstructure-property relationships significantly reduce the time and cost of AM implementation and improves adoption.

Organizers:

Eujin Pei, Brunel University London, UK

David Rosen, Georgia Institute of Technology, USA

Albert To, University of Pittsburgh, USA

Andrew Triantaphyllou, The MTC, UK

Directed energy deposition (DED) processes offer many unique capabilities for component manufacturing and repair applications. Many industries, including aerospace, energy, mining, and construction, have begun realizing the benefits of these processes in recent years, while other industries are still in the nascent stages of adoption.

Organizers:

Jean-Luc Belon, GKN Aerospace, UK

Paul Gradl, NASA, USA

Filo Martina, WAAM3D, UK

Badri Narayanan, Lincoln Electric, USA

In a relatively short time, additive manufacturing has developed from a prototyping tool to an industrial-scale manufacturing platform. Alongside this growth, and broader technology developments, there has been increasing importance and significant progress in the areas of sustainability and economics.

Organizers:

Olaf Diegel, University of Auckland, New Zealand

Gary Ng, A*STAR-ARTC, Singapore

Behrang Poorganji, Morf3D, USA

Nicolas Sabo, General Electric, USA

Additive manufacturing has evolved over the past decade and research has primarily focused on the evaluation of microstructure characterization and mechanical performance with limited emphasis on environmentally induced degradation modes. However, understanding environmental effects (e.g., corrosion, decomposition, stress corrosion cracking, etc.) on additively manufactured alloys is critical to enable use in structural components for engineering applications.

Organizers:

James Burns, University of Virginia, USA

Jiadong Gong, QuesTek, USA

Michael Melia, Sandia National Laboratories, USA

The rapid adoption of additive manufacturing across numerous industry sectors with a wide variety of applications requires methodologies for the characterization and mitigation of risk arising from material flaws. For safety-critical applications, it is particularly important to understand how material characteristics and process defects typical to AM (e.g., pores, lack of fusion, surface roughness, etc.) affect component integrity. Understanding these effects is complicated by the lack of historical data, the potential for variability in AM processes, and the rapid evolution of the technology. The qualification, certification, and safe continued use of AM products in fatigue-critical applications will depend not only on a basic understanding of damage mechanisms and the associated behavior of typical AM defects, but also on the development of robust, validated models and software for predicting fatigue life and fracture risk.

Organizers:

Stefano Beretta, Politecnico di Milano, Italy

Craig McClung, Southwest Research Institute (SwRI), USA

Thomas Niendorf, University of Kassel, Germany

Jutima Simsiriwong, University of North Florida, USA

Doug Wells, NASA-MSFC, USA

In order to produce end-use parts, additive manufacturing involves many pre-processing and post-processing steps, that are required to be safe and under control. These, sometimes non-obvious, steps result from different auxiliary requirements that are not always in the mainstream discussion.

Organizers:

Sara Bagherifard, Politecnico di Milano, Italy

David Brackett, The MTC, UK

Nik Hrabe, National Institute of Standards and Technology (NIST), USA

Jasmin Kathrin Saewe, Fraunhofer ILT, Germany

Brian West, NASA, USA

The rapid advancement of additive manufacturing technologies and increased adoption of the technologies in industry have coincided with the emergence of artificial intelligence and machine learning (AI & ML) in the mainstream. A massive amount of data is being generated in AM from various steps of the AM process, including design, process planning, building, in-situ monitoring, post-processing, inspection, characterization, and testing, as well as operation performance, during the service life of the component. Further, a high number of parameters are being defined for monitoring and control of AM processes. Both data and parameters make AM a great candidate for AI and ML applications. The objective of applying AI & ML is to better understand underlying physical phenomena in AM and fine tune the AM processes.

Organizers:

Kareem Aggour, GE Research, USA

Shaw Feng, National Institute of Standards and Technology (NIST), USA

Branden Kappes, Contextualize, USA

Jia (Peter) Liu, Auburn University, USA

Advancing towards the vision of Industry 4.0, information sharing via a distributed manufacturing framework internally in an organization and over the global internet becomes increasingly utilized with additive manufacturing. AM is a direct digital manufacturing method, and as the AM equipment becomes more closely interconnected with other components of Industry 4.0, it becomes exposed to a variety of cyber- and cyber-physical attacks. Therefore, security of AM should be addressed in a holistic manner. This includes but is not limited to identifying cyber-security threats in AM and how they can be addressed, to ensure and support the advancing of manufacturing to a whole new level. This symposium explores specific security aspects for AM in an Industry 4.0 environment.

Organizers:

Chris Adkins, Identify3D, USA

Nikhil Gupta, New York University (NYU), USA

Mark Yampolskiy, Auburn University, USA

Additive manufacturing presents us with a unique opportunity of generating massive amounts of data from various steps of the AM process, including design, process planning, building, in-situ monitoring, post-processing, inspection, characterization, and testing, as well as operation performance, during the service life of the component. While such data can be used to better understand key process variables (KPVs) and support decision making, it simultaneously presents a big data management challenge. Methods of AM data labeling, acquisition, storage, analysis, security, and sharing are yet to be fully explored. While many companies have developed internal procedures to address the above challenges, the AM community would benefit from standards and best practices that are widely accepted and available to the general public, particularly small and medium size enterprises (SMEs).

Organizers:

Amber Andreaco, GE Additive, USA

Matthew Jacobsen, Air Force Research Laboratory (AFRL), USA

Alex Kitt, EWI, USA

Yan Lu, National Institute of Standards and Technology (NIST), USA

Nick Parry, AdditiveFlow, USA

Established testing standards exist for deriving different mechanical properties; however, it has become clear that conventional procedures may not always be applicable to additive manufactured materials due to the nature of the additive fabrication process. Additionally, unique mechanical characteristics and property dependence often exist under different conditions such as geometry, process parameters and post-process procedures.

Organizers:

Joy Gockel, Colorado School of Mines, USA

Edward Herderick, Ohio State University, USA

Robert Lancaster, Swansea University, UK

Jyi Sheuan (Jason) Ten, A*STAR-SIMTech, Singapore

Phuong (Jonathan) Tran, RMIT, Australia

Key performance metrics and characteristic properties of additively manufactured components are often different from their conventionally manufactured counterparts, owing to AM materials’ distinctive microstructural features (e.g., strong texture, columnar grains, etc.) and possible process induced defects (e.g. lack of fusion/pores, cracks, surface features, etc.). These characteristics arise because of processing conditions unique to AM, such as layer-wise fabrication and exceptionally high cooling rates. It is therefore important to explore the various microstructural characteristics of AM materials and their impact on properties via experiments, models and simulations.

Organizers:

Jonathan Pegues, Sandia National Laboratories, USA

Shuai Shao, Auburn University, USA

Swee Leong Sing, National University of Singapore (NUS), Singapore

Chantal Sudbrack, NETL, USA

While destructive evaluation methods such as mechanical testing and microstructural characterizations are often used to evaluate mechanical performance of additive manufacturing materials and parts, nondestructive evaluation (NDE) methods can provide significant insights without the need for sectioning and damaging the part. Due to the fact that the mechanical performance of AM parts is often significantly influenced by the presence of defects (i.e., pores, lack of fusion, surface roughness, etc.), understanding the critical characteristics, such as type, size, distribution, and location is key to managing performance expectations and qualification.

Organizers:

Alphons Antonysamy, GKN Aerospace, UK

Anton Du Plessis, Stellenbosch University, South Africa / Object Research Systems, Canada

Ben Dutton, The MTC, UK

Patrick Howard, GE Aviation, USA

As the field of additive manufacturing quickly evolves, in-process control and in-situ monitoring become more essential, as the fusion process could significantly impact quality of AM parts. The AM community recognizes that more integrated efforts to accelerate the standardization of in-situ monitoring can play a significant role in advancing AM.

Organizers:

Darren Beckett, Sigma Labs, USA

Ajay Krishnan, EWI, USA

Abdalla Nassar, Pennsylvania State University, USA

Tuan Tran, Nanyang Technological University (NTU), Singapore

Additive manufacturing (AM) technologies are the latest evolution of the CAD/CAM breakthroughs of the last few decades. They have enabled innovation and speed to market though faster prototyping and optimized part geometries. Combining robotics and automation with AM processes is unlocking new production capabilities and scale. Our challenge now is to bring this technology to the production line increasing production efficiency, reducing cost per part produced, and enhancing safety. This symposium will bring together experts from robotics, automation, and additive manufacturing to talk through these challenges, share new capabilities, and propose strategies to take the next step.

Organizers:

Mike Bearman, Vecna Robotics, USA

Joseph Falco, National Institute of Standards and Technology (NIST), USA

Philip L. Freeman, Boeing, USA

Adam Norton, University of Massachusetts Lowell, USA

Aaron Prather, ASTM International, USA

The interest in sinter-based additive manufacturing processes continues to rapidly grow with the promise of enabling new applications by significantly reducing production costs. Sinter-based AM processes now include Binder Jetting (BJT), Material Extrusion (MEX), Material Jetting (MJT) and Vat Photopolymerization (VPP) technologies. Unique In these processes, powder material is bound together with a binding agent during the printing process, commonly referred to as a “green” or “brown” part. Secondary debinding and sintering steps are required to remove the binding agent and consolidate the powder material to the desired final density. While the potential is high, there are many challenges involved in these processes.

Organizers:

Usama Attia, The MTC, UK

Animesh Bose, Desktop Metal, USA

Amy Elliot, Oak Ridge National Laboratory (ORNL), USA

Benoit Verquin, CETIM, France

Graduate and undergraduate students were invited by ASTM Additive Manufacturing Center of Excellence (AM CoE) to participate in the student presentation competition that was held in conjunction with ASTM International Conference on Additive Manufacturing (ASTM ICAM).