Future Foundries is convergent manufacturing in motion. It brings together multiple systems into a single, agile platform.
Convergent manufacturing is particularly beneficial for small- and medium-sized enterprises, enabling them to expand production capabilities, become more data-driven, and strengthen the US manufacturing base in support of the nation’s clean energy and national security missions.
Benefits to industry
Scalability
Modular design enables easy integration of existing equipment, lowering barriers to entry.
Flexibility
Supports high-mix, low-volume production, crucial for small manufacturers.
Cost-Effectiveness
Reduces capital expenditure and operational costs by integrating multiple processes into one platform.
Supplementing domestic casting and forging
Supplementing domestic casting and forging
In recent decades, the US has lost 40 percent of domestic casting abilities to overseas facilities. In response, MDF is developing this new advanced manufacturing platform to help increase domestic production of critical energy and national security components to both strengthen supply chains and achieve the nation’s goal of net zero carbon emissions by 2050.
Key Features
Hybrid Manufacturing System: Combines additive manufacturing with subtractive machining, allowing the creation of complex geometries, multi-material components, and enhanced microstructures. The technology is designed to be easily transformable based on the needs and existing equipment of manufacturers.
Flexible Palletized System: Built on a Fastems FPT500 palletized system, integrated with an Okuma MU4000V machining center, and equipped with a Lincoln Electric wire-arc additive manufacturing (WAAM) system, Ajaxx TOCCO induction heating system, and a Zeiss ATOS Q laser scanner.
Interconnected smart manufacturing technologies: A cyberphysical infrastructure that allows operators to be more data-informed and accelerate production processes; uses In-situ software tools and sensor suites to characterize flaws during prints and reduce the implementation of quality control measures, with targets of catching 99% of targeted flaws and reducing QC measures by 75%; and has the ability to train operators on the technology for broad use and adoption by companies of all sizes.
Federal Funding
Federal Funding
Funding and support is provided by the US Department of Energy Advanced Materials and Manufacturing Technologies Office (AMMTO) and the Department of Defense Industrial Base and Analysis and Sustainment (IBAS) program.
MDF's history at IMTS
Future Foundries is the latest in a long line of emerging technologies, or “moonshots” that ORNL has presented at IMTS. The first was in 2014 when ORNL collaborated with Local Motors and Cincinnati Incorporated to print, machine, assemble a fully operational car, called Strati. To celebrate its 10th anniversary, Strati is on display at IMTS in 2024.
Moonshots like Strati and now Future Foundries underscore the innovative nature of MDF for bringing together multidisciplinary research teams to solve grand challenges in collaboration with industry, from equipment manufacturers to startups to trade associations.