Digital technologies for greater accessibility to rapid certification and qualification
Using digitally informed and model-based qualification has the potential to speed up the certification and qualification process of advanced materials and technologies. MDF has created a digital framework to improve the efficiency, yield, and quality of these processes by integrating simulation, data analytics, visualization, AI, and machine learning.
How the Digital Thread Works
How the Digital Thread Works
Data collected during printing from a variety of sensors, coupled with manufacturing process/domain knowledge, can be used to quickly iterate on and improve printing parameters to an ideal state. Data gathering is then used to confirm the quality of the component after production and thus provide a new, faster, and more efficient strategy for the certification and qualification of additively manufactured components.
Smart manufacturing technologies being developed at MDF aim to provide manufacturers of all sizes with energy, cost, and time saving benefits.
ORNL-Developed Digital Technologies
Data collected during printing from a variety of sensors, coupled with manufacturing process/domain knowledge, can be used to quickly iterate on and improve printing parameters to an ideal state. Data gathering is then used to confirm the quality of the component after production and thus provide a new, faster, and more efficient strategy for the certification and qualification of additively manufactured components.
Smart manufacturing technologies being developed at MDF aim to provide manufacturers of all sizes with energy, cost, and time saving benefits.
Peregrine: AI Software for Additive
Peregrine, ORNL’s most licensed AI software, analyzes in-situ and ex-situ data in order to map anomalies and flaws in close to real time. The development of digital twins via Peregrine helps manufacturers evaluate part quality and predict performance. Data sets for an ever-expanding number of additive systems are released for use nationwide.
Simurgh: Advanced Materials Characterization
Simurgh is an AI powered X-Ray Computed Tomography (XCT) reconstruction software. It specializes in creating high-resolution digital models from fast and sparse data acquisitions, outperforming traditional XCT scans. This technology enables rapid, efficient analysis of dense, complex components. Simurgh not only accelerates XCT scans by more than 12 times but also enhances the detectability of defects by over four times. Additionally, it significantly reduces the operational costs of XCT scans, making advanced non-destructive testing both affordable and less labor-intensive.
SCOPS Sensor Package
SCOPS provides digital image correlation and thermal monitoring during additive manufacturing. The sensors track surface motion with high resolution cameras to measure in-process 3D strains. This digital monitoring method quantifies temperature and distortion over time, enabling dimensional and thermal quality controls for large scale directed energy deposition. SCOPS is deployable to systems of any size regardless of feedstock or heat source.
Slicer Software
Slicer is a software for advanced manufacturing that is in use by more than 50 organizations across equipment manufacturers, end users, and universities. This user-friendly software leverages CAD to g-code for more than 30 varieties of 3D printer, offers site-specific control for localized toolpath instruction, and allows adaptive path planning based on sensor feedback. This technology has opened up possibilities for simulation-guided slicing and adaptive control.
Recent Impacts
Faster Inspections
A software algorithm developed by Oak Ridge National Laboratory (ORNL) has reduced the time needed to inspect 3D-printed parts for nuclear applications by 85 percent.
Peregrine Licensed
Peregrine, an AI software that enables real-time assessment during 3D printing, is ORNL’s most licensed AI software and is an enabling solution for manufacturing companies of all sizes. It is fast becoming the standard for in situ monitoring for government entities.
AM Parts for Nuclear Energy Generation
MDF worked with Framatome to print and certify four “born-qualified” brackets that are currently functioning inside TVA’s Brown’s Ferry nuclear reactor. The smart manufacturing process used has the potential to enable nuclear power for US communities at reduced energy rates and costs.
Get in touch
Vincent Paquit
Section Head
Secure and Digital Manufacturing