Perhaps the biggest advantage of DDM is something the defense industry has not been known for over the last few decades: speed. And for good reason: The Digital Factory promises to completely revolutionize not only manufacturing processes as we know them, but manufacturers themselves. This could lead to a defense industrial base that won’t just be more diverse in its structure, but also would be more responsive to the needs of the war fighter. Having data communicated faster between the many components of a system means faster control and faster configuration of the proper parameters. Chapter 2 Digital Manufacturing Today’s Business Requirements Drive Change & … Digitalization … These systems input the sometimes complex settings required to heat an entire building or an entire complex of buildings using one energy source based on relatively simple user input. Systems of building automation, HVAC, safety instrumented systems, and many other types of direct digital control are possible largely because of data communications and microprocessor technologies. The manufacturing system specific to the modern clothing industry must react in a short time to frequent changes (fashion trends, customers' requirements, quantities, fabrics, etc.). Introduction - Digital Factory vision Digital Factory (DF) entitles the virtual environment for the lifecycle design of manufacturing processes and manufacturing systems using simulation and virtual reality technologies to optimize performance, productivity, timing, costs and ergonomics [1]. As an example, for much of the 20th century, the modern defense industry was intertwined with the commercial industrial base. We are finally at the point where the design part of the weapons manufacturing process can be much more than a physical or digital replica of a part, previously useful only in a lost wax mold for “the real part.” It can now be an actual structural member. DDM can be used to produce these parts, which also turns our present thinking about niche firms and preserving existing markets on its head. Digital manufacturing is utilized across industries. in Computer Integrated Manufacture Senior PLM Consultant, IBM Indonesia (Retired) Senior Manager, Product Development Multistrada Arah Sarana Data Communication & Networking in Manufacturing System. Many safety systems can also benefit from the technologies offered by direct digital control. What Are the Different Types of Digital Process Control. For instance, it's possible to type the desired room temperature into a thermostat and have the direct digital control system maintain that temperature almost indefinitely. DDM can more easily produce organic shapes than the linear ones commonly used in defense manufacturing. Additive manufacturing, or three-dimensional (3-D) printing, is receiving unprecedented at-tention. When evaluating Direct Digital Manufacturing for production, take a methodical analysis of cost, design, assembly, materials, and process to fully understand its benefits. Many military systems have been in service for decades — B-52s, A-10s, surface ships — yet spare parts often become hard to obtain. The Digital Metal DM P2500 is a certified metal 3D printer (CE and UL) that is compatible with certified metal materials (ISO 22068). But the important point is that these units are computer controlled. Data Communication & Networking in. DDM is the fabrication of components in a seamless manner from computer design to actual part in hand. 5. 3D printing (additive manufacturing) will accelerate the transformation of the Swiss manufacturing industry to industry 4.0. @allenJo - I think that’s a fair point. What is Direct Digital Manufacturing (DDM)? (Rare exceptions include disposable sensors like sonobuoys and small-arms ammunition.) Nyckelord: Additive Manufacturing, Direct Digital Manufacturing, massproduktion, bilindustrin, förbränningsmotor, Turbocharger, utveckling, hållbarhetsanalys, livscykelanalys. But one of the most important factors may well be a technological breakthrough that few have heard of: direct digital manufacturing (DDM). As its name implies, additive manufacturing adds material to create an object. Moreover, it lowers the barriers of entry to innovative firms outside the defense space. Other methods of printing include fused deposition modeling, which lays down liquefied plastic or metal through a thin filament that forms into the desired shape as it hardens; stereo-lithography, which uses ultraviolet lasers to cure photopolymer “resin” one layer at a time; and selective laser sintering, which uses a high-powered laser to selectively fuse powders of plastic, ceramic, glass and even metals such as titanium and aluminum into the desired 3D shape. In execution, the process is a bit more complex. The Internet has added its own twist; companies can now control virtual and distributed machine tool capacity. In July, engineers at the University of Southampton displayed an innovative new aircraft. Cyber Physical System (CPS) innovations that could find direct application in vertical sectors are currently accounting for more than $32.3 trillion in economic Driven by analog, then digital, computers, they transformed the heart of defense manufacturing from blue-collar work on the shop floor to white-collar design in the cubicle. Companies like Philco built not only radios, refrigerators and the first televisions for suburban homes, but also computers for National Security Agency and the Navy. Additive manufacturing uses data computer-aided-design (CAD) software or 3D object scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes. An automotive original equipment manufacturer (OEM) can design the entire manufacturing process digitally (tooling, machining, assembly sequencing, and factory layout) at the same time that designers are designing the next vehicle program. Much like industrial control systems, this type of control may be essential to high-risk jobs such as drilling and extracting oil. For example, if you wanted the room temperature at 75 degrees and you set the thermostat accordingly, the computer would activate the heater or AC until that desired temperature was reached – and then shut off. An old-style craftsman might slowly shape a piece of clay by hand into a handmade mug. This future is bright for defense DDM, but not yet rosy. Today, most defense firms focus mainly on the defense customer and have a production model that looks more like Ferrari. Digital Manufacturing Services & Capabilities Slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Should the temperature drop below acceptable levels, direct digital control systems can make the proper adjustments, whether those adjustments involve turning on more radiators or encouraging air circulation by turning on an array of fans and air ducts. Now we can add in the ability to rapidly fabricate the real part or system using the same digital file. Additive Manufacturing (AM) is an appropriate name to describe the technologies that build 3D objects by adding layer-upon-layer of material, whether the material is plastic, metal, concrete or one day…..human tissue.. Common to AM technologies is the use of a computer, 3D modeling software (Computer Aided Design or CAD), machine equipment and layering material. By the late 1980s, this technique was the norm. The actions we take in the near term in establishing the ground work for DDM will largely determine whether the defense industrial base forges ahead in the 21st century, or falls behind. With microprocessors as efficient as they are, I think they can act quickly to restore the target temperature. The computer kicks in with the AC to bring the temperature back down to 75. Using a laser sintering machine, they produced SULSA (Southampton University Laser Sintered Aircraft), a small, remote-controlled aircraft with elliptical wings like a World War II-era Spitfire. This type of application shows the benefit to this type of control, because a system build to monitor safety may be able to detect malfunctions long before human intervention is possible. ), which would then be assembled on a production line, often through welding. Take something like a wing actuator support for an F/A-18 fighter jet. I don’t know all the technical specs but I am sure that in the event of a fire, the unit sends a message to the central monitoring facility, based on temperature sensors. In order for the computer to maintain a certain temperature in an HVAC control system, it needs to kick in well before room temperature rises or falls from the target temperature, I would think. Compared to other consumer-focused industries, pharmaceutical and biotechnology have traditionally been slow to adopt emerging technologies. Whatever lag times may exist will be minimal in my opinion. @David09 - A DDC control system is not just limited to air conditioners or heaters however. Today, we stand poised at another critical turning point for manufacture and design — indeed, at the very intersection of these numerically controlled fabrication and simulation-based design trends. There is no way to make sure that the temperature never gets away from the target temperature; after all, it’s the very increases or decreases in temperature that act as the triggers for the heater or air conditioning units to kick in. The race to embrace Digital Factory enablers—manufacturing capabilities that drive operational improvements through the innovative use of technology (Figure 1)—is now well under way. This metal AM machine is able to churn out serial production series efficiently and reliably; one of the company’s first DM P2500 printers has been running 24/7 since 2013, according to Digital Metal. Designing for Additive Manufacturing 6. DDM is commonly explained through the example of creating a coffee cup. Technologies like digital manufacturing, the internet of things, big data, but also other innovations like crowd-sourcing, circular economy will significantly impact manufacturing and associated services and reshape competitiveness in manufacturing. Design techniques advanced as well. Two decades hence, the defense industry may look vastly different, thanks to shrinking Pentagon budgets, industrial consolidation and continuing globalization. Presently, DDM is not an option, not just because of capability but due to issues of process, safety and certification. Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Manufacturing System. In 1969, NASA released Nastran. The first of many structural analysis software packages in use today, it helped launched simulation-based design. For instance, a safety instrumented system might monitor the wellhead pressure of an oil well and take action if the pressure of that well exceeds what is considered safe. Direct Digital Radiography or Direct Capture Radiography - Direct Digital Radiography or Direct Capture Radiography Bushong Ch. Europe should … Direct Digital Manufacturing (DDM) is a process that produces parts directly from a CAD file. Contributors Include Industrial Designers and Mechanical Engineers on the FATHOM Engineering & Design Team While additive manufacturing (AM) has mostly been used as a prototyping tool, in the 3-D printing bureaus and do-it-yourself rapid prototyping machines are located around the world. What is Direct Digital Manufacturing (DDM)? This is largely due to regulatory constraints, intellectual property issues, and a generally conservative culture. But the impact will not just be at the spare part or subcontractor level. Direct Digital Manufacturing, Distributed Manufacturing and Mass Customization 8. Unlike traditional machining methods, which involve working from a rough mold and then cutting away to achieve the desired complex shape, direct digital manufacturing creates the shape precisely and instantly, using additive fabrication. To accomplish whatever task the system has been created to maintain, it might rely on collecting and processing data before changing conditions or attempting to meet certain specifications. Total Manufacturing Cost includes the costs of all resources put into production during the period (meaning, the direct materials, direct labor and overhead applied). In the 1950s, the Air Force and Army fostered the industry’s adoption of numerically controlled machine tools, lending these automated systems to contractors as part of a government-furnished equipment program. Digital manufacturing science is a science which deals the basic concepts and pivotal technologies, methods of informatics and system engineering with a target of optimal operation of the digital manufacturing system Additive Manufacturing I Additive Manufacturing (AM) refers to a process by which digital 3D design data is used to build up a component in layers by depositing material. And in this arena, as with so many other past industrial breakthroughs, military support has been important. This annual competition invites student designers to use their imagination to arrive at an innovative design, which exploits the geometric capabilities of direct digital manufacturing (DDM) to the fullest. Introduction. Other DoD-supported research projects are poised to take DDM to the next technical level, such as efforts to develop ever-more sophisticated lasers and manufacturing systems, further work on industrial- and military-strength products, and efforts to make DDM work at an even more scalable level, including through the use of nanotechnology. Wikibuy Review: A Free Tool That Saves You Time and Money, 15 Creative Ways to Save Money That Actually Work. In general, these kinds of systems include multiple components that are controlled from some central location. Additive manufacturing is a suite of emerging technologies that fabricates three-di-mensional objects directly from digital models through an additive process, typically by depos - Digital Transformation Focus on business processess that can be digitised THE BUSINESS STRATEGY CONFERENCE @luisella Hannover, Feb13th – 15th 2017 2. manufacturing is related to ICT intensive services and out of every dollar invested in manufacturing infrastructure 19 cents go to ICT services. Post was not sent - check your email addresses! The point I am making is that there may be some lag time as the HVAC is trying to “maintain” room temperature. An operative aircraft had been designed in days and could be manufactured in minutes. The ability to design, simulate and test in the virtual world allows a much more rapid turnaround than traditional techniques. Digital Manufacturing Challenge. Selecting the most suitable Additive Manufacturing (AM) process for a particular application can be difficult. Manufacturing’s Digital Business Transformation Manufacturers must fully embrace social, mobile, analytics and cloud technologies to achieve the operational excellence, agility, innovation and customer centricity required to remain relevant with customers, business partners and the entire manufacturing … More than any other manufacturing industry such as the automotive or electronics components, the clothing industry is work intensive and energy consuming. Direct digital control usually refers to a system in which a digital device such as a computer automatically controls some process based on certain conditions. Here are suggested tips. To put it another way, the defense industrial base used to be defined by firms such as Chrysler or Ford that had a foot in both defense and civilian sectors and were engaged in mass production. The very large range of available 3D Printing technologies and materials often means that several of them may be viable, but each offers variations in dimensional accuracy, surface finish and post-processing requirements.. For instance, a safety instrumented system might monitor the wellhead pressure of an oil well and take action if the pressure of that well exceeds what is considered safe. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Be careful not to confuse the terms total manufacturing cost and cost of goods manufactured with each other or with the cost of goods sold. Now, AM can bring digital flexibility and efficiency to manufacturing operations. Over the next 10 to 20 years, we may see a shift toward real-time manufacturing of components on an “as needed basis,” with parts and even entire systems being designed and produced at the time of need and even at the location of use. 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