NAVAL AIR SYSTEMS COMMAND ADDITIVE MANUFACTURING 31 March

NAVAL AIR SYSTEMS COMMAND ADDITIVE MANUFACTURING 31 March 2020 Presented to: Do. D JTEG Forum Presented by: Dr. Alan Pentz Additive Manufacturing Lead Air Systems Group Naval Air Warfare Center – Aircraft Division Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096

Navy Leadership Focus “We will be the Navy the nation needs now, and we will build the Navy the nation needs to fight and win in the future — always guided by our core values, ” – Adm. Mike Gilday, Chief of Naval Operations “We need to look at everything with a sense of urgency. It's all about talent enabling talent; giving them the tools they need, getting the talent into our acquisition enterprise. – James Geurts, Assistant Secretary of the Navy (Research, Development & Acquisition) Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096

NAVAIR’s Role in Naval Aviation • Develop, acquire and support aircraft, weapons and related systems which can be operated and sustained at sea • Provide analysis and decision support for cost / schedule / performance trades and investment decisions • Increase Navy and Marine Corps capability, readiness and affordability in a joint / coalition environment Our capabilities support the unique mission of naval aviation Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096

NAVAIR Snapshot Products Full Life-Cycle Management Requests, Risks from Fleet, OPNAV Materiel Solution Analysis Technology Maturation & Risk Reduction Engineering and Manufacturing Development Operations & Support Production & Deployment NAWCAD East Coast Hub NAWCWD Tactical Aircraft West Coast Hub Lakehurst NAWCAD Patuxent River China Lake NAVAIR HQ, PEOs, NAWCAD NAWCWD Atsugi, Japan Fleet Readiness Center Point Mugu Air ASW, Assault & Special Mission Cherry Point NAWCWD Fleet Readiness Center East North Island Fleet Readiness Center Southwest Jacksonville Fleet Readiness Center Southeast COMFRC Unmanned Aircraft & Strike Weapons Fleet Readiness Centers Orlando NAWCAD 30, 380 1, 597 11, 366 Civilians Military Contractors FY 16 Workforce Numbers Common Systems, Mission Systems, Training, ALRE Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096

Naval Aviation Enterprise Mission Sustain required current readiness and advance future warfighting capabilities at best possible cost. NAVAIR is part of the Naval Aviation Enterprise (NAE) Led by Commander, Naval Air Forces; Marine Corps Deputy Commandant for Aviation; Commander, NAVAIR Includes all naval aviation communities Facilitates collaboration, information sharing and process improvement Helps stakeholders understand costs, readiness degraders and resources Ensures naval aviation is aligned, from the warfighter at sea or on the ground to the providers in government and industry nae@navy. mil www. nae. navy. mi l Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096

NAVAIR Commander’s Intent Three Priorities: MISSION – PEOPLE – RELATIONSHIPS Shared Identity – We are providers. We enable readiness and field capabilities that meet Fleet requirements. Shared Vision – Taking readiness and speed to new levels of performance will ensure the Fleet’s success Strategic Imperatives: Increase Readiness and Speed Increase material readiness Deliver new capabilities with increased speed Roles & Responsibilities: Commands (NAWCs, FRCs) and PEOs own & execute; Competencies support Team leads are empowered to LEAD “NAVAIR’s success is measured by program / Fleet success. We share ownership in their performance and outcomes. ” – VADM Dean Peters Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096

“Mainstreaming” AM for Naval Aviation • Make AM a part of how we do business • Leverage the NAVAIR AM Command Initiative progress to standardize and scale AM across the NAE • • NAVAL AVIATION ENTERPRISE AM GOALS “Maximize the use of AM to fabricate hard-to-source or obsolete parts, reduce cost, field more effective systems and reduce reliance on vulnerable supply chains through production at the point of need” – CNO Design 2. 0 Develop and deliver the means to design, certify, produce, and use AM components across the life cycle of aviation platforms and systems RAPID DECISION MAKING AND ENGINEERING RIGOR RESILIENT AND SECURE DIGITAL ECOSYSTEM AGILE SUSTAINMENT AND DISTRIBUTED SUPPLY ACQUISITION THAT LEVERAGES AM Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 7

Where are we? • • 2015 thru 2019 Approach for qualification and certification of over 200 metal and polymer components validated Readiness improvements for “one-off” degraders demonstrated Schedule/cost improvements for small production runs (500 -2500 items) of low complexity components validated Increase in production totals with very short lead time via “distributed printing” across sites demonstrated AM technical data process and content baseline established Mainstreaming Challenges Integrating industry as we mainstream – engineering, digital, sustainment Optimizing organic and industry capacity to meet our AM goals NAVAIR AM Production Totals by 3587 Year AM Production % by Site 8% 12% 1379 80% 1005 75 2016 2017 2018 2019 D Level Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 I Level 8

Maturing Metal AM Qualification/Certification NAVAIR Metal Red Team - Outcomes • Accelerated qualification / certification of metal AM parts for 9 components in 2019 • Focused on metal AM readiness driver parts across the NAE • Matured process for metal component qual / cert F/A-18 STS Manifold Part Consolidation (Steel) CH-53 E T 64 Engine components (Aluminum) AV-8 B Engine components (Steel) 3 Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 9

Rapid Response to Grounded Aircraft Urgent Fleet Need • Marine All-Weather Fighter Attack Squadron (VMFA) 242 F/A-18 D Hornet in Japan was unable to fly due to a damaged metal shorting plug • Supply lead time estimated at up to 500 days to manufacture and ship a replacement part to Japan • NAVAIR designed and built a technical data package in 3 days and sent to Marine Aviation Logistics Squadron (MALS) 12 to validate. • MALS-12 worked with NAVAIR to update and finalize the design using their on-site 3 D printer. • Final design was approved by NAVAIR, and printed and installed by MALS-12. Aircraft back in service seven days after request. Outcomes • Validation of process to redesign a component to be printed on an available on-site printer • Demonstration of schedule/readiness impacts for “one-off” component that grounded aircraft Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 10

Hand Held Radio Thumb Rest “Just in Time” Manufacturing • • • Original HHR thumb rest rips during use and is lost. Designed AM replacement HHR thumb rest that is not susceptible to damage during use. NAVAIR produced and kitted 600 units for immediate need. Total demand is approximately 60, 000 items Rapid production timeline (10 days for 600 kits with 6 printers/2 sites) Ability to quickly turn production on/off enabled lower shelf stock approach Outcomes • Validation of ability to print high demand quantities with minimal lead time for production setup • Reduced inventory cost for shelf stock Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 11 11

Aircrew Cockpit Monitoring Device “Slam Stick” - New Design • • “Slam Sticks” are a monitoring device used by aircrew to track cabin environmental data during flight Recording is interrupted when pressure is applied to the power button and the device is inadvertently turned off A power button guard to prevent aircrew from turning off the device was needed, 2500 power button guards requested ASAP 4 design iterations completed in 5 days Production across 7 sites/15 total printers including 2 NAVAIR sites and 5 Marine Aviation Logistics Squadrons Production in accordance with NAVAIR and Maintenance Squadron policy with no interference with standard operations 2500 items delivered in 8 weeks Outcomes • Updated design process and AM Technical Data content to account for machine/material variation across sites. • Validation of manufacturing quality control requirements for distributed sites • Development of manufacturing yield rate basis for distributed manufacturing Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 12 12

AM Integration into NAVAIR Digital Transformation From a Legacy Manufacturing Process Significant Time Savings To a Digital Manufacturing Workflow • • • NAVAIR’s Digital Transformation includes standup of product life cycle management capability starting with sustainment processes NAVAIR’s first increment of “Digital Thread” capability for engineering and manufacturing data management and connectivity was online in 2019. Time improvements of 25% over legacy initial manufacturing requests and 98% over legacy for subsequent requests have been realized AM digital workflows scheduled for integration into “Digital Thread” in 2020. Outcomes • Validation of digital transformation value for legacy processes • Digital Thread can be leveraged to integrate AM digital requirements at reduced cost • AM unique tools and data will be integrated and available across all NAVAIR platforms and the sustainment community Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 13

1 4 Fleet AM Capability • • • Plan to standardize printers, materials, processes and qualification approach for multiple tiers of printer capabilities for Fleet use at fixed and expeditionary sites Develop long-term sustainment strategy for Fleet AM capabilities Alignment with industry to develop common standards for qualification of “industry equivalent” will enable distributed printing across Navy and industry sites Outcomes • Qualified and certified Fleet AM capabilities to enable production at “point of need” Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 14

“Mainstreaming” Next Steps • AM has implications across Naval Aviation and can significantly improve how we develop, produce, and sustain our systems • We must integrate AM and align with our military service and industry partners to ensure realize the potential of AM technology • We need help from industry to align our investments, processes, and business model to enable AM • We need confidence in our engineering understanding of AM benefits and risks to ensure we use it safely Distribution Statement A – Approved for public release; distribution is unlimited – NAVAIR SPR #2020 -096 15