Tech Revolution Unveiled

AMT’s Emerging Technology Center (ETC), located at the entrance of the North Building, explores advancements in automation, efficiency, agility and productivity within the industry. The ETC addresses solutions and advancements in sectors like additive manufacturing, reshoring,  aerospace, defense and robotics. 

“In the ETC, we want to push the boundaries of what's possible in manufacturing and showcase the most innovative advancements,” says Bonnie Gurney, AMT vice president – strategic content and partnerships, who spearheads the ETC. “Our goal is to bring together the latest technologies that not only address current industry challenges, but also pave the way for future growth and efficiency. From the Next-Generation Hybrid System from Oak Ridge National Laboratory to groundbreaking presentations from leaders at BlueForge Alliance, Apptronik and MTConnect, we’re excited to offer IMTS visitors a firsthand look at the cutting-edge tools and processes that are shaping the future of manufacturing.” 

Next-Generation Hybrid System

A highlight of the ETC is the Next-Generation Hybrid System, developed by Oak Ridge National Laboratory (ORNL). This integrated multi-process convergent manufacturing cell incorporates existing technologies into a custom configuration. Key components include: 

• Machining center: Supplied by Okuma, along  with cutting tools from Kennametal. 

• Robotic Wire-Arc Additive Manufacturing (WAAM): Featuring metal additive manufacturing technology from Lincoln Electric, Arc Specialties, Open Mind, Yaskawa and Roboris. 

• Machining center: Supplied by Okuma, along with cutting tools from Kennametal. 

• Pallet tower: Provided by Fastems, designed for extended unattended operation. 

• Heat-treating system: From Ajax Tocco, intended for microstructure enhancement. 

• 3D laser scanning metrology station: Supplied by Zeiss for precision measurement. 

The hybrid system’s objectives are to reduce lead times, lower costs  and replace traditional castings and forgings to reshore production, particularly for parts like turbine blades, valve bodies, conformal heat exchangers  and propellers.  

“Our convergent manufacturing platform integrates discrete technologies in a way that makes them adaptable, modular and easily accessible to produce functional parts,” says project leader and ORNL R&D staff member Thomas Feldhausen. “We want to give manufacturers more tools for their toolbox. IMTS visitors can engage with us, and we can help them find the right technologies for their application.”  

Additionally, the ORNL hybrid system is featuring  three demonstrations, including: 

1. Tooling-oriented: This demonstration produces a numbered challenge coin for each day of the show by producing a custom mold for each every day of IMTS. 

2. Casting and forging: This demonstration is based on the “Platypus”, as defined in the NAVSEA qualification publication T9074-BD-GIB-010_0300, which serves as the first article casting the Navy uses to qualify a new foundry. It also spotlights  the addition of features to a bar stock using nickel-aluminum-bronze filler wire.   

3. Clean-energy: This demonstration simulates tooth  repair on wind turbine gear. 

BlueForge Alliance 

The BlueForge Alliance (BFA) exhibit at the ETC showcases advancements in naval manufacturing, particularly through collaborations with the U.S. Navy and key industry players such as Newport News Shipbuilding, Electric Boat and Austal. The exhibit features interactive digital content and interviews that highlight the progress in submarine construction, as well as the role of partnerships in progressing naval capabilities. 

Model-Based Engineering Environment (MBEE) Film 

The ETC is also presenting a film documenting the creation of a model-based engineering environment (MBEE) produced by William Sobel, co-founder of  Metalogi and chief architect of the MTConnect standard. The accompanying live presentations and Q&A sessions further explore MBEE’s potential to provide a standardized, bi-directional flow of information across various platforms.  

“MBEE provides a single source of truth and bi-directional flow of information, resolving the current tension and disconnect between defense contractors, OEMs and contract manufacturers. We need open, standardized information from the top suppliers that is agnostic to the software platform and within the financial means of smaller participating shops,” says Sobel.

Apollo: Apptronik’s AI-Powered General Purpose Humanoid Robot 

Apptronik Inc. exhibits Apollo, the AI-powered general purpose humanoid robot. Unveiled in August 2023, Apollo is designed for mass manufacturability and user-friendly operation, aiming to address labor challenges by preventing injuries and enhancing productivity. The robot’s humanoid form enables simple integration into existing spaces, and a key feature includes Apptronik’s patented actuator technology. Apptronik’s presentation is particularly focusing upon Apollo’s current advances and future applications.