The global advantage in manufacturing is shifting away from countries who win on mere prototyping and cheaper retrofitting. There is now less separation between what is practical and optimal in design for the military, and that is good for the warfighter. In the field of additive manufacturing, engineers get closer to their products than ever before and the process of meeting the needs of futuristic systems becomes more infused with individual artistry and creativity in a streamlined process. Huntsville’s defense community offers opportunities for careers that are meaningful in process and product.
In October of 2019, the Secretary of Defense issued Directive 2019-2029, “Enabling Readiness and Modernization Through Advanced Manufacturing.” This document formalized the priority of using 3D printing, digital blueprints, laser welding, and other methods that reduce waste and allow more complexity in design. The wars of the future may not look like the ones that were based on production volume and defined beginnings and ends. Multi-domain combat means constant advancement in technology, speed, and precision. The 3D printing market for global aerospace and defense is expected to grow from $1.56 billion this year to $5.9 billion by 2026. Private companies who understand military contract processes will be essential to this directive.
What can additive manufacturing do for the military? More specific products designed and manufactured quickly in-house with multiple prototypes, tests, and low-runs of final products; further, those products are cheaper, lighter, more durable and customizable. Intuitive Research and Technology Corporation (INTUITIVE®), a professional engineering firm in Huntsville, has been using 3D printing and related technology for over a decade in the areas of development and rapid prototyping and production systems support.
Applications
- Rapid Prototyping: the risk of trial and error is much more cost effective with additive manufacturing, so INTUITIVE can produce various working models at low runs
- Direct Digital Manufacturing: the designer is often able to use computers to produce the end-use part without delays or delegation
- 3D Printing: the hallmark of additive manufacturing is that it uses layers of material to achieve a perfect manifestation of a computer-created design
- Low-Rate Initial Production: large factories of the past could not afford the low-run volumes required of current military needs; subtractive manufacturing cannot keep pace with innovation
- Mold Making and Tooling: Sometimes the product is for production of another product. Tools can be created specific to an innovative new product
- Proof of Concept: Projects can be explored to demonstrate feasibility with more precision than ever before
The Passion for 3D Printing
This is exciting work for those who invested in the skill set required when 3D printing was still a rarity because it is a field set to expand. Tommy DuPuy, an Additive Manufacturing Subject Matter Expert at INTUITIVE explained that a passion for solving problems with technology is at the core of being successful in the field. The hugely influential series, Star Trek awakened ideas of a possible future in many aerospace innovators, and Tommy was no exception. “I vividly remember being captivated by a machine called “the replicator”—you would ask it for your item and out pops a usable copy!” he said. Those early interests led toward computer building (and dismantling) as a hobby, and now, over a decade of experience in additive manufacturing.
Although he found out about 3D printing in late high school, there was nowhere to formally study it or have access to the rare machines. “I focused on a range of engineering courses relevant to the new technology and those that I enjoyed: CAD design, electronics, and materials science,” said DuPuy. Before he arrived at INTUITIVE, he had his first access to a 3D printer, where he gained experience prototyping, manufacturing, designing and testing. “Being a subject matter expert is about using insights from hands-on experience: I can modify professional printers to work with more materials, to have broader capabilities, and allow more applications than were previously possible,” he said.
Be Part of the Future: Traits for a Career in Additive Manufacturing
“Additive Manufacturing is the future,” said DuPuy. “The impact of this technology is changing the world right now in innumerable ways. Medical applications include precise replicas of tumors, dental crowns and teeth aligners, advancements in bionics and prosthesis, customized knee and hip replacement joints; the military uses 3D printing to enable rapid replacement parts to complete a mission, or to do in field repairs; Astronauts on the ISS are able to print items that they need and recycle them back down for another item later.”
The demand for experts in engineering, materials, CAD software and the actual printers themselves will increase exponentially in the future. Here are the traits that DuPuy says seem most integral to those successful in the field:
- Driven individuals with a passion for what they do
- A love of working on something new every day
- An ability to search for solutions to extant problems
- The foresight to strategize for alleviating potential problems before they occur
- Humble, yet knowledgeable (it’s a huge area of expertise that overlaps with many others)
- The willingness to learn something new
- A sense of boldness; individuals must not be afraid to approach a problem from a different angle
Finally, if prospective employees are looking to join the INTUITIVE team, they need to understand and relate to the mission of the warfighter. “I am proud to know that what I am working on will save lives and benefit those tasked with keeping us safe,” said DuPuy.
Finding the Right Employer
Professionals in additive manufacturing often work in small teams and have to think on their feet. A supportive environment that supports this analytic creativity is important. Tommy DuPuy researched INTUITIVE to find just that, the focus was “people first.” He recommends that job seekers find a place where they are confident to grow and learn, accumulating hands-on experience. “INTUITIVE operates like a family-run shop and prioritizes work-life balance in the process; that is an ideal environment for this career,” he said.
The possibilities feel endless in his role, and DuPuy appreciates that there’s something new to learn constantly. “Oh, I didn’t know you could do that is the best part of my day!” said DuPuy. “I never know exactly what will do it or when it will happen, but when it does, a world of new possibilities opens for a colleague or client because of my knowledge and passion for additive manufacturing.” He describes that individual spark of wonder as the catalyst for technological advancement. The young people who can identify and cultivate that spark could have a bright future in Huntsville.
If you’re interested in joining a premier team of innovative, dedicated problem-solvers, please visit irtc-hq.com/careers to see what possibilities exist at INTUITIVE for you.