Texas A&M Accelerates Certification of Critical Military Additive Manufacturing Components

Texas A&M Advances Certification of Military Additive Manufacturing Components

Texas A&M University in College Station has secured $1.6 million from DARPA’s SURGE program to fast-track certification of critical military Additive Manufacturing components. Currently, evaluating the lifespan of a 3D-printed military part can take up to eighteen months using supercomputers. Texas A&M’s new approach will drastically reduce this time, allowing faster production and deployment of reliable components. As a result, the Department of Defense (DoD) will benefit from quicker adoption of Additive Manufacturing and significant cost savings.

The research team will integrate in-situ process data with microstructural analysis to predict part durability accurately. Dr. Mosen Taheri Andani, assistant professor of mechanical engineering, explained that this fusion bridges process monitoring with property evaluation, enabling faster and more reliable deployment of AM parts. Therefore, Texas A&M is poised to become a key player in transforming the Additive Manufacturing industry for military applications.

Focus on Accelerating Military Additive Manufacturing Certification

The focus on accelerating certification addresses a major hurdle in widespread AM adoption for defense. Each additively manufactured part carries unique microstructural defects that influence its lifespan. These unavoidable features vary even among parts made on the same machine with the same materials. Texas A&M’s multidisciplinary team, including experts in materials science and engineering, will develop sensor technology and AI-driven defect detection systems. This will improve the accuracy and speed of identifying flaws during production, meeting rigorous military standards.

In collaboration with industry partners and universities, the project aims to develop an integrated sensor package for commercial AM machines. This package will capture real-time data to support defect prediction. Meanwhile, Texas A&M will coordinate efforts with other institutions to accelerate the prediction of microstructural changes during manufacturing. These advancements will enhance the reliability of AM parts, enabling faster qualification and deployment in critical defense systems.

SuperMetalPrice Commentary:

Texas A&M’s DARPA-funded project highlights a vital leap forward in Additive Manufacturing certification, particularly for military applications where reliability is paramount. Accelerating the qualification of AM parts can reshape defense supply chains, reducing costs and downtime while enhancing performance. Moreover, the integration of AI and sensor data signals the increasing digitization of industrial manufacturing processes. As other sectors follow suit, this initiative underscores the critical role of innovation in sustainable and efficient metal production. This breakthrough may well set new industry standards globally, supporting the broader adoption of AM in high-stakes applications.