Grant: Alliance Grants

The Pan-Canadian NSERC Strategic Network, "Holistic Innovation in Additive Manufacturing (HI-AM)," was established in 2017 to coordinate and accelerate national research efforts in additive manufacturing (AM). Despite the challenges posed by the pandemic, HI-AM 1.0 achieved exceptional outcomes. For example, the initial goal of training 85 highly qualified personnel (HQP) was surpassed when 131 HQP were successfully trained. The network's principal investigators and HQP generated 405 publications, filed ten patents and invention disclosures, and registered two standards development working groups with ASTM/ISO. One of the standards drafts is currently undergoing an international ballot. Building on the success of HI-AM 1.0, the team will leverage the established network through multiple independent NSERC Alliance proposals. The current proposal focuses on Directed Energy Deposition (DED) Processes, one of the seven classes of AM. It aims to address two primary research thrusts: 1) Model Driven Workflow for In-Situ Monitoring and Quality Assurance in Robotics DED Platforms used for Large-scale AM, and 2) DED Process Development for Advanced Materials, Novel Products, Large Scale Manufacturing, and Parts Refurbishment/Repair. The multidisciplinary HI-AM 2.0-DED team, comprising seven universities and eleven companies, has made significant advancements in intelligent control technologies, innovative DED processes, and new materials. These achievements provide a foundation for overcoming obstacles in commercial AM applications within the framework of HI-AM 2.0 and position Canada as an important player in the global AM supply chain. The team's industry partners span sectors such as aerospace, automotive, defense, energy, natural resources, and tooling, underscoring the potential impact of their research. This project aims to sustain the momentum of AM initiatives in Canada, given the critical timing amidst global geopolitical and supply chain challenges. The proposed Alliance seeks to establish partnerships, develop intellectual property, and train HQP essential for Canada's competitiveness in the emerging field of AM.