Sentient Science
DigitalClone for In-Situ Monitoring
Implementation of additively manufactured parts for aerospace is significantly hampered by lack of process insight and in-situ quality controls
About
Problem
Thousands of military parts are candidates for transition to additive manufacturing, due to obsolescence or excessive lead times. The main obstacle is qualifying the AM process.
Solution
DigitalClone physics-based modeling framework predicts the fatigue life performance of metals – and when integrated with AM machines enables layer-by-layer monitoring that can autonomously detect and correct defects to ensure part fatigue life and accelerate qualification.
Field Validation
SBIR Phase II (NASA JPL), SBIR Phase II (US Army DEVCOM AvMC), ongoing SBIR Phase II (AFWERX) Technology Maturity (TRL): TRL 6 (results from Army Ph II: 25% less defects, 60% longer fatigue life vs parts printed in traditional AM process)
Strategic Advantage
Fatigue modeling relies on patented component life prediction (CLP) technology
Go-to-Market
Awarded 5-yr/$9M SBIR Phase III IDIQ (2023) from US Army Futures Command DEVCOM AvMC for DigitalClone enhancements Access to Amazon Migration Acceleration Program (private cost-share up to $10M)
Dual-Use Potential
Automotive, Civil Aerospace, Energy, Industrial Equipment
Team
Jason Rios (Defense lead, USMA grad, MBA, former Honeywell) Dr Nathan Bolander (CTO, PhD Purdue University) Dr Behrooz Jalalahmadi (Additive Manufacturing VP, PhD Purdue University) Dr Guru Madireddy (Additive Manufacturing Scientist, PhD Univ of Nebraska-Lincoln, formerly at Oak Ridge National Lab)
Primary User
Engineers (qualification) and DoD AM machine operators (printing)
Problem
Implementation of additively manufactured parts for aerospace is significantly hampered by lack of process insight and in-situ quality controls