Architecting and Industrializing Advanced Production and Manufacturing Systems for Critical Industries

ABSTRACT

Advanced production systems play a vital role in modern society. Such systems are developed and industrialized over multiple years and at great expense. The complexities of these systems are exacerbated in the case of metal additive manufacturing, which involves numerous process variables and relies on various auxiliary systems. These systems generate vast amounts of data along the digital thread to produce quality components. With increased complexity comes increased risk, which in turn increases qualification and certification burdens, posing challenges to the wider adoption and industrialization of these technologies. Critical industries, including aerospace, medical, nuclear, and defense, are exploring approaches to effectively and efficiently develop and qualify these advanced manufacturing technologies, thereby providing flexibility and enhancing supply chain resilience.

This research aims to demonstrate an end‐to‐end application of model‐based systems engineering tools and techniques for the design and development of advanced production and manufacturing systems. This addresses the full lifecycle of an advanced production system to control and manage information and complexity. System levels and alternate threads are architected to facilitate flexibility and resilience. Production processes are segmented into modular production units for reuse in different production scenarios and contexts. A case study was performed for the development of a laser powder bed fusion production system for aerospace applications. The system was implemented and tested at industrial and academic facilities following a phase‐based test campaign, which demonstrated its capability to produce material that conforms to material specification requirements. Industry stakeholders believe the system has verified material maturity through technology demonstration articles and provides value for future additive manufacturing industrialization undertakings.