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IALR Becomes Siemens Digital Industries Software Academic Program Partner

IALR Becomes Siemens Digital Industries Software Academic Program Partner

IALR to use the same technology in its classrooms that companies worldwide depend on to embrace digital transformation and drive innovation

The Institute for Advanced Learning and Research (IALR) today announced it has received a grant of software from Siemens Digital Industries Software.

The software, part of the Siemens Xcelerator portfolio, gives more than 1,000 students access to the same technology that companies around the world depend on to develop innovative products in a wide variety of industries, including automotive, aerospace, machinery, shipbuilding, high-tech electronics and many more. This software will be implemented in two primary programs:

  • Accelerated Training in Defense Manufacturing (ATDM): Housed at and instructed by IALR, ATDM prepares adult learners for manufacturing careers that support the maritime industrial base. By 2026, more than 800 students will graduate annually from this four-month program, which trains workers in CNC machining, additive manufacturing, welding, metrology and non-destructive testing.
  • Integrated Machining Technology (IMT): A third-year precision machining program offered by IALR and Danville Community College, IMT produces manufacturing leaders with a comprehensive understanding of manufacturing processes and operations and critical leadership skills.

“IALR is excited to have access to industry-leading software in our classrooms,” said Jason Wells, Executive Vice President of Manufacturing Advancement at IALR. “As the industry evolves, our graduates’ STEM skills must also evolve. This technology from Siemens Digital Industries Software will help ensure our students have the relevant digital skills necessary to succeed in Industry.”

Siemens Digital Industries Software is a leading global provider of engineering, manufacturing and electronics software.

The software provided by the Siemens Digital Industries Software academic program delivers technology for different skill levels. Graduates with training, experience and working knowledge of this type of software are highly recruited candidates for advanced technology jobs.

The software for IALR includes the following tools from Siemens Xcelerator:

  • Tecnomatix® portfolio, the industry-leading digital manufacturing software
  • NX™ software, a leading integrated solution for computer-aided design, manufacturing and engineering (CAD/CAM/CAE) and the Fibersim™ portfolio of software for composites engineering
  • Solid Edge® software is an intuitive product development platform for accelerating all aspects of product creation, including 3D design, simulation, visualization, manufacturing and design management
  • Simcenter™ portfolio, a robust suite of simulation software and test solutions
  • Siemens’ Tecnomatix FactoryCAD is a top manufacturing simulation tool Engineering‘s expert team leverages for customers to improve their planning and production processes.
  • Jack is a human modeling and simulation tool that enables you to improve the ergonomics of your product designs and to refine industrial tasks.
  • Siemens’ Tecnomatix Plant Simulation is a simulation software used for modeling, simulating, and optimizing production systems and processes.

“Bridging the gap between industry, academia and government is essential to building a sustainable talent pipeline equipped with the advanced skills required for the future of manufacturing,” said Melanie Spare, Director, Academic and Workforce Development. “This partnership exemplifies that mission—by aligning classroom training with the exact tools and technologies used by leading defense manufacturers, we’re not only accelerating workforce readiness, but also reinforcing critical Department of Defense initiatives. Through programs like ATDM and facilities like AM CoE, we’re creating a direct and seamless pathway from learning to doing, ensuring students are job-ready from day one.”

Many of IALR’s Manufacturing Advancement initiatives focus heavily on Department of Defense (DOD) requirements, and this software partnership significantly enhances that alignment. Students in the ATDM program will now train and operate using the same software as leading DOD suppliers, creating valuable continuity between classroom training and real-world defense manufacturing environments. Additionally, several of these Siemens products are already used within IALR’s Center for Manufacturing Advancement (CMA) and the U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE) due to their compliance with International Traffic in Arms Regulations (ITAR). This further strengthens the synergy between the AM CoE and ATDM, benefiting students by better preparing them for successful careers in defense manufacturing.

About IALR

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg along with the cities of Martinsville and Danville. 

Note: A list of relevant Siemens trademarks can be found here.

Inside IALR Podcast: Measuring Down to the Micron: How Metrology Supports National Defense

Inside IALR Podcast: Measuring Down to the Micron: How Metrology Supports National Defense

In this episode of Inside IALR, we dive deep into the world of metrology, a crucial trade that plays a significant role in national defense manufacturing. The episode features Tony Almeida, Regional Sales Manager at Mitutoyo, and Jarrod Hankins, Metrology Instructor at IALR’s Accelerated Training in Defense Manufacturing (ATDM) program.

Metrology is the science of measurement. It ensures that parts are manufactured with incredible precision, often down to microns. Together, they highlight how metrology ensures that parts used in defense manufacturing, particularly in the Navy’s shipbuilding and repair operations, meet the highest standards of quality.

Highlights include:

  • 0:47 – What is metrology, and how is it used in manufacturing?
  • 3:09 – The role of IALR’s precision metrology lab in supporting the Navy’s Additive Manufacturing Center
  • 6:56 – Key metrology tools, from calipers to 3D laser scanning
  • 8:36 – Inside the precision metrology lab: The significance of the Coordinate Measuring Machine (CMM)
  • 17:04 – The importance of calibration and ensuring precision in every tool
  • 22:06 – How metrology helps support the national defense industrial base

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ATDM & AM CoE Summit Bolsters Defense Manufacturing Workforce and Partnerships

ATDM & AM CoE Summit Bolsters Defense Manufacturing Workforce and Partnerships

Leaders from across the defense and manufacturing sectors came together in Danville, Virginia, for the fourth annual joint summit hosted by the Accelerated Training in Defense Manufacturing (ATDM) program and the U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE). Held at the Institute for Advanced Learning and Research (IALR), this year’s event, themed All Hands on Deck, focused on addressing workforce and manufacturing shortfalls in Navy shipbuilding and repair.

2025 ATDM & AM CoE Summit

One of the summit highlights was a keynote address from Admiral James Kilby, USN, Vice Chief of Naval Operations, who spoke to the deep investment the Navy is making in workforce development and innovation as the pillars of our maritime strength.

“This Summit extends far beyond a two-day gathering—it’s strengthening America’s maritime industrial foundation,” said Matthew Sermon, direct reporting program manager for the Maritime Industrial Base. “With over 450 participants sharing insights and solutions, the ATDM Maritime Training Center is creating a pipeline of skilled workers, while the Additive Manufacturing Center of Excellence is revolutionizing how we produce critical components, reducing production timelines from years or months to weeks or days. Both are gamechangers….and together, these complementary initiatives address both the human talent and technological capabilities needed to build and sustain the fleet our nation requires.”

The summit highlighted the growth and momentum of the ATDM program. Earlier this year, the new 100,000-square-foot ATDM Maritime Training Center opened at the IALR campus, expanding the program’s capacity to train more students in its 16-week accelerated program. The ATDM Maritime Training Center provides the space needed for the program to graduate up to 1,000 students per year to meet industry demand, a target it is on track to achieve.

“At IALR, we’re pioneering new accelerated training methods while building the future workforce for defense and maritime manufacturing,” said Telly Tucker, president of IALR. “The new ATDM Maritime Training Center is a vital step in growing the talent pipeline, and by hosting the Navy’s Additive Manufacturing Center of Excellence on our campus, we’re integrating emerging technologies directly into the hands-on training process. This model ensures our graduates are equipped to meet challenges in shipbuilding and advanced manufacturing.”

Alongside workforce training, the co-located AM CoE continues to push the boundaries of additive manufacturing for Navy applications. The center is actively reducing production timelines for complex parts and exploring how advanced processes can support both new builds and fleet sustainment. The AM CoE is also providing connective tissue for ATDM students as they gain experience in additive manufacturing.

Throughout the summit, attendees heard from defense contractors, technical experts and government officials about the real-world impact of programs like ATDM and AM CoE. Representatives from major shipbuilders and supply chain companies discussed how the ability to hire ATDM graduates has shortened ramp-up times and helped meet production schedules.

The summit wrapped up with a clear sense of shared purpose and momentum. By combining accelerated training with cutting-edge innovation, ATDM and AM CoE are shaping a model for how public-private collaboration can secure the future of U.S. maritime power.

About ATDM

Accelerated Training in Defense Manufacturing (ATDM) was created to teach the skills needed to increase military equipment production in the United States. The program is located at the Institute for Advanced Learning and Research in Danville, Virginia. Students at ATDM are trained in the skills needed to repair, upfit and build submarines, and these skills are transferable to other defense industry companies. Students earn the skills needed to secure great-paying, in-demand defense industry jobs in these skilled trades: additive manufacturing, CNC machining, non-destructive testing, quality control inspection (also known as metrology) and welding.

Visit the ATDM Website 

About IALR

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg along with the cities of Martinsville and Danville. 

 

Inside the Navy’s Additive Manufacturing Center of Excellence

Inside the Navy’s Additive Manufacturing Center of Excellence

Nobody likes delays.

The stakes are even higher when a mission depends on getting the right parts at the right time. For the U.S. Navy, a delayed part can stall a mission and force a vessel to remain tied to the pier instead of patrolling the seas.

This is where the U.S. Navy Additive Manufacturing Center of Excellence (AM CoE) steps in. Housed within the Center for Manufacturing Advancement (CMA) on the Institute for Advanced Learning and Research (IALR) campus, this collaborative project reduces delays and increases part availability and production capabilities. Involving eight partners, including Austal USA and IALR, the AM CoE helps develop digital technical data packages, or “manufacturing recipes,” that activate suppliers in the Maritime Industrial Base (MIB).

This shift enables quicker turnaround times and provides the U.S. Navy with options that did not exist a few years ago. Rather than waiting on months-long casting or forging lead times, which are susceptible to a high level of quality-related issues, the Navy can distribute these recipes to qualified suppliers, speeding up production and ensuring higher quality and accuracy on each part produced. 

“The AM CoE is the nexus of additive integration.” – Aaron Wiest, Additive Manufacturing Program Manager, MIB Program

An Ambitious Goal

As part of the MIB Program, the AM CoE project supports the Navy’s ambitious goal of producing one Columbia-class and two Virginia-class submarines annually. Achieving this build rate while simultaneously maintaining the existing fleet and supporting the recent AUKUS agreement is challenging because it requires a dependable supply of thousands of parts, both for the suppliers and at the shipyards themselves.

Many of those parts are traditionally produced using castings and forgings, which result in significant constraints on where and how many can be made.

By shifting to digital “recipes” for additive manufacturing, the AM CoE provides a more flexible path that reduces cost, time and reliance on limited foundries. These technical data packages guide approved suppliers, ensuring consistency across the supply chain. Instead of waiting on a single foundry, multiple vendors can print identical parts from the same digital file.

“When you move to a digital paradigm, you have a digital casting mold or an additive data file that allows you to use a 3D printer and manufacture the shape that you need, which will then later go through value-added processing. The CoE gets to be the repository of those files for any of the companies that wish to join in that collaborative network and support the U.S. Navy.” – Aaron Wiest, Additive Manufacturing Program Manager, MIB Program

IALR’s Center for Manufacturing Advancement supports the AM CoE’s work by providing a high-performance environment for this manufacturing optimization. Its ISO-certified CNC Machining Innovation Lab refines subtractive processes for additively produced parts, and the Precision Metrology Lab’s advanced inspection capabilities ensure quality. Both labs also serve other clients seeking process improvements. Emerging technology is tested, proven and implemented within this ecosystem for immediate impact.

AM CoE Partners

The Additive Manufacturing Center of Excellence includes many partners, several of which have staff stationed on the IALR Campus full-time. 

  • Austal USA Advanced Technologies: enterprise team lead overseeing program management and technical execution
  • Commonwealth Center for Advanced Manufacturing (CCAM):  lead for digital thread and digitally enhanced qualification
  • FasTech, LLC: provides parameter and post-process development, DED & PBF, CNC and enterprise beta testing
  • IALR: provides post-processing services in the CoE. This includes CNC machining, saw cutting and processing of test samples
  • Industrial Inspection & Analysis, Inc.® (IIA):  provides in-house qualification and testing
  • Mitutoyo: provides coordinate measuring machining (CMM) services
  • Phillips Corporation: serves as principal for the additive manufacturing processes, part selection process and part digitization
  • The SPECTRUM Group: provides strategic oversight and guidance for the AM CoE

Rapid Results When Needed

Though the AM CoE focuses on developing processes, it has swiftly produced parts to meet urgent demands. Three recent examples exemplify its ability to deliver results:

Employees of the Phillips Corporation work on a large 3D printer inside the U.S. Navy’s Additive Manufacturing Center of Excellence on the IALR campus.

Case One: Reducing Delivery Time

A small bracket helps a destroyer’s hangar door sensor function properly. It functions like a garage door sensor–ensuring nothing is under the door before it closes.

Due to limited supply chains, a malfunctioning helo hangar door bracket on a U.S. Destroyer threatened to delay its mission for months.

Over the 2023 holiday season, the AM CoE printed, machined, inspected and delivered the bracket in under three weeks. A few months later, another request came for the same part, and the turnaround dropped to just 13 days.

“Two different destroyers went out and were able to maintain their mission because of the CoE.” – Jesse Geisbert, Advanced Manufacturing Director, MIB Program

The bracket is now a procurable item, meaning future suppliers can produce it on demand.

Case Two: Addressing Quality Challenges

The interior liner for a submarine’s trash disposal is certainly not glamorous and may seem insignificant, but it is integral to submarine operations. During underwater missions, submarines compact waste and securely store it in sealed metal containers, which are then safely released into the ocean.

Six of these large trash disposal liners units were delivered to a shipbuilder producing a submarine in 2024, and all six were defective and could not be used.

“It’s a very hard to cast alloy, somewhat complex part, and they didn’t have a path forward, which meant stalled submarine construction for one piece,” Wiest said. 

In just nine days, the AM CoE modeled and printed a first article of manufacture. In contrast, a cast part would have taken months to deliver. This solution is expected to restore momentum and prevent submarine construction from grinding to a halt.

Case Three: Providing Sustainment Solutions for Parts that No Longer Exist

Aging ships and submarines like the USS Michigan also rely on critical parts, many of which are no longer produced by traditional methods. The Michigan is a 42-year-old submarine, and its trim and drain valves, especially the tailpiece, regularly corrode due to operational conditions.

The AM CoE printed the tailpiece using both laser powder bed fusion and wire arc methods, creating multiple additive manufacturing data files. This dual approach provides flexibility, ensures future availability and supports other classes of submarines that use similar components. Instead of uncertain wait times for casting or forging, the Navy now has proven digital recipes to quickly produce these vital parts when the next repair cycle comes around.

“In one place now, we’ve created two different AM data files that can be distributed,” Geisbert said. “The Ohio class will be around still for quite a considerable amount of time, and now we have a better way to produce these trim and drain valves when they need to be replaced.” 

A One-Stop Shop

How to best print the part is only one part of the digital recipes provided by the AM CoE. The AM CoE also provides instructions on post-printing machining, metrology and measurement techniques and heat treatment.

“The CoE project has end-to-end capabilities. The team provides data on how to take an additive part through all the various steps, like machining and heat treatment, to make it a finalized, finished component. We learn things at each one of those stages that we can implement into a more well-rounded and complete end-to-end strategy.” – Jason Wells, Executive Vice President, Manufacturing Advancement, IALR

In addition to what’s happening in the AM CoE, skilled workers are trained at the adjacent Accelerated Training in Defense Manufacturing (ATDM) program. This program prepares workers for the Maritime Industrial Base, ensuring a talent pipeline ready to operate cutting-edge equipment. A spinoff of ATDM that is also located on the IALR campus, the Naval Aviation School for Additive Manufacturing (NASAM) program trains active-duty Navy personnel to use additive manufacturing equipment and techniques on ships and submarines.

Manufacturing machines lined up in the Additive Manufacturing Innovation Lab.

“The AM CoE is a one-stop shop for industry to come learn about additive, get qualified, understand the Navy requirements.” – Jesse Geisbert, Advanced Manufacturing Director, MIB Program

Activating the Industrial Base

The AM CoE is a unique public-private partnership where industry, academia and government work together toward a common goal. This collaborative approach maximizes resources, knowledge sharing and innovation. Instead of operating in separate silos, partners pool their expertise and align their efforts, ultimately strengthening the entire industrial base.

“We have an era of unprecedented collaboration,” Wiest said. “It is amazing to see companies willing to jump in, willing to share some of their IP actually to help the industrial base grow.” 

This kind of cooperation ensures that if one supplier faces delays, another can step in, preventing bottlenecks. Over time, the public-private partnership model builds resilience, scalability and trust across the network of suppliers and shipbuilders supporting the U.S. Navy.

“The AM CoE is that connective tissue for the OEMs and the shipbuilders and the industrial base at large.” – Jesse Geisbert, Advanced Manufacturing Director, MIB Program

Making an Impact

The three success stories highlight how critical this work has become. A hangar door bracket was delivered in under three weeks, a trash disposal unit liner was produced in days rather than months, and a valve component for an aging submarine was quickly developed.

However, the goal of producing these digital recipes is to have even more success stories where approved suppliers utilize an existing recipe to produce needed parts on demand.

Each success means more time at sea, more deterrent strength and more efficient use of national resources. The Navy’s ambitious goals, the expansion of additive manufacturing and the AM CoE’s model all point to a future with fewer delays and heightened readiness.

“The AM CoE is a model,” Geisbert said. “Nothing is stopping us from creating something like the CoE, operated by public-private partnerships and intended for production outside every shipyard.”

The CMA’s mission to help manufacturers integrate technology and optimize processes extends beyond the Navy. It reflects a broader push for more innovative, faster and resilient manufacturing across various industries.

Inside IALR Podcast: Collaborative Forces in Maritime and Additive Manufacturing

Inside IALR Podcast: Collaborative Forces in Maritime and Additive Manufacturing

The U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE), a linchpin in maritime technological advancement, is located inside the Center for Manufacturing Advancement on the IALR campus. This episode highlights the AM CoE as a collaborative hub of strategic importance in meeting the U.S. Navy’s ambitious submarine production goals. This project is driving manufacturing innovation forward. 

IALR Executive Vice President of Manufacturing Advancement Jason Wells is joined by Advanced Manufacturing Director Jesse Geisbert and Additive Manufacturing Program Manager Aaron Wiest, both from the Maritime Industrial Base (MIB). They discuss the impact of the Navy’s AM CoE and the success stories where the project has prototyped and delivered mission-critical parts for ships and submarines much quicker than traditional methods, such as castings and forgings, and supply chains could have. This informative discussion includes:

  • What is the Maritime Industrial Base? (01:03)
  • Advanced manufacturing technology development (06:54)
  • Partnering with the Maritime Industrial Base (08:54)
  • Additive Manufacturing Center of Excellence (11:25) 
  • Public/private partnerships (18:41)
  • Success stories (24:44)
  • NASAM & ATDM (31:54)
  • Another success story (40:04)
  • AM CoE partners (50:27)
  • Parting thoughts (53:15)

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Inside IALR Podcast: CNC Machining Innovation Lab

Inside IALR Podcast: CNC Machining Innovation Lab

The “Inside IALR” team showcases the CNC Innovation Lab inside the Center for Manufacturing Advancement (CMA) with CMA Operations Manager Kevin Thompson and CNC Technologist Jeremiah Williams. This episode highlights how the 5,791-square-foot CNC Machining Innovation Lab enables new and existing businesses to evaluate their processes, build out improvements and incorporate efficiencies without disrupting current operations. This space empowers manufacturers to increase global competitiveness (02:44). They discuss the role of CNC machining (04:18) and its primary role within the manufacturing industry (06:06). The equipment and processes (08:27) are the main attraction for industry. Kevin and Jeremiah explain the specific services provided by the CNC Innovation Lab (14:46) and also provide a short explanation of the Navy’s Additive Manufacturing Center of Excellence (AM CoE) and how the CNC Lab fits into that (19:14).

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Top-Tier Metrology Equipment and Services Driven by Partnerships

Top-Tier Metrology Equipment and Services Driven by Partnerships

300,000

That’s how many points are scanned per second on the laser scanner on the Mitutoyo Crysta-Apex V163012 Coordinate Measuring Machine (CMM), one of the largest on the East Coast. Even a relatively small part has tens of millions of scannable points. In addition to the laser scanner, the CMM boasts a variety of unique qualification and measurement capabilities.

Equipped with the CMM and a bevy of other top-tier qualification tools and equipment, the Institute for Advanced Learning and Research’s (IALR) Metrology Lab provides critical measurement and qualifications services for the Navy’s Additive Manufacturing Center of Excellence (AM CoE) and has the capability to provide support for private industry. Located inside the Center for Manufacturing Advancement in Southern Virginia, the Metrology Lab with NIST Certified Inspection is the result of strong partnerships. IALR owns the equipment and space, but applications engineers with Mitutoyo and Master Gage & Tool Co. operate the equipment.

“The Metrology Lab is a unique resource for local industry and a key component of the Navy’s efforts to improve additive technologies and processes. The Metrology Lab also epitomizes several core tenets of IALR, including our mission of economic transformation, commitment to partnerships and penchant for utilizing state-of-the-art technology.” – Tim Robertson, Chief Operating Officer, Manufacturing Advancement

Top-Tier Metrology Through Partnerships

Metrology, officially defined as the science of measurement, is a crucial element of any manufacturing process. In the Metrology Lab at IALR, application engineers can perform relatively simple measurements, such as physical dimensions, and highly complex qualifications of factors like shape, hardness and many other physical qualities.

The CMM inside the Metrology Lab can perform some of the most sophisticated yet critical measurement and qualification processes possible. It has a work area that can accommodate pieces as large as five feet wide, nearly 10 feet long and almost four feet tall, but the space can also be used for smaller parts. For instance, staff could place dozens of the same parts on the surface area and program the CMM to perform identical qualification tasks on each.

 

“The Mitutoyo Crysta-Apex V163012 Coordinate Measuring Machine can pretty much do any type of inspections that would be needed in the industry.” – Carlos Cabello, Applications Engineer, Mitutoyo

Every measurement the machine makes is down to the micron.

Some of the services offered by the Metrology Lab with NIST Certified Inspection include:

  • Contract inspection
  • CMM programming
  • Laser scanning
  • Automation integration
  • Reverse engineering
  • Calibration services
  • Application engineering support

Qualification and Measurement for Navy and Industry

The Navy established its Additive Manufacturing Center of Excellence (AM CoE) inside the CMA. Tasked with scaling and maturing additive technologies for the production of submarine components to bolster naval shipbuilding and repair supply chains, the AM CoE includes the Navy and nine other organizations. The AM CoE team develops new technical data packages (TDP), which are essentially comprehensive “recipes” for utilizing additive manufacturing, or 3D printing, techniques to manufacture particular components.

The Metrology Lab – as well as the CNC Machining Innovation Lab that IALR owns and operates – plays a critical role in this operation. In fact, the team in the Metrology Lab will conduct three separate inspections of every part:

  • Initial inspection after a part is 3D printed. The team will compare physical measurements to the Computer-Aided Design (CAD) model.
  • After heat treatment, the team conducts another inspection to ensure that the part holds its shape.
  • After final CNC machining work is completed, the team conducts a final inspection that involves checking every dimension.

“It’s very honorable work, and I’m very proud to be a part of this project.” – Sean Cobb, Master Gage and Tool

While the AM CoE utilizes the lab to complete numerous inspections, the partners can also use the equipment to provide services and support to industry. The CMM and other equipment allows industry in need of testing support to accurately and affordably measure and certify products.

“In order for a company to do this level of measurement and qualification, they’re going to have to make major capital investments and slow down production. We can provide those testing services in a convenient and certified way without impeding production.” – Kevin Thompson, CMA Operations Manager

The Center for Manufacturing Advancement, which houses the Navy’s AM CoE and impactful technology and resources like the Metrology Lab, is located in Danville, Virginia, on the IALR campus. Companies that are interested in partnering with IALR in the CMA by utilizing the services of the Metrology Lab, collaborating with the CNC Innovation Lab, or learning about automation in the Industry 4.0 Integration Lab should contact the IALR team.

CNC Machining Innovation Lab to Support the U.S. Navy and Industry

CNC Machining Innovation Lab to Support the U.S. Navy and Industry

A specialized camera that shoots up to 400,000 frames per second, allowing true slow-motion views of the manufacturing process.

Cutting-edge sensors that measure factors like cutting force and harmonic vibrations.

Infrared cameras that show temperature patterns throughout an operation.

These are just a few of the specialized pieces of equipment within the Computer Numerical Control (CNC) Machining Innovation Lab, which is housed inside the Institute for Advanced Learning and Research’s (IALR) Center for Manufacturing Advancement (CMA). The CNC Machining Innovation Lab also plays a crucial role in the U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE), also housed within the CMA.

Featuring state-of-the-art equipment and cutting-edge technology, the CNC Machining Innovation Lab will support private industry through testing services and process optimization and help the AM CoE develop world-leading additive manufacturing “recipes” for the development of parts needed by the U.S. military.

“The vision of the CNC Machining Innovation Lab is twofold. We support the AM CoE, but we also have a vision to support industry. We’re trying to develop partnerships to help industry drive innovation and productivity with increased profitability in a rapidly changing environment.” — Kevin Thompson, Operations Manager for the Center for Manufacturing Advancement, IALR

Industry Innovation and Support: CNC Machining

Computer Numerical Control (CNC) Machining is a manufacturing process where computer-controlled machines create precise and intricate parts and components. Commonplace in industries such as aerospace, electronics and healthcare, this is a subtractive manufacturing process – meaning that an existing block or item is whittled down or shaped.

The CNC Machining Innovation Lab partners with public and private manufacturers of all sizes to modernize their processes, identify and integrate emerging technologies and provide data-driven process development and optimization. Some of the capabilities include process development, process optimization, CNC programming, the integration of emerging technology, automation integration, turn-key solutions and application engineering support.

“Companies don’t have the capacity to be able to stop and try a new process. They have to find external ways of doing that, and that’s a huge role we can play. Companies can present a challenge to us and continue to produce goods while we develop a solution that suits their needs.” — Jeremiah Williams, CNC Technologist, IALR

The CNC Machining Innovation Lab boasts a broad inventory of specialized equipment, including sensors to measure factors like cutting force, slow-motion cameras to track chip formation, infrared cameras to analyze the impact of heat and much more, all with the goal of “trying to optimize processes for customers,” Thompson explains. IALR is even allowing other companies to test and utilize specialized sensors inside of the CNC Lab machines for data collection.

“Our job is not to compete with industry. Our job is to support industry.” – Kevin Thompson, Operations Manager for the Center for Manufacturing Advancement, IALR

Businesses can:

  • Test various processing configurations to determine the most effective design.
  • Review and improve existing manufacturing processes without disrupting operations at existing facilities.
  • Replicate processing anomalies or other challenges in a controlled environment.

The CNC Machining Innovation Lab is ISO 9001:2015 compliant, reassuring customers and partners alike that we have an internationally validated system in place to address and prevent quality issues.

The CNC Machining Innovation Lab is located across from the CMA’s state-of-the-art Metrology Lab that features one of the largest Coordinate Measuring Machines (CMM) on the East Coast with 3D scanning capability along with optical measurement systems, hardness and roundness testers and support equipment. Through a partnership with Mitutoyo and Master Gage & Tool, IALR offers the services of the Metrology Lab to regional businesses and partners who may not otherwise have access to such capabilities.

“The Metrology Lab is ideal for emerging or developing businesses to have access to this capability while building justification for their own capital investment.” – Kevin Thompson, Operations Manager for the Center for Manufacturing Advancement, IALR

“Everything we do at IALR involves partnerships and is driven by the needs of industry. Through the CNC Machining Innovation Lab and the Metrology Lab, IALR is simultaneously contributing to our nation’s defense and supporting current, new and prospective companies in Southern Virginia with needed services.” – Telly Tucker, IALR President

The CMA also includes a dynamic Industry 4.0 Integration Lab that serves as a demonstration site, showing manufacturing companies what is possible. Companies that are interested in partnering with IALR in the CNC Machining Innovation Lab or in the CMA should contact the IALR team.

Supporting the Navy’s Additive Manufacturing Center of Excellence

The submarine industrial base (SIB) is a system of thousands of companies that produce parts and equipment used in the production and maintenance of submarines for the U.S. Navy. IALR has partnered with the U.S. Navy – along with many other public and private organizations – in a two-pronged approach to support the SIB, the development of new submarines, and the maintenance of the existing fleet: the federal Accelerated Training in Defense Manufacturing (ATDM) program and the U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE).

ATDM increases the pool of skilled labor in areas like additive manufacturing, CNC machining, welding, metrology and non-destructive testing – trades that are needed by the SIB. On the other hand, the AM CoE is focused on implementing additive technologies and processes that will allow for more efficient development of parts. Don Hairston, General Manager of Austal USA Advanced Technologies, used the analogy of making cookies during a recent presentation at the ATDM AM CoE Summit at IALR. When making cookies and especially in manufacturing parts for the U.S. Navy, each of these variables must be accounted for and done correctly for successful production: raw materials, equipment, manufacturing know-how, post-processing and finishing and quality control.

In the simplest terms, “scaling the supply chain” is one of the primary goals of the AM CoE, Hairston explained.

The AM CoE will scale and mature additive technologies that enable innovative production of submarine components to bolster naval shipbuilding and repair supply chains. Involving nine different partners, the AM CoE will increase overall manufacturing capacity and close the supply-demand gap in critical markets like castings, forgings, fittings and fasteners.

The AM CoE team will develop new technical data packages (TDP), which are essentially comprehensive “recipes” for how to utilize additive manufacturing techniques to manufacture particular components. The workflow inside the AM CoE will typically go something like this:

  • A team from Phillips Corporation converts 2D drawings into computerized 3D models.
  • IALR will provide post-processing operations, including CNC machining, saw cutting, and processing of test samples
  • Once all the partners sign off on the approved design, the team from Phillips Corporation will print the part.
  • The team from the Metrology Lab, which is operated and staffed by applications engineers from Mitutoyo and Master Gage and Tool, will complete the initial inspection. 
  • Industrial Inspection Analysis (IIA) provides non-destructive testing at the end of the process.

As part of the Navy’s AM CoE, the CNC Machining Innovation Lab will be utilized after the initial printing of a part, verifying that the design used for additive manufacturing can successfully be machined. Simultaneously, the IALR team will also explore and implement advanced strategies that better align with today’s manufacturing equipment and methods.

“Basically, what we will do is verify that the part that has been printed can be successfully and correctly machined without any issues.” – Jeremiah Williams, CNC Technologist

Additive manufacturing, which can also be referred to as 3D printing, is a subset of manufacturing where an object is built “from the ground up” based on a 3D model. It may seem odd that a subtractive manufacturing method would play such an integral role in the Navy’s additive manufacturing operations. While 3D printing and additive manufacturing are the primary focus of the AM CoE, subtractive methods are still essential in creating and verifying any part.

“With the current technology and dimensional requirements of the parts, you can’t simply print and install a component. You’re going to have to print it and then do some final subtractive work before the part can be utilized.” – Jeremiah Williams, CNC Technologist

Once perfected and tested, the TDPs will be shared with Navy suppliers, providing them with the “recipe” they need to produce the part correctly and efficiently. As of mid-October, the AM CoE has released 28 TDPs to the companies that will be manufacturing the parts.

Partners of the Navy’s Additive Manufacturing Center of Excellence include:

Austal USA Commonwealth Center for Advanced Manufacturing (CCAM) FasTech, LLC
Industrial Inspection & Analysis Institute for Advanced Learning and Research Master Gage & Tool Co.
Mitutoyo Phillips Corporation The SPECTRUM Group
The U.S. Navy Opens Additive Manufacturing Center of Excellence in Danville

The U.S. Navy Opens Additive Manufacturing Center of Excellence in Danville

Joint Navy-OSD Accelerated Training in Defense Manufacturing Program to Benefit from new Multi-Million-Dollar Training Facility

The U.S. Navy is launching its Additive Manufacturing Center of Excellence (AM CoE) within the State of Virginia’s Center for Manufacturing Advancement (CMA) on the Danville Institute for Advanced Learning and Research (IALR) campus. The creation of the AM CoE marks the first project partnership for the CMA. It demonstrates the Navy’s commitment to investing in and delivering the skilled workforce necessary to strengthen and expand the Navy’s industrial base to achieve the Nation’s strategic defense objectives.

A first for the Navy, the AM CoE will provide a platform for training a skilled additive manufacturing workforce through partnership with the Accelerated Training in Defense Manufacturing (ATDM) program, a rigorous, focused 24/5 training schedule that graduates student cohorts every four months in multiple disciplines critical to the defense industrial base (DIB). Industrial manufacturing partners include major shipbuilders like General Dynamics Electric Boat, Huntington-Ingalls Newport News Shipbuilding, Austal USA as well as key industry experts like Phillips Corporation, Industrial Inspection and Analysis, FasTech, Mitutoyo, and Master Gage & Tool, to bring multiple processes utilized by the DIB under one roof to improve efficiencies and reduce barriers to entry for manufacturers hoping to enter additive manufacturing.

Utilizing three full bays dedicated to accelerating and scaling additive manufacturing parts and qualification processes, the AM CoE’s principal functions will be to:

  • Promote adoption of mature industrial qualification processes and data to earn technical warrant holder approval for additive manufacturing production;
  • Enable scale and speed to address material readiness challenges and critical fragilities in the castings/forgings market space;
  • Pave a path for sustainable and scalable additive manufacturing production capability in the submarine industrial base.

“Building and sustaining the Navy’s defense industrial base workforce has become a national security imperative, and the demonstration of partnership and collaboration that is represented here in Danville, Virginia today is part of the ‘Whole Government, Whole of Industry’ approach that must be in place to ensure the domestic manufacturing capacity that is required to maintain the Navy’s maritime edge, and surge to meet a dynamic threat environment,” said Matt Sermon, Executive Director, PEO Strategic Submarines.

A ribbon-cutting ceremony for the AM CoE was held during the second annual ATDM Summit where the U.S. Navy, Office of the Secretary of Defense, and additional federal, state and local government officials joined with partners from defense industry and academia to convene topics pertaining to closing skills and workforce gaps within the naval defense industrial base.

During the ceremony, the announcement was also made that the ATDM program, which aims to provide 800-1,000 qualified candidates to fill critical vacancies in the DIB annually by 2024, will expand with the creation of a regional training facility adjacent to the CMA. The multimillion-dollar investment into over 100,000 square feet of dedicated training capability, capacity, and infrastructure will enable ATDM to rapidly scale up to its full potential and add to the economic momentum in Southern Virginia. The Danville and Pittsylvania County Regional Industrial Facility Authority provided land for the initiative.

“The launch of the AM CoE and the announcement of scale-up potential for ATDM go hand-in-hand with IALR’s approach to support the technological and workforce development needs of Industry. We are excited to leverage our new Center for Manufacturing Advancement and work with the Navy and other partners,” said Telly Tucker, President, IALR. “ATDM is one of the strongest examples of what full integration of industry in the training process looks like, by bringing key partners together to be vested in the time-to-talent process and ensuring the unique requirements of shipbuilders and suppliers are achieved quickly to meet the demands of our nation’s defenses.”

“The events we celebrate today – centered on workforce, technology, and the space where those two priorities must meet – are game changing. The scale and urgency needed in these areas is a fundamental differentiator in our Navy’s ability to preserve peace, and when necessary, compete and win,” added RADM Scott Pappano, PEO Strategic Submarines.”