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ATDM Students Tackle Real-World Projects

ATDM Students Tackle Real-World Projects

Inside the Institute for Advanced Learning and Research (IALR) Industry 4.0 Integration Lab, students from the Accelerated Training in Defense Manufacturing (ATDM) program and their instructor examine the robots, fixtures, work areas and CNC machines. They take detailed measurements and ask questions.

Butch Kendrick, IALR’s Director of Digital Manufacturing, has explained several “problems” he’s encountered in the lab. He asks these students to develop creative solutions using additive manufacturing to design and print different fixtures; the goal is to better support the Industry 4.0 Integration Lab’s mission of demonstrating and teaching Industry 4.0 concepts.

During the four-month program that prepares adult learners to work in the Maritime Industrial Base (MIB), ATDM students don’t just learn theory; they tackle real-world problems.

“Working on real projects while in the ATDM program significantly enhances the students’ readiness and confidence as they enter the workforce.” – Cheryl Terry, Director of ATDM Training and Technology, IALR

ATDM: Rapid Training for Meaningful Careers

The Accelerated Training in Defense Manufacturing program at IALR is a hands-on training initiative designed to address the MIB workforce needs.

Currently, ATDM offers tracks in welding, additive manufacturing, CNC machining, quality control inspection (metrology) and non-destructive testing (NDT). Students benefit from tuition-free training, supportive services and guaranteed opportunities to earn industry-recognized certifications.

ATDM’s emphasis on real-world, hands-on learning ensures that students gain practical skills directly applicable to manufacturing challenges.

“We get so much more buy-in from our students when they work on real-world situations. They get more gratification from fixing problems than just doing their homework.” – Tim Holland, ATDM Additive Manufacturing Instructor, IALR

Student-Driven Fixture Design Project

To date, every cohort of additive manufacturing students has worked on a project in the Industry 4.0 Integration Lab. One of the first cohorts actually 3D printed the head of Rosie, one of the lab robots. The robot was designed to look like Bender from Futurama and eventually got the name Rosie from a Facebook naming poll.

Aaron Jacob Garcia with Rosie

“I make sure that the students understand the purpose of what they’re doing and how it all connects,” Kendrick said. “Once we do the initial session with them, the lab is open to them coming back and taking measurements and doing whatever they need to do.”

This cohort tackled four projects, including refining an existing fixture to ensure better robotic interaction and stability. Students fully managed their designs, from taking precise measurements to ensuring the fixture would securely interface with multiple table configurations.

“There is a problem, and they have to figure out how to fix it, but there’s no instruction list on how to do it,” Holland said.

Recent graduate Aaron Jacob Garcia said the experience taught him about the potential of additive manufacturing, the need for detailed, reliable measurements and the importance of understanding the end use.

“I learned that sometimes you have to make changes to make a part work for what it will be used for,” he said.

The Natural Partnership with Industry 4.0 Integration Lab

Allowing additive manufacturing students the opportunity to contribute to the Industry 4.0 Integration Lab is mutually beneficial.

“I think it’s a great opportunity for students to come out of the classroom into a real-life situation that isn’t too high pressure,” said Kendrick. “It gives them a chance to take what they’ve learned, mix it with their imagination and see what they can come up with.”

The Industry 4.0 Integration Lab provides an autonomous manufacturing environment featuring advanced robotics, automation and digital technologies. This focus makes it an ideal platform for training future manufacturing professionals, demonstrating real-world Industry 4.0 principles, and creating tangible outcomes for students and industry partners.

The Lab is housed within the Center for Manufacturing Advancement (CMA) on the IALR campus. The CMA equips manufacturers to be globally competitive by supporting the seamless integration of emerging technology into manufacturing processes.

“Allowing students to participate in these types of real-world, hands-on projects is mutually beneficial for everybody involved and furthers the mission of both the ATDM program and the CMA.” – Jason Wells, Executive Vice President, Manufacturing Advancement, IALR

IALR, a Proven Partner: 2024 Annual Report Highlights

IALR, a Proven Partner: 2024 Annual Report Highlights

“I love that IALR moves at the speed of business. Things happen here fast.” – Virginia Governor Glenn Youngkin

The Institute for Advanced Learning and Research (IALR) is proud to announce the release of its Annual Report for Fiscal Year 2024, covering the period from July 1, 2023, to June 30, 2024. This year was defined by strategic collaboration that drove collective innovation, growth and success across Southern Virginia.

Read the Full Report 

“At IALR, our success is not achieved in isolation but through meaningful collaborations across sectors.” – Telly Tucker, IALR President

Below are some of our valued partners:

  • Commonwealth of Virginia
  • U.S. Navy and U.S. Department of Defense
  • Economic and workforce development organizations
  • Local governments and school divisions across Virginia
  • Community colleges, universities and higher education institutions
  • Local and global businesses and companies
  • AmeriCorps and other service agencies
  • Civic groups and nonprofits
  • Private foundations and funding partners

Here are the key highlights that showcase how our work and partnerships are making a difference.

Career Readiness Starts Early

One of the most significant achievements last year was the expansion of the Great Opportunities in Technology and Engineering Careers (GO TEC®) program. Through a network of partnerships involving public schools, higher education and industry leaders, over 6,000 Virginia students received hands-on career introductions. GO TEC continues to inspire students and build dependable talent pipelines for strategic sectors, ensuring our youth are prepared for tomorrow’s careers.

GO TEC curriculum will be taught in 52 middle schools across the Commonwealth of Virginia during the 2024-2025 academic year.

“GO TEC is awesome because it allows students to explore careers and equipment that they would not have access to otherwise.” – Amy Maloskey, GO TEC Teacher, Rural Retreat Middle School, Wythe County

Learn More in the 2024 Annual Report 

Expanding Work-Based Learning Opportunities

The Expanding Talent through Registered Apprenticeship (ExTRA) program saw remarkable progress, supporting the creation of apprenticeship programs across nontraditional sectors. This year marked the launch of Virginia’s first Registered Apprenticeship programs for EMTs and paramedics. The program’s success demonstrates the importance of partnerships between employers, training providers and community organizations to meet our region’s workforce needs.

In partnership with IALR, the Danville Life Saving Crew – the primary Emergency Medical Services provider for the City of Danville – signed 13 individuals as Virginia’s first Emergency Medical Technician (EMT) registered apprentices during an October ceremony.

ExTRA Impact in Numbers:

  • 50 new apprentices hired.
  • 12 new Registered Apprenticeship programs created.
  • Virginia’s first EMT and paramedic Registered Apprenticeship launched.

IALR was also selected to lead the Virginia Talent + Opportunity Partnership (V-TOP) Region 3 Regional Work-Based Learning Collaborative. This initiative develops opportunities for employers and students to connect through work-based learning – and prepares both students and employers for those opportunities.

See Our Collaborative Work in the 2024 Annual Report 

Manufacturing Training Programs

The Accelerated Training in Defense Manufacturing (ATDM) program continues to grow in partnership with the U.S. Navy, rapidly training talent for the defense industry. Approximately 328 students graduated across four cohorts in the 2024 fiscal year. 

By 2025, the ATDM program aims to graduate 800 to 1,000 students annually, solidifying the region’s status as a hub for advanced manufacturing training.

“ATDM’s ability to refine and scale to meet our urgent workforce needs is crucial to building America’s submarine fleet. Together, we’re not just training workers, we’re securing America’s maritime future.” – Erica Logan, Maritime Industrial Base Director for Workforce Development

Additionally, the Integrated Machining Technology (IMT) program, a legacy initiative of IALR and Danville Community College (DCC), remains a cornerstone of our manufacturing training efforts.

See Our Successful Partnerships in the 2024 Annual Report 

Advancing Economic Development in Southern Virginia

In collaboration with local governments, the Virginia Economic Development Partnership and the Southern Virginia Regional Alliance, our Economic Development team contributed to significant economic progress in the region. Over $212 million in new capital investments and the creation of 253 new jobs were key outcomes this year, providing a solid foundation for future economic growth. IALR also hosted essential events such as the 2023 Southern Virginia Regional Housing Summit and the 2024 Workforce Solutions Summit to support long-term development.

“The efforts of the SVRA and the many regional partners should be considered best practices for other communities and regions to follow.” – Edward D. Ober, Grant Management Associates

Discover More Impact in the Annual Report

Advancing Additive Manufacturing

Through a series of strategic initiatives, IALR is advancing additive manufacturing (AM) technology, equipping end users with the skills needed to leverage these capabilities, and driving the growth of additive manufacturing across Southern Virginia. Much of this work is in partnership with the U.S. Navy through the Naval Sea Systems Command (NAVSEA) and Naval Air Systems Command (NAVAIR).

Initiatives in Additive Manufacturing:

By combining training, technology development and partnerships, IALR is making significant strides in establishing Southern Virginia as a leading hub for additive manufacturing.

See More in the 2024 Annual Report 

Collaborative Optimization for Manufacturers

As Virginia’s hub for high-performance manufacturing optimization and advancement, the Center for Manufacturing Advancement (CMA) equips manufacturers to be globally competitive. The CMA at IALR is the destination for innovative manufacturers ready to optimize their operations and scale. With state-of-the-art facilities and technology—including a CNC Machining Innovation Lab, Industry 4.0 Integration Lab and Precision Metrology Lab – the CMA is helping clients and partners optimize operations and scale.

See the Complete Annual Report 

Breakthroughs in Applied Research

IALR’s Applied Research division offers various services in controlled environment agriculture (CEA), analytical chemistry, biotechnology and life sciences. These include conducting contract research, providing chemistry testing services and supporting biotechnology development—all aimed at meeting the needs of industry partners and advancing the scientific community.

“IALR has provided Canon the environment and expertise to grow plants under various stress conditions in an effort to understand how these stresses present themselves in the plants. IALR is unique in this capability.” – Benjamin Welch, Principal Engineer, Canon

View the Full Annual Report

Conference Center Growth

Equipped with state-of-the-art and flexible facilities, the IALR Conference Center experienced impressive growth, hosting over 30,000 guests last year. This increase is a testament to its role as a vital space for collaboration across business, education and community sectors.

“The IALR Conference Center offers a turnkey experience and state-of-the-art technology to deliver a high level of professionalism and engagement. Their staff are accommodating, easy to work with and attentive to the details.” – Stephanie Mann, Center for Early Success

View the Full Annual Report

STEM, Service and Lifelong Learning

IALR’s Advanced Learning team collaborates with numerous partners to increase STEM capacity, promote lifelong learning, and provide regional service-learning opportunities. These initiatives contribute to a better Southern Virginia where all can thrive.

“IALR is an exceptional and long-standing partner to Serve Virginia. The services they provide through their AmeriCorps program, Dan River Year, are impactful and make a real difference in the communities they serve.” – Samantha Lukasiewicz, AmeriCorps Manager

View the Full Annual Report

Growing Campus to Meet Regional Needs

FY 2024 was notable for the growth of IALR’s campus and support services. The number of team members nearly doubled to meet increasing demands, reflecting the strength of the partnerships and the impact IALR has cultivated in Southern Virginia. With new facilities like the Navy’s National Training Center opening in early 2025, IALR is poised to continue driving regional growth and innovation.

“The near doubling of our team and the expansion of our campus highlight the incredible momentum we’ve gained through strategic internal and external collaboration. With new facilities like the Navy’s National Training Center on the horizon, IALR’s IT, Facilities and other support services ensure seamless operations for efficient growth and regional success for years to come.” – John H. Hughes, IV, Ed.D, Executive Vice President, Operations, IALR

View the Full Annual Report

A political subdivision of the Commonwealth of Virginia, IALR is governed by a Board of Trustees. 

“As we review another year of strong financial performance, it’s clear that our partnerships and strategic initiatives deliver real value to the region. Our board remains dedicated to guiding IALR toward continued success, ensuring that every dollar invested helps drive meaningful economic transformation in Southern Virginia.” – Donald W. Merricks, Chairman, IALR Board of Trustees

Andrew Williams of IALR’s CMA Participates in Leadership Training Series

Andrew Williams of IALR’s CMA Participates in Leadership Training Series

Andrew Williams, Process Engineer for the Center for Manufacturing Advancement (CMA), at the Institute for Advanced Learning and Research (IALR), is enhancing his leadership skills through an exclusive Six Course Leadership Training Series. The series, which focuses on equipping manufacturing professionals with the skills to drive growth and innovation, is offered by GENEDGE in partnership with Danville Community College and the Danville Pittsylvania County Chamber of Commerce.

GENEDGE is a leader in improving productivity, growth, and innovation for Virginia’s manufacturing sector. As a Virginia Manufacturing Extension Partnership (MEP) center, GENEDGE supports businesses with programs designed to deliver scale and competitive advantage.

“I’m looking forward to gaining new leadership tools to help me better support the CMA and our partners in the manufacturing industry. This training will be a great asset in driving our mission forward.” – Andrew Williams, CMA Process Engineer, IALR

Williams’ role at the CMA includes serving as quality manager and supporting engineering, subtractive manufacturing and metrology efforts. His work ensures compliance with ISO 9001:2015, supporting the CMA’s overall excellence. As part of the IALR campus, the CMA empowers industry to integrate emerging technology into their manufacturing processes with a focus on optimization and advancement. The CMA is part of IALR’s Manufacturing Advancement division, which focuses on workforce development and optimization. 

Before joining IALR, Williams was a project engineer at a precision tooling company, managing key accounts and developing tooling designs.

Kevin Thompson, CMA Operations Manager at IALR and Williams’ supervisor, praised Williams’ initiative: “Andrew’s participation in this program highlights his commitment to personal growth and our team’s success. His dedication to continuous improvement is exactly what we need to drive innovation at the CMA.”

Bert Eades, GENEDGE Business Services Director, will teach the six-course series, which will cover essential leadership topics, including communication, coaching, goal setting and conflict resolution. The sessions from September to November are designed to enhance operational efficiency, team dynamics, and leadership within the manufacturing sector.

As Virginia’s hub for high-performance manufacturing optimization and advancement, the CMA at IALR equips manufacturers to be globally competitive. The CMA empowers industry to seamlessly integrate emerging technology into their manufacturing processes, boosting efficiency, effectiveness and profitability while maximizing ROI.

IALR’s Center for Manufacturing Advancement Earns ISO 9001:2015 Certification

IALR’s Center for Manufacturing Advancement Earns ISO 9001:2015 Certification

The Institute for Advanced Learning and Research (IALR) announces that its Center for Manufacturing Advancement (CMA) has achieved the prestigious ISO 9001:2015 certification. This globally recognized certification demonstrates the CMA’s commitment to maintaining operational integrity and delivering high-quality processes and outcomes for clients and partners.

The ISO 9001:2015 certification helps organizations of all sizes and sectors to improve their performance, meet customer expectations and demonstrate their commitment to quality.

The CNC Machining Innovation Lab inside the CMA provides first-rate process optimization and reliable testing services for manufacturers around the world.

“Achieving this level of ISO certification is a significant milestone for the CMA. It reflects our commitment to quality and reliability and assures our clients and partners that we are constantly improving and aligning with international standards.” – Jason Wells, Executive Vice President, Manufacturing Advancement, IALR

The International Organization for Standardization, or ISO, brings global experts together to agree on the best way to do things—for anything from making a product to managing a process. The ISO 9001:2015 certification establishes an effective quality management system, enabling organizations to improve efficiency, ensure product consistency and meet the highest standards of customer satisfaction.

The CMA equips companies to increase global competitiveness through cutting-edge technology, industry expertise and state-of-the-art facilities. The ISO certification reinforces the CMA’s mission of helping manufacturers deploy emerging technologies and advanced solutions with precision and efficiency.

The CMA features a state-of-the-art metrology lab equipped with one of the largest Coordinate Measuring Machines on the East Coast.

“Obtaining this certification demonstrates that we are serious about meeting the needs of our clients and partners efficiently and consistently, allowing them to thrive in a competitive global market.” – Kevin Thompson, CMA Operations Manager, IALR

The ISO certification increases the reliability of service provided by two labs housed inside the CMA that provide critical services to industry. The CNC Machining Innovation Lab enables manufacturers to evaluate their processes, develop improvements and incorporate efficiencies without disrupting current operations. The fully equipped Metrology Lab provides integrated inspection capabilities that allow manufacturers to validate quality and accurately and affordably measure and certify products. Though not part of the scope of the ISO certification, the CMA’s Industry 4.0 Integration Lab also plays a pivotal role in supporting manufacturers as they transition to digital strategies, integrate automation and advance to the next stage of their growth cycle.

Featuring elite equipment, innovative technology and a staff of talented machinists, the CNC Machining Innovation Lab enables new and existing businesses to evaluate their processes, develop improvements and incorporate efficiencies without disrupting current operations.

Through a collaborative approach, the CMA partners with advanced manufacturing companies to optimize their operations, adopt new technologies and enhance processes—all while minimizing disruption and maximizing return on investment (ROI).

For manufacturers relocating to the U.S. or expanding in Southern Virginia, the CMA offers a seamless experience with immediate access to expertise, technology and workforce development programs. Located adjacent to the Navy’s National Training Center, the CMA benefits from proximity to the Accelerated Training in Defense Manufacturing (ATDM) program, further enhancing its capabilities to drive innovation and growth. The CMA also houses the Navy’s Additive Manufacturing Center of Excellence.

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

Inside IALR Podcast: Two Years for IALR President Telly Tucker

Inside IALR Podcast: Two Years for IALR President Telly Tucker

IALR President Telly Tucker returns for the one-year anniversary episode of Inside IALR to discuss the biggest successes and lessons learned from his two years with the organization. As IALR continues to grow, Telly explains the level of growth and impact not only regionally but nationally and internationally in areas such as GO TEC, ATDM and Applied Research. Telly also highlights his vision for IALR two years from now.

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Jason Wells Joins IALR as Executive Vice President of Manufacturing Advancement

Jason Wells Joins IALR as Executive Vice President of Manufacturing Advancement

The Institute for Advanced Learning and Research (IALR) is pleased to announce that Jason Wells will join the leadership team as Executive Vice President of Manufacturing Advancement, effective June 3. Wells most recently served as President of Kyocera SGS Tech Hub, a manufacturing and research hub within the cutting tool division of Kyocera Corporation, and brings nearly 30 years of experience in high-performance manufacturing. He will provide executive-level strategic management and oversight of IALR’s growing Manufacturing Advancement division and will report directly to IALR President Telly D. Tucker.

“As the Institute for Advanced Learning and Research continues to expand into a leading hub for high-value, high-tech companies and growing, targeted industries like advanced manufacturing, placing globally minded and accomplished leadership at the helm is critical. I am excited to welcome Jason Wells to IALR and have full confidence that his comprehensive industry expertise and proven commitment to the community will position us well to serve the manufacturing optimization, technology and workforce training needs of advanced manufacturers.” – Telly Tucker, IALR President 

One of Wells’ key charges will be to oversee the operation and strategic direction of the Center for Manufacturing Advancement (CMA), which offers manufacturing optimization expertise in CNC machining, metrology services and Industry 4.0; all of which help manufacturers introduce new and emerging technology into their operations. The CMA is also home to the United States Navy’s Additive Manufacturing Center of Excellence.

Wells will also have responsibility for the oversight of additional training programs including the collaborative and innovative Accelerated Training in Defense Manufacturing (ATDM) program, a federal initiative of the U.S. Navy and Department of Defense to meet the critical workforce needs for skilled trades like welding, CNC machining, quality control inspection (metrology), non-destructive testing and additive manufacturing. The program, housed and led by IALR, will achieve full capacity in 2025, graduating 800 to 1,000 work-ready individuals annually.

Prior to his leadership role at Kyocera SGS Tech Hub, Wells amassed significant management and advanced manufacturing experience in an array of roles with leading companies. Some of his more recent posts include Director of U.S. Tech Center Operations at YG-1 America Inc., a global manufacturer of high-quality cutting tools, and Global Product Manager and Director of Product Development and Marketing for SGS Tool Company. Wells acted as primary inventor on six product patents recognized in several countries, and he established two U.S.-based divisions and manufacturing units for two different internationally headquartered manufacturing companies. Wells has authored a number of articles in leading trade periodicals and was selected as one of the 100 people to meet in Virginia in 2020 by Virginia Business magazine. He has also been a featured speaker and panel member at multiple lectures at industry-based events and symposiums.

“As a business leader with a unique connection to Southern Virginia and IALR, I am deeply honored to assume the role of Executive Vice President of Manufacturing Advancement, and I sincerely thank all of my outstanding mentors, colleagues and partners for their support throughout my career. My journey of the past eight years, engaging with the community, the schools and IALR has filled me with profound appreciation for the task ahead. I am motivated and inspired by the vision and mission set forth, to nurture the next generation of industrial talent, implement the evolution of technology, fuel the renaissance of the region, and support our nation’s defenses. I embrace this opportunity wholeheartedly, committed to contributing to a brighter future for all.” – Jason Wells, IALR Executive Vice President of Manufacturing Advancement 

A degreed Journeyman Tool Maker and Tool Application Engineer, Wells holds various industry-recognized certifications. He has also served on a variety of local, state and international boards and councils, including the Great Opportunities in Technology and Engineering Careers (GO TEC®) advisory board, the industry technology advisory council for Danville Community College as well as the boards of the Commonwealth Center for Advanced Manufacturing, the University of Sheffield Advanced Manufacturing Research Centre and the United Way of Danville-Pittsylvania County.

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation through 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. 

About IALR 

Robotic Simulation Software Training Hosted at CMA

Robotic Simulation Software Training Hosted at CMA

The Institute for Advanced Learning and Research (IALR) hosted a three-day robotic simulation class on April 16-18, providing regional community college and high school instructors with needed training for FANUC ROBOGUIDE simulation software. This was the first external training opportunity provided in the Center for Manufacturing Advancement (CMA).

A total of 15 instructors participated in the three-day course, which was taught by Butch Kendrick, IALR’s Director of Digital Manufacturing, at the CMA and sponsored by Amtek Company – the FANUC educational representative for Virginia and several other southern states.

“This workshop helped these instructors understand the possibilities and capabilities of this software and how to better integrate that knowledge into their courses. We are happy to utilize the CMA as a hub for technical training and information for industry and educators alike.” – Butch Kendrick, Director of Digital Manufacturing, IALR

Participants came from a variety of educational institutions, including Patrick & Henry Community College, New River Community College, the Southern Virginia Higher Education Center, the Pittsylvania County Career and Technical Center and a technical college in West Virginia. The hands-on, three-day workshop allowed participants to learn the operations and functionality of the FANUC ROBOGUIDE software. Fanuc is a leading supplier of robotics and automation solutions for industry.

This workshop was designed specifically for teachers working to obtain their FANUC Certified Robot Operator I certification.

“We wanted to hold a local class for our teachers in Virginia and West Virginia to highlight how to use the ROBOGUIDE software, prepping them for the certification exam and helping them better teach this program in their classrooms.” – Gary Daniels, Sales Consultant Amtek Company

Percy Pass, Instructor of the Automation and Robotics Course at the Pittsylvania County Career and Technical Center, has 10 of these robots in his classroom, and this training will help him and his students have a better experience working with them.

“This will allow the students to become familiar with the controls and overall operations of the robot, both the physical version and the simulator.” – Percy Pass, Instructor, Pittsylvania County Career and Technical Center

While no future workshops are currently on the schedule, staff in the CMA plan to offer additional training opportunities and operational workshops on the operation of different robots.

Housed on the campus of IALR, the CMA serves as the destination of choice for innovative manufacturers ready to optimize their operations and scale. The CMA features an Industry 4.0 Integration Lab focused on automation and robotics, a CNC Machining Innovation Lab that helps businesses to evaluate processes and incorporate efficiencies, and a Metrology Lab with integrated inspection capabilities required to validate product quality. The CMA is also home to the Navy’s Additive Manufacturing Center of Excellence.

Tour of IALR – Manufacturing Advancement

Tour of IALR – Manufacturing Advancement

Join us for a free guided group tour of the manufacturing workforce development programs and industry solutions on the campus of the Institute for Advanced Learning and Research (IALR). Discover our impact and explore our innovative training facilities and cutting-edge optimization and support services. Our Manufacturing Advancement division focuses on meeting and exceeding the optimization and workforce needs of new and existing industry.

This one-hour tour will include a brief overview of IALR before a deep dive into the focus areas of our Manufacturing Advancement division. Participants will see:

  • The Center for Manufacturing Advancement, which allows advanced manufacturing companies to collaborate and enhance processes, improve quality, and more.
  • Several labs from the Accelerated Training in Defense Manufacturing (ATDM) program, which quickly trains qualified candidates in essential manufacturing skills and trades that will help the United States Navy build submarines.
  • The Naval Aviation School for Additive Manufacturing (NASAM), a new, six-week program that provides active-duty Navy sailors and marines with foundational skills in additive manufacturing
  • The Gene Haas Center for Integrated Machining, which houses both CNC Teacher Training for high school and community college instructors and the Integrated Machining Technology program – a third-year program that takes advanced machining skills training and knowledge to the next level.

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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.

Inside IALR Podcast: Industry 4.0: Robots, Automation and Efficiency

Inside IALR Podcast: Industry 4.0: Robots, Automation and Efficiency

What is Industry 4.0? It involves interconnected machines and data analysis capabilities, and it’s what allows three robots to utilize two CNC machines and several other tools and processes to convert a piece of raw material into a finished packaged product without any human involvement inside IALR’s Industry 4.0 Integration Lab.

The “Inside IALR” team is on location inside the Center for Manufacturing Advancement (CMA) with Butch Kendrick, Director of Digital Manufacturing, to outline the goals and capabilities of the Industry 4.0 Integration Lab (0:33), discuss the main principles of Industry 4.0 (1:47), and explain the processes and technologies inside the lab (12:03). Butch describes some of the challenges in designing and implementing the Industry 4.0 Integration lab (17:38) and highlights additional technologies and processes that he hopes to add to the lab in the future (21:13).

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Growing Impact Showcased in 2023 Annual Report

Growing Impact Showcased in 2023 Annual Report

The Institute for Advanced Learning and Research (IALR) has published its 2023 annual report, which highlights the growing impact IALR and partners are making in Southern Virginia and beyond. In FY 23, IALR expanded its impact with the scaling of programs and the growth of the campus, technology and team.

“The last fiscal year was one of tremendous growth and expansion for our region. All the while, each of our five divisions upheld our mission of economic transformation in critical ways.” – Telly Tucker, IALR President

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Just some of the new initiatives and programs launched, announced or expanded during FY 2023:

  • The Accelerated Training in Defense Manufacturing (ATDM) program continued scaling up toward its target of 800-1,000 annual graduates by 2025.
  • The Great Opportunities in Technology and Engineering Careers (GO TEC®) program is expanding across the Commonwealth thanks to a $3.4 million grant from GO Virginia and public and private investments.
  • The inaugural Controlled Environment Agriculture (CEA) Summit East brought more than 220 participants from around the world to the IALR campus.
  • The Institute Conference Center hosted 27,600 guests at events and programs, ranging from multi-day conferences to executive business meetings to training seminars.
  • IALR opened and began operations in the Center for Manufacturing Advancement, which supports industry with a variety of services and houses the U.S. Navy’s Additive Manufacturing Center of Excellence.
  • Nearly 30 industrial sites across Southern Virginia received a higher certification from the Virginia Business Ready Sites Program, with 21 moving from Tier 2 to Tier 4 and an additional eight sites moving from Tier 2 to Tier 5, which denotes a shovel-ready graded pad site.
  • A new Public Health AmeriCorps program launched to expand public health capacity through education and outreach, including public health workshops.
  • IALR entered into 15 new non-disclosure agreements to partner with companies around the world by providing contract analytical and testing services.
  • Five new companies announced projects in Southern Virginia and four existing companies announced expansions. These projects total 545 new jobs and $335.7 million in capital investments.
  • In its ninth year, the Career ChoICE Youth Expo expanded to a second location at Hampden-Sydney College, allowing the event to reach additional students across more than a dozen Virginia localities.
  • IALR received a $497,890 grant from the Tobacco Region Revitalization Commission for the ExTRA (Expanding Talent through Registered Apprenticeship) program to grow state-registered apprenticeship in 15 Southern Virginia localities.
  • Megabytes café launched a new and improved menu.
IALR December 2023 Newsletter

IALR December 2023 Newsletter

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The December edition of IALR at a Glance is jam-packed with exciting news and updates! Learn more about…

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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
U.S. Navy breaks ground on new Regional Training Center (RTC) at IALR Campus

U.S. Navy breaks ground on new Regional Training Center (RTC) at IALR Campus

The new center will accommodate full-scale growth of the defense manufacturing training program, providing a pipeline of 800-1,000 skilled workers per year for high-demand jobs.  

The United States Navy broke ground on a new regional training center for the Accelerated Training in Defense Manufacturing (ATDM) program in Danville today. The new 100,000-square-foot training facility, located on the campus of the Institute for Advanced Learning and Research (IALR), will allow more students to enroll in accelerated four-month training programs to help them reskill or upskill for high-paying jobs. Estimated to open by 2025, the Regional Training Center expects to graduate 800-1,000 students per year to fill critical vacancies across the defense industrial base.

The groundbreaking ceremony was held during the annual ATDM & U.S. Navy Additive Manufacturing Center of Excellence (AM CoE) Summit, which gathered the Navy, Office of the Secretary of Defense, state and local officials, and industry partners to increase awareness of these important initiatives and promote participation and contributions by industry and other stakeholders. This year, ATDM instructors and students were joined by Secretary of the U.S. Navy Carlos Del Toro and Rear Admiral Scott W. Pappano to celebrate the success of the past year and discuss goals going forward.

“The incredible progress made over the past year here in Danville, both in building the next generation of submarine builders at ATDM and in advancing the manufacturing technology we need to succeed at AM CoE, proved that we are on the right path. This past year established the foundation for the critical leaps forward we need in the coming years to scale both programs to ensure we have the skilled workforce with the technology and capabilities needed to build the Navy’s next generation of submarines.” — Rear Adm. Pappano, program executive officer, Strategic Submarines, U.S. Navy

“The groundbreaking of the Regional Training Center is a key milestone in scaling ATDM by providing a dedicated training facility with the infrastructure and equipment necessary to reach our full capacity of training potential,” said Dr. Debra Holley, director of the ATDM program.

Darrell Dalton, Chair of the Pittsylvania County Board of Supervisors, remarked that the construction of the Regional Training Center is a “win for our local economy, as it will bring up to 1,000 students a year to Danville and Pittsylvania County, and all of whom will live, work, and play here. By building its training facility in Danville, the Navy has provided a capital investment that further shows the growing prominence of this region in manufacturing and related industry sectors.”

ATDM Summit 2023

“We are especially fortunate that the Navy has recognized the forethought of our local leaders who have worked over the years to create educational programs that emphasize the type of knowledge and skills needed for this program,” Dalton continued.

In partnership with the Industrial Base Analysis and Sustainment Program Office (IBAS) in the Office of the Secretary of Defense (OSD) and the Navy’s Program Executive Office (PEO) Strategic Submarines, ATDM trains workers in critical manufacturing skills to establish a steady and sustainable flow of workers into the SIB/DIB to fill critical skills gaps and labor shortages. The AM CoE directly supports the growth of our nation’s industrial base by using additive manufacturing for the production of submarine components to bolster naval shipbuilding and repair supply chains.

America’s defense industrial base (DIB) is still greatly in need of workers who can build and repair naval ships. The lack of workforce and manufacturing shortfalls in this area impact the material readiness of the current naval fleet; major maintenance and overhaul availability; and new construction. The construction of the “1 COLUMBIA + 2 VIRGINIA” naval ships beginning in FY26 will further stress the Submarine Industrial Base (SIB) and increase the need for qualified talent in the workforce. The AM CoE, which formally opened at last year’s summit, directly supports growth of our nation’s industrial base by scaling and maturing additive manufacturing technologies in the SIB. The technologies enable innovative production of submarine components to bolster naval shipbuilding and repair supply chains. As a result, the AM CoE will increase overall manufacturing capacity and close the supply-demand gap in critical marketspaces like castings, forgings, fittings, and fasteners.

Secretary of the U.S. Navy Carlos Del Toro (right) and Rear Admiral Scott W. Pappano (left) sign a steel beam that will be part of the new ATDM Regional Training Center.

The Institute for Advanced Learning and Research (IALR) has also been selected by the U.S. Navy Program Executive Office, Strategic Submarines (PEO SSBN) as the designated memorial location for the Ex-USS Buffalo (SSN 715) sail and the Ex-USS Providence (SSN 719) rudder to preserve and commemorate the history of these submarines and honor the service of their crews. This memorial demonstrates the strong partnership between the Navy and Accelerated Training in Defense Manufacturing (ATDM).

“Today marks a new chapter in the exciting growth of the ATDM program and further exemplifies the educational, workforce, and technological innovation that is taking place in Virginia. The investments made here are vital to the economic progress of the entire commonwealth,” said Telly Tucker, president of the Institute for Advanced Learning and Research, which leads the multi-year ATDM pilot project. IALR’s Center for Manufacturing Advancement is also home to the Navy’s AM CoE.

“The ATDM program marks a bold step forward,” said Danville City Councilman Lee Vogler. “This initiative stands at the forefront of addressing the challenges facing our defense industrial base and, by extension, our nation’s security.”

The sail was part of the Ex-USS Buffalo (SSN 715), a decommissioned United States Navy LOS ANGELES Class nuclear-powered attack submarine. USS Buffalo (SSN 715) was commissioned in November 1983, and decommissioned in January 2019. During that time, she saw most of her service in the Pacific area of operation.

The rudder hails from Ex-USS Providence (SSN 719), also a decommissioned United States Navy LOS ANGELES Class nuclear-powered attack submarine. Ex-USS Providence (SSN 719) was commissioned in July 1985. In August 2021, USS Providence was transferred from Naval Submarine Base New London in Groton, Conn., to Kitsap Naval Base in Bremerton, Wash., for decommissioning after 37 years of service.

To learn more about the new regional training center, or ATDM program classes and cohorts, please visit www.atdm.org.

About ATDM

Accelerated Training in Defense Manufacturing is a prototype training platform for rapidly training skilled workers in key trades such as CNC machining and welding for employment in the defense industry. ATDM was developed as a public-private consortium between the DoD, the Institute for Advanced Learning and Research (IALR), Danville Community College (DCC), Phillips Corporation, and The Spectrum Group in consultation with the defense industry. IALR is leading a multi-year pilot project to test and evaluate ATDM as a training platform for regional training centers supporting the defense industrial base. The pilot project is funded through the National Imperative for Industrial Skills initiative, which was launched in 2020 by the Industrial Base Analysis and Sustainment Program Office (IBAS) in the office of the Undersecretary of Defense for Acquisition and Sustainment.

About IALR

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation through 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. For more information, visit www.ialr.org.