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Applied Data Science Program Delivers Practical Skills to 12 BWXT Employees

Applied Data Science Program Delivers Practical Skills to 12 BWXT Employees

Artificial intelligence is here. And “AI bootcamps” and “AI training courses” are seemingly everywhere.

Those offerings are rapidly maturing to meet the needs of specific industries, organizations and departments. The best programs are designed with real-world applications purposefully built into the training experience.

That’s what the Center for Manufacturing Advancement (CMA) at the Institute for Advanced Learning and Research (IALR) created: a custom, 300-hour Applied Data Science Accelerator tiered program to upskill engineers into data science practitioners. Twelve BWXT employees graduated from this pilot program on July 8.

“The Applied Data Science Accelerator Program stands out in a crowded AI training landscape by focusing on practical capability development and measurable business impact, not just conceptual learning,” said Meredith Gregory, Director of Digital Strategy and Program Management at IALR.

“We’re building a workforce that doesn’t just understand AI but uses it. This program equips our teams to apply BWXT’s unique data and expertise to real manufacturing challenges, making us faster, more precise, and more competitive. By training our people to work directly with data and models, we’re turning BWXT’s hard‑won expertise into actionable insight we can use to boost speed, cut rework, and strengthen performance.” – Shane Jacobs, General Manager, BWXT.

Creating a Program that Meets the Mission

BWXT, which manufactures naval nuclear components and reactors, has consistently hired graduates of the Accelerated Training in Defense Manufacturing (ATDM) program at IALR to work at its facilities in Lynchburg, Virginia, and in Mount Vernon, Indiana. The company has also received optimization services from IALR’s CMA, which helps manufacturers deploy proven technology, strengthen processes and build workforce capability in ways that deliver results on the floor.

The idea for this accelerated program happened during a meeting between IALR and BWXT staff. Those conversations quickly went from discussing the need to outlining a possible structure and scope.

Over the next several months, seven staffers of the CMA and IALR, as well as two expert consultants, had varying levels of involvement in the program’s development and execution. BWXT provided needed insight to adapt what we were planning to their environment and by extension, manufacturing environments. The course officially launched on April 8.

“Not everyone can just create a class like this if you don’t have a good idea of what works,” Gregory said. “We pulled a lot of what works from our other workforce training programs and even machine learning and AI internship experiences we offered in the summer of 2025.”

This training equipped these 12 BWXT employees to implement AI technologies more effectively into plant operations. In short, they can manipulate data, train models, evaluate those models, and put those models into production.

Tiers of Capability

While grounded in traditional lecture and assessment style instruction, the course focuses on the application of skills through an organization-selected Agile class project. This course integrates proven practices from data science, team development, and engineering education to help organizations cultivate a data science capability within their existing workforce, emphasizing both technical and soft skills.

The program was designed to train four different tiers. Graduates from this cohort were spread across tiers 2-4.

  1. Data Science Foundations: Understands core data science and AI concepts at a conceptual level. Can identify appropriate use cases, recognize risks and engage in informed conversations, but is not expected to build, implement or own technical work. 16 hours
  2. Data Science Practitioner: Can execute well-defined data science tasks with guidance. Uses Python/SQL basics, supports pipeline and model implementation, and follows established processes. Limited ownership, but contributes effectively within structured workflows. ~ 300 hours
  3. Data Science Associate: Operates as an independent contributor. Can design and build models and pipelines with minimal oversight, analyze results and communicate insights to stakeholders. Begins contributing to technical decisions and may own smaller projects. ~300 hours
  4. Tier 4: Functions as a technical leader and system architect. Designs scalable solutions, owns technical decisions, ensures quality and performance, and leads projects end-to-end. Communicates effectively across stakeholders and mentors others while driving business impact. ~ 300 hours

“The CMA is built around a simple idea: manufacturers achieve better outcomes when people, processes and technology advance together. This program demonstrates how developing workforce capability in parallel with digital transformation efforts can accelerate adoption and create lasting impact on the production floor.” – John Ring, Vice President, Center for Manufacturing Advancement

Lessons Learned and Future Opportunities

Throughout the program, BWXT employees provided consistent feedback about what elements of the course were working and what weren’t. They shared this feedback every day, at the end of every sprint (2 weeks) and at the midpoint.

“Pilot programs hinge on feedback and short iteration cycles. BWXT could not have been more gracious in providing invaluable feedback,” Gregory said.

Now that this curriculum is developed, the CMA stands ready to deliver this course – informed by the lessons learned during this pilot phase and customized to each customer’s needs. The Applied Data Science Accelerator Program will help more manufacturers effectively integrate AI, machine learning and applied data science into their operations.

BWXT Applied Data Science Accelerator Program Graduation

Inside IALR Podcast: Full-Stack Manufacturing Optimization | Bridging the Valley of Death

Inside IALR Podcast: Full-Stack Manufacturing Optimization | Bridging the Valley of Death

What does it actually take to move a new technology from the lab to the shop floor and make it stick?

In this episode of Inside IALR, host Caleb Ayers is joined by Jason Wells, John Ring, Josh Sims, and Jeremiah Williams for a deep dive into IALR’s Center for Manufacturing Advancement (CMA).

Together, they highlight how CMA functions as a hands-on optimization arm focused on operationalizing existing technologies and helping manufacturers avoid the infamous “valley of death” between readiness levels and real production. It’s not a research institute,

The conversation covers CMA’s full-stack approach to manufacturing advancement, from precision machining, additive post-processing, and metrology to automation, robotics integration and digital/AI enablement.

The team explains how the CMA serves as a non-biased third-party testbed where manufacturers can explore new technologies, validate processes and refine workflows without shutting down production or making massive capital bets. The CMA comes alongside companies as a partner—not a vendor—to help them get to “more, better, faster, cheaper” without just shifting bottlenecks somewhere else.

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Inside IALR Podcast: Beyond the Surface: Exploring the History, Science, and Impact of Non-Destructive Testing

Inside IALR Podcast: Beyond the Surface: Exploring the History, Science, and Impact of Non-Destructive Testing

What do submarines, aircraft and even theme park rides have in common?

They all rely on Non-Destructive Testing (NDT) to ensure safety and reliability.

In this episode of Inside IALR, host Caleb Ayers talks with Phil Bowers, NDT instructor for the Accelerated Training in Defense Manufacturing (ATDM) program, and Michael Donnelly, NDT manager with Industrial Inspection & Analysis at the Center for Manufacturing Advancement. Together, they unpack the fascinating history of NDT — from its origins in the railroad era to its role in modern defense manufacturing — and explore the science behind methods like ultrasonic testing, X-ray imaging and eddy current inspection.

Plus, find out why NDT careers are in high demand and how technology like AI and robotics is shaping the next generation of inspections.

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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 qualifications.

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

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. 

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. 

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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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