Institute for Advanced Learning and Research
Driving Economic Transformation
The July 2026 edition of IALR at a Glance is packed with exciting news and updates! Learn more about…
The Institute for Advanced Learning and Research (IALR) and Danville Community College (DCC) are pleased to announce the graduation of the latest cohort of the Integrated Machining Technology (IMT) program.
This year’s cohort includes 11 graduates who spent the past nine months building advanced machining expertise while strengthening leadership, teamwork and problem-solving skills essential to success in modern manufacturing. Most graduates have secured employment or are actively interviewing with prospective employers while a smaller number plan to continue their studies through IMT’s transfer pathway into Old Dominion University’s Bachelor of Science in engineering technology program, concentrating in manufacturing engineering technology.
The IMT program is a collaborative, capstone-style experience developed by DCC and delivered in partnership with IALR to prepare students for high-demand careers in advanced manufacturing. Rather than focusing solely on classroom instruction, students work in a simulated “flow cell” environment that mirrors real-world production. They manage the full manufacturing process, from ordering materials and scheduling machine time to inspecting finished parts and meeting quality standards. This year’s cohort produced scope mounts for shotguns, fishing reels and golf putters.
Through this hands-on approach, students gain experience in multi-axis CNC programming, Lean Six Sigma principles and modern inspection techniques while also learning to communicate effectively, adapt to challenges and take ownership of outcomes.
“This program takes years of learning applicable hard skills and allows students the opportunity to mature those skills in a more realistic environment,” said Jason Wells, Executive Vice President of Manufacturing Advancement at IALR. “IMT graduates can immediately come in and contribute at a level that is much broader than simply standing in front of a machine and operating it.”
Employers continue to recognize the value of IMT training. Confirmed employers for this graduating class include IALR’s Center for Manufacturing Advancement, BWX Technologies, GE Aviation, Progressive Machine Works and Sandvik Coromant.
“Programs like Integrated Machining Technology demonstrate what is possible when education and industry work hand in hand to prepare students for the future,” said Dr. Cornelius Johnson, President of Danville Community College. “Through our partnership with IALR, students are gaining advanced technical skills, leadership experience, and real-world problem-solving abilities that position them for immediate success in today’s manufacturing workforce. We are incredibly proud of this 11th cohort and are excited to see the impact these graduates will make across our region and beyond.”
Throughout the program, students also focus on developing soft skills such as leadership, collaboration and conflict resolution, which help distinguish IMT graduates as they enter competitive job markets.
Graduates of the program pursue careers across a range of industries, including aerospace, defense and advanced manufacturing, while others continue their academic journeys to build on their technical foundation. Many IMT alumni choose to remain in Southern Virginia, supporting regional manufacturers and contributing to long-term economic growth.
Brandon Furgurson
“Watching this cohort grow from students into confident manufacturing professionals has been incredibly rewarding. The IMT program pushes them beyond the classroom and into real-world responsibility, and they’ve proven they’re ready to step into industry and make an immediate impact.” – Brandon Furgurson, IMT Instructor, DCC
Here’s what a few members of this year’s IMT graduating class had to say:
“This program is hands-on and personal. It’s a nice experience getting to collaborate with your classmates. More people should definitely sign up for IMT.” – Massimo Bianchi, IMT Graduate
“The IMT program is bringing me more opportunities and putting more on my resume. It adds to DCC’s two-year machining program and goes beyond it.” – Ryan Lewis
“I really enjoyed learning the different styles and types of CNC Machines.” – Leah Holder, IMT Graduate
IMT is one of several workforce training programs supported and administered by IALR’s Manufacturing Advancement division, which works closely with regional employers to align education with evolving industry needs.
Ryan Lewis
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 initiatives. IALR’s primary footprint includes Southern Virginia and the surrounding region.
Danville Community College is a two-year institution within the Virginia Community College System. DCC serves the City of Danville, Pittsylvania County and Halifax County. For more information about the college’s academic programs, visit www.danville.edu.
The March 2026 edition of IALR at a Glance is packed with exciting news and updates! Learn more about…
By Jason Wells, Executive Vice President of Manufacturing Advancement, IALR
The recent Southern Virginia Living Wage and Job Availability Study shows that more manufacturing workers are available than manufacturing job openings across GO Virginia Region 3.
At face value, that suggests a surplus of workers.
But that’s not what our team hears when talking with manufacturing companies across our region, whether it’s a metalworking shop in Halifax or a major defense supplier scaling production.
What I hear is: We can’t find enough people with the right skills.
So which is it? Are we long on manufacturing talent or short on it?
As is often the case in workforce development, the truth lives in the tension between the two.
And this tension is exactly why our region cannot simply focus on technical skills alone. Readiness also depends on communication, reliability, professionalism and work ethic — the difference between being job‑oriented and being truly career‑minded.
It’s not just about the number of workers. It’s about who they are, where they live and what they’re prepared to do.
The report’s regional snapshot captures job postings at a moment in time. But manufacturing doesn’t behave like some other sectors. A firm may have robust headcount on paper and still feel understaffed because:
Another dynamic is hiring itself: many employers continue using the same recruitment practices while expecting different results. Hiring needs to evolve just as manufacturing evolves, and too often, it hasn’t.
In other words, a surplus on a spreadsheet doesn’t always translate to a talent pool at the door.
And employers will tell you that directly. Many are balancing production deadlines with training gaps, or they’re promoting inexperienced technicians into advanced roles simply because there’s no one else in the pipeline.
That’s a skills‑alignment problem rather than a surplus problem.
GO Virginia Region 3 is large, stretching from Patrick County eastward toward the Richmond frontier. The study’s macro view smooths over significant variation.
Some localities genuinely have more manufacturing workers than openings. Others, especially those closest to emerging industrial sites, already feel tight.
This regional imbalance shows up in workforce conversations every week. A plant manager in one county may be turning away applicants. Another, 40 miles away, may be struggling to hire despite higher wages.
Without strong networks intentionally linking people to jobs, employers to training providers and communities to each other, surplus and shortage can exist side by side.
For manufacturers evaluating expansion or relocation, this alignment signals regional capability. They are not simply assessing today’s headcount; they are evaluating whether the region can mobilize talent, scale training and collaborate across boundaries when opportunities arise.
If we only plan for the present, we’re already behind.
Already, we know of two major manufacturing plants on their way to Southern Virginia. Microporous announced in November of 2024 that it will create a $1.35 billion battery separator manufacturing facility at the Southern Virginia Megasite at Berry Hill. And just this month, Avio USA Inc. announced a $500 million new solid rocket motor manufacturing facility to be located at the Southern Virginia Multimodal Park in Hurt.
Together, these two projects will create more than 3,000 jobs, with the vast majority in manufacturing.
These projects are fundamentally reshaping the demand curve in Southern Virginia. And they are not the only ones. Over the past several years, our region’s manufacturing ecosystem has steadily expanded in capability, technology and national visibility.
I am confident more announcements will come.
Today’s surplus could become tomorrow’s severe shortage.
In manufacturing, the lead time to develop talent is long. You don’t train a CNC machinist, quality technician or AM operator in a few weeks.
This is part of why employer conversations feel so different than the report’s topline numbers. Businesses are looking to prepare their workforce for future capabilities, production demands and contracts.
During conversations with industry partners, one theme comes up constantly: “We have applicants. We need contributors.”
Manufacturing requires technicians who understand not just how to run equipment, but how processes flow, how tolerances stack, how documentation supports quality and how automation integrates with upstream and downstream operations. Those capabilities don’t appear automatically in the workforce just because workers exist.
Skills gaps arise because:
As my team engages with manufacturers in the region and across the nation, we repeatedly hear those exact needs for employees who can contribute at a high level faster than ever before.
Across our campus, we have deliberately aligned our programs around the skills‑to‑production pipeline, from early-career exploration to advanced, hands‑on training to real‑world technology adoption.
Our Accelerated Training in Defense Manufacturing (ATDM) program takes what is traditionally a year and a half of focused training and condenses it into an intense, disciplined 16‑week experience. Graduates leave with foundational technical competency, hands‑on repetition under pressure, and a mindset oriented toward excellence and urgency.
This kind of talent pipeline directly addresses employers’ requests for speed, reliability and readiness.
We also know that readiness begins early. The Great Opportunity in Technology and Engineering Careers (GO TEC) program exposes middle schoolers to welding, machining, robotics and other pathways long before they step into high school CTE or dual‑enrollment programs.
The Integrated Machining Technology program, which is taught by Danville Community College and housed at IALR, gives emerging technicians the “third-year” experience where all the pieces finally come together.
And our partnership network ensures those pathways form a cohesive ladder, not a scattered series of steps.
If you zoom out, a pattern emerges.
Yes, the report shows a surplus of manufacturing workers today.
And yes, employers are sounding the alarm about skills gaps today.
But tomorrow’s picture is already taking shape:
New industrial employers are coming.
Existing employers are expanding.
Advanced manufacturing technologies are accelerating.
The region is being asked to produce more, faster and with greater precision.
The question isn’t whether we have enough people.
It’s whether we have enough prepared people in the right places, with the proper training, aligned to the right future.
And that brings me back to something I shared recently with our entire Manufacturing Advancement team:
“When the rate of change outside exceeds the rate of change inside, the end is near.” — Jack Welch
Manufacturing is living that reality every day. The pace of external change — new employers, new technologies, new federal expectations, new supply‑chain vulnerabilities — is accelerating. If our talent systems, training pipelines and regional partnerships don’t evolve at the same speed, we won’t just fall behind. We’ll miss the moment entirely.
Southern Virginia, however, is choosing a different path.
We are choosing to change faster.
To prepare sooner.
To build forward.
IALR’s mission has always been to serve as a forward-looking catalyst. And the work happening across our campus today, from ATDM to IMT and GO TEC, is positioning this region not only to meet the demands ahead, but to lead in ways few would have predicted a decade ago.
We’re not preparing for the workforce or the job count we have today.
We’re preparing for the workforce we will need tomorrow
Jason Wells is IALR’s Executive Vice President of Manufacturing Advancement. With decades of experience in the toolmaking industry, Wells now leads IALR’s manufacturing training and optimization efforts.
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.
In this episode of Inside IALR, host Caleb Ayers is joined by Ereina Avery (Austal USA), Jon Harrison (Phillips Corporation), and Jason Wells (IALR) for a deep dive into the Additive Manufacturing Center of Excellence (AM CoE). Together, they explore how this unique public-private consortium is transforming the Navy’s supply chain by developing and deploying 3D-printed parts for ships and submarines. From powder bed fusion to wire arc deposition, the team breaks down the technologies, the challenges of scaling additive manufacturing and the mission-driven collaboration that makes it all possible.
Hear how the AM CoE has delivered critical parts in record time, created transferable technical data packages, and built a model for innovation that supports both the warfighter and the future of manufacturing.
The Institute for Advanced Learning and Research (IALR) celebrated the completion of the 19th cohort of the Accelerated Training in Defense Manufacturing (ATDM) program on Oct. 7, 2025. The ceremony honored 20 adult learners who completed intensive training in Non-Destructive Testing (NDT), a critical skill set for ensuring the integrity and safety of components within the defense manufacturing sector.
Each completer finished more than 600 hours of hands-on instruction, earning industry-recognized credentials that prepare them for immediate employment within the Maritime Industrial Base (MIB). The NDT track equips students with specialized techniques to evaluate materials and structures without causing damage.
Student speaker Emery Harris reflected on the transformative nature of the program:
“I wanted a career that challenged me in new ways and gave me skills that really mattered. And that’s what brought me to ATDM,” Harris said. “ATDM has been more than just a training program. It’s been a launchpad. It’s given me the tools, the confidence and the direction that I was looking for.”
Jason Wells, Executive Vice President of Manufacturing Advancement, commended the graduates for their commitment and emphasized the broader impact of their achievement:
“This program is unlike anything else in the country. What these graduates have accomplished is extraordinary—not just in skill, but in resilience. Today, we don’t just recognize them as graduates; we honor them as skilled tradespeople whose work will quietly but powerfully shape the safety, strength and future of our nation. ATDM is more than training—it’s about restoring hope, building possibility and renewing the American dream.” — Jason Wells, Executive Vice President of Manufacturing Advancement
Graduates of the Non-Destructive Testing – 1st Shift
Participants in the ATDM program benefit from comprehensive scholarships covering tuition and housing. This support enables individuals from diverse backgrounds—including transitioning service members, career changers and industry newcomers—to thrive.
With a goal of training over 800 students annually, ATDM remains a cornerstone initiative in strengthening the U.S. defense manufacturing workforce.
The Accelerated Training in Defense Manufacturing program provides focused, industry-driven training to equip participants with skills critical for defense manufacturing. This initiative is funded through the National Imperative for Industrial Skills by the Industrial Base Analysis and Sustainment Program Office within the Office of the Undersecretary of Defense for Acquisition and Sustainment.
The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg along with the cities of Martinsville and Danville. The organization houses and leads the ATDM program with the support of various partners.
The Institute for Advanced Learning and Research (IALR) today announced it has received a grant of software from Siemens Digital Industries Software.
The software, part of the Siemens Xcelerator portfolio, gives more than 1,000 students access to the same technology that companies around the world depend on to develop innovative products in a wide variety of industries, including automotive, aerospace, machinery, shipbuilding, high-tech electronics and many more. This software will be implemented in two primary programs:
“IALR is excited to have access to industry-leading software in our classrooms,” said Jason Wells, Executive Vice President of Manufacturing Advancement at IALR. “As the industry evolves, our graduates’ STEM skills must also evolve. This technology from Siemens Digital Industries Software will help ensure our students have the relevant digital skills necessary to succeed in Industry.”
Siemens Digital Industries Software is a leading global provider of engineering, manufacturing and electronics software.
The software provided by the Siemens Digital Industries Software academic program delivers technology for different skill levels. Graduates with training, experience and working knowledge of this type of software are highly recruited candidates for advanced technology jobs.
The software for IALR includes the following tools from Siemens Xcelerator:
“Bridging the gap between industry, academia and government is essential to building a sustainable talent pipeline equipped with the advanced skills required for the future of manufacturing,” said Melanie Spare, Director, Academic and Workforce Development. “This partnership exemplifies that mission—by aligning classroom training with the exact tools and technologies used by leading defense manufacturers, we’re not only accelerating workforce readiness, but also reinforcing critical Department of Defense initiatives. Through programs like ATDM and facilities like AM CoE, we’re creating a direct and seamless pathway from learning to doing, ensuring students are job-ready from day one.”
Many of IALR’s Manufacturing Advancement initiatives focus heavily on Department of Defense (DOD) requirements, and this software partnership significantly enhances that alignment. Students in the ATDM program will now train and operate using the same software as leading DOD suppliers, creating valuable continuity between classroom training and real-world defense manufacturing environments. Additionally, several of these Siemens products are already used within IALR’s Center for Manufacturing Advancement (CMA) and the U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE) due to their compliance with International Traffic in Arms Regulations (ITAR). This further strengthens the synergy between the AM CoE and ATDM, benefiting students by better preparing them for successful careers in defense manufacturing.
About IALR
The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg along with the cities of Martinsville and Danville.
Note: A list of relevant Siemens trademarks can be found here.
The Institute for Advanced Learning and Research (IALR) and Danville Community College (DCC) are pleased to announce the graduation of the 10th cohort of the Integrated Machining Technology (IMT) program. Over several months, these 14 students refined advanced machining skills while embracing vital leadership and problem-solving practices, preparing them for high-demand roles in today’s modern manufacturing sector.
The IMT program is a collaborative effort between DCC and IALR, offering a capstone-style experience that pushes students beyond typical classroom training. They spend time in a simulated “flow cell,” juggling everything from ordering raw materials and scheduling machine operations to conducting inspections on finished products. By taking full responsibility for every stage of production, they gain a strong command of multi-axis CNC programming, Lean/Six Sigma principles and effective teamwork and leadership strategies.
“We see each cohort of IMT students taking real responsibility for the entire manufacturing process, from idea to final inspection. That level of ownership produces confident, capable graduates who are ready to make a difference in advanced manufacturing. IMT graduates train on the latest equipment with industry-informed curriculum, generating the ideal pipeline for career-ready talent.” – Jason Wells, Executive Vice President of Manufacturing Advancement at IALR
“The success of our Integrated Machining Technology graduates reflects the power of hands-on education, industry partnership, and student determination,” said Dr. Cornelius Johnson, Interim President of Danville Community College. “These graduates are stepping into high-demand careers with the skills and confidence to make an immediate impact. We are proud to celebrate their achievements and the role they will play in strengthening our regional workforce.
Throughout the program, students also sharpen soft skills like teamwork, conflict resolution and leadership—competencies that set them apart as they enter their careers.
Graduates of IMT often move on to rewarding positions across industries such as aerospace, automotive and defense. Many choose to stay in Southern Virginia, where their expertise bolsters local companies and helps drive economic development. Over its 10-year history, the IMT program has produced a total of 160 graduates with the skills to positively impact the workforce of regional manufacturing companies.
“This program prepares us for those advancements in technology and manufacturing,” said Parker Turpin, who will be working in a local machine shop. “The program raises the bar higher and higher to prepare students for the actual workforce.”
“It’s definitely been beneficial learning the different manufacturing techniques,” said Jackson Wiles, who is interviewing with multiple companies. “We learned more about the coordinate measuring machines, and I became familiar with three plus two machining, five-axis machining and advanced tool paths.”
MEP—an aerospace firm in IALR’s rapid‑launch space—hired a 2024 IMT graduate full‑time, then took on a 2025 cohort member part‑time during the program; that student now joins MEP full‑time after graduation.
“The complexity of the work we do at MEP can be demanding, even for experienced CNC machinists, but our IMT students hit the ground running,” said Forrest Ashworth, Operations Manager with MEP. “Their problem-solving abilities, positive attitude, and willingness to go the extra mile have made them strong assets to our team. IMT graduates bring a high level of skill, dedication and professionalism that aligns perfectly with our mission at MEP.”
Founded a decade ago to meet an urgent regional need for higher‑level machining talent, IMT was shaped by local industry and education leaders who saw advanced skills as the key to economic growth. IMT is one of several training programs supported and administered by IALR’s Manufacturing Advancement division.
“We were looking at what would give us a competitive advantage as a region. A group of thought leaders saw that a skilled workforce would be that competitive advantage,” said Troy Simpson, who helped launch the program and later led IALR’s Manufacturing Advancement division.
The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses on Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg and the cities of Martinsville and Danville.
Danville Community College is a two-year institution of higher education under the statewide Virginia Community College System. DCC’s service area includes the City of Danville, Pittsylvania County and Halifax County. For more information about the College’s programs of study, visit www.danville.edu.
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
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
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.
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
Effective learning blends theoretical instruction with real-world application. At the Institute for Advanced Learning and Research (IALR), hands-on training is a core principle across diverse programs.
“Theory is important, and it has value. However, my years working in and with educators has taught me that most learners are visual kinesthetic learners, and the most impactful learning tends to be hands-on learning.” – Telly Tucker, IALR President
This approach equips participants with practical skills and boosts their confidence in real job environments. Whether middle school students or seasoned adults, participants walk away with experiences they can immediately apply.
The Great Opportunities in Technology and Engineering Careers (GO TEC®) program exposes middle school students to the emerging technologies shaping tomorrow’s industries. Students learn about and, more importantly, get to practice with virtual reality welding tools, desktop CNC mills, different types of robots and much more, offering a direct glimpse into in-demand careers.
“Middle school is the perfect time to spark a lasting interest in STEM. Getting to touch and try these business-relevant technologies shows that advanced concepts and careers are within reach.” – Julie Brown, Ph.D., Vice President of Advanced Learning
Dual-enrollment students in the Academy for Engineering and Technology (AET)—a collaboration with Danville Community College and the local school divisions—learn concepts in the classroom and apply them immediately. This balance of theory and application strengthens their problem-solving abilities and prepares them for modern challenges.
“We’ve seen impressive results when students can test what they learn right away,” Dr. Brown says. “That combination pushes them to think critically and perform with confidence.”
IALR also houses students in the Piedmont Governor’s School for Mathematics, Science, and Technology. Every year, seniors in this program participate in a senior research project, some seeking support from IALR’s Applied Research division.
Accelerated Training in Defense Manufacturing (ATDM) equips adult learners with the skills needed to work with Navy suppliers in the Maritime Industrial Base. In just four months, participants build foundational knowledge and participate in hundreds of hours of hands-on practice with actual machinery.
“ATDM bridges the gap between classroom insights and real-world shop floors. Graduates leave ready to excel in high-demand defense manufacturing roles.” – Jason Wells, Executive Vice President of Manufacturing Advancement
In the Integrated Machining Technology (IMT) program, developed with Danville Community College, students face the pressure of meeting manufacturing quotas and deadlines. This setup mirrors the intensity of a true manufacturing environment.
“It’s a simulated manufacturing flow cell,” Wells said. “We put these students in a position to practice how all the pieces they’ve learned come together.”
IALR also hosts shorter programs on topics like Fanuc robotics, precision machining for instructors and industrial fermentation. These workshops blend conceptual lessons with live experimentation in a condensed timeframe.
“Our recent industrial fermentation workshop revealed how hands-on demos deepen understanding. When participants participate in the process, they gain a better understanding.” – Scott Lowman, Ph.D., Vice President of Applied Research, IALR
The journey does not end with a certificate or first job. Through various computer training workshops and the Wonder Community of Lifelong Learning, people can refresh their skills or discover new interests at any stage.
IALR’s commitment to lifelong learning and service learning opens pathways for professionals and hobbyists alike.
From virtual reality welding in GO TEC® to advanced precision machining in IMT, practical immersion helps learners of all ages gain a deeper understanding. Hands-on learning is particularly beneficial in the STEM fields, as shown by many different studies, including from Purdue University and the Proceedings of the National Academy of Sciences of the United States of America. With IALR’s goal of expanding STEM Capacity, this focus on hands-on, practical learning is what drives success.
“Practical experiences let learners see immediate results,” Tucker says. “When students engage directly, they become more prepared for today’s job market.”
The February 2025 edition of IALR at a Glance features a sleek new look that is packed with exciting news and updates! Learn more about…
Nobody likes delays.
The stakes are even higher when a mission depends on getting the right parts at the right time. For the U.S. Navy, a delayed part can stall a mission and force a vessel to remain tied to the pier instead of patrolling the seas.
This is where the U.S. Navy Additive Manufacturing Center of Excellence (AM CoE) steps in. Housed within the Center for Manufacturing Advancement (CMA) on the Institute for Advanced Learning and Research (IALR) campus, this collaborative project reduces delays and increases part availability and production capabilities. Involving eight partners, including Austal USA and IALR, the AM CoE helps develop digital technical data packages, or “manufacturing recipes,” that activate suppliers in the Maritime Industrial Base (MIB).
This shift enables quicker turnaround times and provides the U.S. Navy with options that did not exist a few years ago. Rather than waiting on months-long casting or forging lead times, which are susceptible to a high level of quality-related issues, the Navy can distribute these recipes to qualified suppliers, speeding up production and ensuring higher quality and accuracy on each part produced.
“The AM CoE is the nexus of additive integration.” – Aaron Wiest, Additive Manufacturing Program Manager, MIB Program
As part of the MIB Program, the AM CoE project supports the Navy’s ambitious goal of producing one Columbia-class and two Virginia-class submarines annually. Achieving this build rate while simultaneously maintaining the existing fleet and supporting the recent AUKUS agreement is challenging because it requires a dependable supply of thousands of parts, both for the suppliers and at the shipyards themselves.
Many of those parts are traditionally produced using castings and forgings, which result in significant constraints on where and how many can be made.
By shifting to digital “recipes” for additive manufacturing, the AM CoE provides a more flexible path that reduces cost, time and reliance on limited foundries. These technical data packages guide approved suppliers, ensuring consistency across the supply chain. Instead of waiting on a single foundry, multiple vendors can print identical parts from the same digital file.
“When you move to a digital paradigm, you have a digital casting mold or an additive data file that allows you to use a 3D printer and manufacture the shape that you need, which will then later go through value-added processing. The CoE gets to be the repository of those files for any of the companies that wish to join in that collaborative network and support the U.S. Navy.” – Aaron Wiest, Additive Manufacturing Program Manager, MIB Program
IALR’s Center for Manufacturing Advancement supports the AM CoE’s work by providing a high-performance environment for this manufacturing optimization. Its ISO-certified CNC Machining Innovation Lab refines subtractive processes for additively produced parts, and the Precision Metrology Lab’s advanced inspection capabilities ensure quality. Both labs also serve other clients seeking process improvements. Emerging technology is tested, proven and implemented within this ecosystem for immediate impact.
The Additive Manufacturing Center of Excellence includes many partners, several of which have staff stationed on the IALR Campus full-time.
Though the AM CoE focuses on developing processes, it has swiftly produced parts to meet urgent demands. Three recent examples exemplify its ability to deliver results:
Employees of the Phillips Corporation work on a large 3D printer inside the U.S. Navy’s Additive Manufacturing Center of Excellence on the IALR campus.
A small bracket helps a destroyer’s hangar door sensor function properly. It functions like a garage door sensor–ensuring nothing is under the door before it closes.
Due to limited supply chains, a malfunctioning helo hangar door bracket on a U.S. Destroyer threatened to delay its mission for months.
Over the 2023 holiday season, the AM CoE printed, machined, inspected and delivered the bracket in under three weeks. A few months later, another request came for the same part, and the turnaround dropped to just 13 days.
“Two different destroyers went out and were able to maintain their mission because of the CoE.” – Jesse Geisbert, Advanced Manufacturing Director, MIB Program
The bracket is now a procurable item, meaning future suppliers can produce it on demand.
The interior liner for a submarine’s trash disposal is certainly not glamorous and may seem insignificant, but it is integral to submarine operations. During underwater missions, submarines compact waste and securely store it in sealed metal containers, which are then safely released into the ocean.
Six of these large trash disposal liners units were delivered to a shipbuilder producing a submarine in 2024, and all six were defective and could not be used.
“It’s a very hard to cast alloy, somewhat complex part, and they didn’t have a path forward, which meant stalled submarine construction for one piece,” Wiest said.
In just nine days, the AM CoE modeled and printed a first article of manufacture. In contrast, a cast part would have taken months to deliver. This solution is expected to restore momentum and prevent submarine construction from grinding to a halt.
Aging ships and submarines like the USS Michigan also rely on critical parts, many of which are no longer produced by traditional methods. The Michigan is a 42-year-old submarine, and its trim and drain valves, especially the tailpiece, regularly corrode due to operational conditions.
The AM CoE printed the tailpiece using both laser powder bed fusion and wire arc methods, creating multiple additive manufacturing data files. This dual approach provides flexibility, ensures future availability and supports other classes of submarines that use similar components. Instead of uncertain wait times for casting or forging, the Navy now has proven digital recipes to quickly produce these vital parts when the next repair cycle comes around.
“In one place now, we’ve created two different AM data files that can be distributed,” Geisbert said. “The Ohio class will be around still for quite a considerable amount of time, and now we have a better way to produce these trim and drain valves when they need to be replaced.”
How to best print the part is only one part of the digital recipes provided by the AM CoE. The AM CoE also provides instructions on post-printing machining, metrology and measurement techniques and heat treatment.
“The CoE project has end-to-end capabilities. The team provides data on how to take an additive part through all the various steps, like machining and heat treatment, to make it a finalized, finished component. We learn things at each one of those stages that we can implement into a more well-rounded and complete end-to-end strategy.” – Jason Wells, Executive Vice President, Manufacturing Advancement, IALR
In addition to what’s happening in the AM CoE, skilled workers are trained at the adjacent Accelerated Training in Defense Manufacturing (ATDM) program. This program prepares workers for the Maritime Industrial Base, ensuring a talent pipeline ready to operate cutting-edge equipment. A spinoff of ATDM that is also located on the IALR campus, the Naval Aviation School for Additive Manufacturing (NASAM) program trains active-duty Navy personnel to use additive manufacturing equipment and techniques on ships and submarines.
“The AM CoE is a one-stop shop for industry to come learn about additive, get qualified, understand the Navy requirements.” – Jesse Geisbert, Advanced Manufacturing Director, MIB Program
The AM CoE is a unique public-private partnership where industry, academia and government work together toward a common goal. This collaborative approach maximizes resources, knowledge sharing and innovation. Instead of operating in separate silos, partners pool their expertise and align their efforts, ultimately strengthening the entire industrial base.
“We have an era of unprecedented collaboration,” Wiest said. “It is amazing to see companies willing to jump in, willing to share some of their IP actually to help the industrial base grow.”
This kind of cooperation ensures that if one supplier faces delays, another can step in, preventing bottlenecks. Over time, the public-private partnership model builds resilience, scalability and trust across the network of suppliers and shipbuilders supporting the U.S. Navy.
“The AM CoE is that connective tissue for the OEMs and the shipbuilders and the industrial base at large.” – Jesse Geisbert, Advanced Manufacturing Director, MIB Program
The three success stories highlight how critical this work has become. A hangar door bracket was delivered in under three weeks, a trash disposal unit liner was produced in days rather than months, and a valve component for an aging submarine was quickly developed.
However, the goal of producing these digital recipes is to have even more success stories where approved suppliers utilize an existing recipe to produce needed parts on demand.
Each success means more time at sea, more deterrent strength and more efficient use of national resources. The Navy’s ambitious goals, the expansion of additive manufacturing and the AM CoE’s model all point to a future with fewer delays and heightened readiness.
“The AM CoE is a model,” Geisbert said. “Nothing is stopping us from creating something like the CoE, operated by public-private partnerships and intended for production outside every shipyard.”
The CMA’s mission to help manufacturers integrate technology and optimize processes extends beyond the Navy. It reflects a broader push for more innovative, faster and resilient manufacturing across various industries.
The December 2024 edition of IALR at a Glance is jam-packed with exciting news and updates! Learn more about…
The U.S. Navy’s Additive Manufacturing Center of Excellence (AM CoE), a linchpin in maritime technological advancement, is located inside the Center for Manufacturing Advancement on the IALR campus. This episode highlights the AM CoE as a collaborative hub of strategic importance in meeting the U.S. Navy’s ambitious submarine production goals. This project is driving manufacturing innovation forward.
IALR Executive Vice President of Manufacturing Advancement Jason Wells is joined by Advanced Manufacturing Director Jesse Geisbert and Additive Manufacturing Program Manager Aaron Wiest, both from the Maritime Industrial Base (MIB). They discuss the impact of the Navy’s AM CoE and the success stories where the project has prototyped and delivered mission-critical parts for ships and submarines much quicker than traditional methods, such as castings and forgings, and supply chains could have. This informative discussion includes:
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.
The August 2024 edition of IALR at a Glance is jam-packed with exciting news and updates! Learn more about…
