Artificial Intelligence and Machine Learning (AI/ML) for Additive Manufacturing (AM)

The DON26BZ01-NV030 solicitation seeks proposals for Artificial Intelligence and Machine Learning (AI/ML) to automate additive manufacturing (AM) processes. The objective is to leverage AI/ML, digital twins, and process simulation to select optimal materials and manufacturing parameters for mission-critical components, improving performance and reducing lead times. The prototype tool(s) should be able to take material type, part geometry, and AM system details to automatically generate optimized build parameters and predict mechanical performance. The focus is on integrating the entire material lifecycle from pre-build to performance in a single package, particularly for legacy parts requiring rapid production. The tool(s) must be agnostic to both the part and the AM build system for scalability. Phase I requires concept development, modeling, simulation, and physical testing on a single component, along with a plan for Phase II expansion. Phase II involves full prototype development and validation using additional components of different material classes and AM systems, demonstrating reduced fabrication time, defect rates, and material waste. Phase III focuses on delivering the final prototype tools to U.S. Navy facilities and subsequent demonstrations to other government and industry partners, aiming for broad adoption of the efficient digital tools.