Solid Freeform Fabrication Program

Date: Fri Jul 25 1997 - 16:09:04 EEST

-- [ From: Al Hastbacka * EMC.Ver #2.5.3 ] --

Program for SOLID FREEFORM FABRICATION. In order to meet the
Government's objectives, I am soliciting potential team members for the
SFF Program. A description of what DARPA is looking for is enclosed
with this message. Companies or universities with a potential interest
in participating in this program with SDI as the team leader or team
member should respond directly to me. (Note-Proposal is due on October
17, 1997)

Al Hastbacka
603-654-6100 X302
603-654-2586 FAX

SOLID FREEFORM FABRICATION (SFF) The Defense Advanced Research Projects
Agency (DARPA) is soliciting proposals which demonstrate reduced time
and cost for validation of advanced design concepts through combining
Solid Freeform Fabrication (SFF) and design technologies. Successful
efforts will incorporate advances in both computational and hardware
related technologies for the innovative design of high performance
components, enabling the analysis of components, the selection and
specification of advanced materials, and the design and control of
fabrication processes. The technologies are to be demonstrated through
the design, fabrication, test and evaluation of defense relevant
components. The current SFF Program has been developing machine
capabilities to convert virtual objects (i.e., CAD files) directly to
components with form, fit and function. Ceramics for high temperature
structural applications have been the primary focus. The new work is
expected to expand on these technologies through efforts such as: the
extension of machine capabilities to new materials and combinations of
materials; the improvement of dimensional tolerances and surface finish;
the extension of machine capabilities to nonplanar build layers; the
development of machine capability for positional control of composition
or crystal tenure; the development of novel methods to facilitate the
sharing and exchange of key material and SFF process information and
knowledge supporting design optimization software; and the extension of
software tools to utilize product performance information in planning
and defining the SFF process. It is expected that the resulting
demonstration components will have functionality that would not be
achievable through the use of conventional fabrication methods and
design methodologies due to cost, time to field, and/or the ability to
fabricate. The technologies should address the limitations of existing
approaches (e.g., support the substitution of components) and
demonstrate the approach taken to overcome these limitations. Component
demonstrations are expected to utilize the developed machine
capabilities to optimize both design and materials. Demonstrations of
novel concepts in support of advanced gas turbine or rocket engine
technology are of particular interest, although other novel applications
are encouraged. In most cases, teams with expertise in system
integration and design optimization; machine design and process control;
and materials science and engineering will be required to execute such
programs. The total program is planned to be 24 months in duration with
$8 M of funding. Multiple awards are expected.

In order to ensure that all technically relevant aspects of this program
will be addressed, teaming of industry, national laboratories, and/or
academic institutions with complementary areas of expertise is
encouraged. PROPOSALS: Evaluation of proposals will be accomplished
using a technical review process whereby each proposal will be scored
using the following criteria, which are listed in descending order of
relative importance: (1) demonstrated technical and scientific merit of
the proposed program, (2) impact of the successful development on the
potential performance of DoD systems, (3) offeror's capabilities and
recent related experience, including personnel, facilities, equipment,
and data to perform the work, and (4) realism of cost.

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