NGen's 2021-22 Additive manufacturing demonstration program

NGen completed its first year managing the Additive Manufacturing (AM) Demonstration program under an NRC IRAP funded program. Launched in June 2021, NGen engaged with more than 100 companies, primarily SMEs, from across Canada and completed 54 AM projects.

The AM demo program is designed to help Canadian companies learn about the transformative potential of AM, and de-risk early trials of this exciting technology. The goal of this program is to create awareness and encourage the adoption of AM technology, and to reinforce Canada’s AM supply chain, thus improving Canada’s manufacturing and exporting sectors and our global competitiveness.
Additive manufacturing expertise and know-how is not widely available in Canada. The limited knowledge and experience base has slowed the adoption of this essential technology by many companies that could potentially benefit from AM deployment, particularly in the aerospace, medical and automotive sectors. In addition, some companies have AM capabilities but lack the accreditation to do the work, while other companies have the accreditation but little to no AM expertise.

How the program works:

• NGen identifies eligible SMEs and OEMs interested in participating from within its network of over 4,700 members as well as from referrals from IRAP ITAs.
• NGen’s program manager has an introductory meeting with the participating company to discuss the project’s objectives and feasibility with respect to the use of AM.
• If the project is approved as a good candidate for AM, NGen determines whether to allocate funding for testing of small parts and/or coupons to assess microstructure, material, hardness, mechanical strength and AM’s suitability as part of the company’s supply chain.
• The most suitable technology and service providers are identified based on their ability to meet additive manufacturing objectives.
• NGen further supports approved projects by providing feedback and coordination between companies and contracted service providers to ensure project success.

The objective of the program is to introduce companies to the concept of using 3D printing for more than just prototyping and educating them on how it can be used in production as part of their supply chain. The program helped provide companies with project funding support to have parts manufactured. The idea is to develop a better understanding of the advantages and business opportunities resulting from the adoption of additive manufacturing technology and processes including cost savings, reduced new product development cycle times, improved design and efficiencies, and identify potential new suppliers to reinforce supply chains.
Creating a collaborative, hands-on learning experience for OEMs, suppliers, and process providers directly addresses the process knowledge gap and enables OEMs to recognize and implement new design concepts and product lines, ultimately driving the market for additive manufacturing. All engagements, even ones that did not 3D print, provided valuable lessons about this advanced technology. Sometimes the best knowledge is knowing that AM might not be the solution you need at this time.

NGen’s AM Demonstration program aims to increase the confidence and awareness of manufacturing companies in applying metal AM new materials for specific tooling and applications. It thereby helps to reinforce and diversify Canada’s additive manufacturing supply chain.

To carry out the program, NGen built a network of more than 20 leading Canadian service providers from all regions of the country who have advanced AM technologies. These companies and organizations provided participating firms with a finished part or coupon as well as guidance and advice with respect to the advantages offered by AM. Project costs ranged from a low of $880 to $10,000. With NRC-IRAP’s financial support, and in-kind support from the service providers, NGen was able to offer this service free of charge to Canadian SMEs.

The initial contribution agreement (CA) with IRAP was for $100,000 and 13 projects. Because of the program’s popularity and full engagement, we secured four amendments to the CA for a total contribution of $350,000. Our objective was to support 48 projects, which we surpassed with 54 completed projects.

Service Providers
Across the Board Creation, BC
Burloak, ON
MAYA TTC, QC
Additive Metal Manufacturing, ON
Canadore College (Icamp), ON
Nanogrande, QC
Anubis 3D, ON
Equispheres, ON
P3D, QC
AON 3D, QC
Exergy, AB
Precision ADM, MB
Axis Prototype, QC
Forgelabs, BC
Produtique Quebec, QC
Bayview Yards/Invest Ottawa, ON
Lincoln Laser Solutions, ON
Red Deer Polytechnic (RDP), AB
Metafold, ON Trosnosjet, PEI

Project Profiles
The technologies used for the projects varied from Powder Bed Fusion (PBF) to Binder Jetting, Directed Energy Deposition (DED), Material Extrusion and Material Characterization. An excellent example is the AEM Power Systems inc. and Additive Metal Manufacturing (AMM) collaboration for a redesigned and fabricated Oscillating Unit. IRAP ITA Rob Whent referred AEM to NGen who then met with AEM to assess their level of insight into AM and their project idea. NGen advised them to meet with AMM, who proceeded to undertake the following steps re-designing for additive manufacturing:

A - The initial STEP file provided by AEM contained critical internal features that had been design optimized and could not be changed.

B & C - AMM was able to offer design alternatives through several different iterations.

D - AMM took the approach that it would only print what was necessary to achieve the intended result and focus the design around the

critical features This allowed for the unit to be substantially decreased in size/mass whilst maintaining the integrity of the channel design

This project was so transformational to AEM that they went on to develop a far more in-depth NGen-funded pilot project with AMM. Eugene Ryzer of AEM Power Systems offered this endorsement, “NGen has been instrumental in its role at supporting and connecting AEM Power Systems with key additive manufacturing companies leading to significant improvement in development of its core technology”.
The ease with which companies access this program, a simple referral from their Industrial Technology Advisor (ITA) starts the project, makes the AM demo program a valuable steppingstone and stimulant to AM adoption in Canada.

NGen is pleased that IRAP extended the program into the new fiscal year so that NGen can continue engaging with companies for new projects. With a full year delivering the program, it is hoped that with additional support NGen can surpass the 54 projects completed since the June launch.

If you have any questions, contact frank.defalco@ngen.ca

If you are interested in participating go here to apply.