White Papers on Advanced Manufacturing Questions pptx

 DRAFTWorkingPapersVersion040510



WhitePapersonAdvancedManufacturingQuestions

PreparedfortheAdvancedManufacturingWorkshopofthe
President’sCouncilofAdvisorsonScienceandTechnology’s
StudyonCreatingNewIndustriesthroughScience,Technology,andInnovation

DRAFT

April5,2010



Disclaimer:Thisdocumentisadraftanalysisofthescientific,technical,
andpolicyissuesregardingadvancedmanufacturing.Itwaspreparedby
theScienceandTechnologyInstitute(STPI)forusebythePresident’s
CouncilofAdvisorsonScienceandTechnology(PCAST).STPIisa
federallyfundedresearchanddevelopmentcenter(FFRDC)forthe
OfficeofScienceandTechnologyPolicy(OSTP).Theanalysiswas
conductedbySTPIanddoesnotrepresenttheviewsofPCASTorOSTP.






ScienceandTechnologyPolicyInstitute
1899PennsylvaniaAvenueNW,Suite520

Washington,DC20006

 DRAFTWorkingPapersVersion040510
 DRAFTWorkingPapersVersion040510


 DRAFTWorkingPapersVersion040510 i
 DRAFTWorkingPapersVersion040510
Foreword1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23

24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

Overview
ThissetofwhitepaperswaspreparedattherequestoftheOfficeofScienceandTechnologyPolicy(OSTP)asinput
fortheAdvancedManufacturingWorkshopofthePresident’sCouncilofAdvisorsonScienceandTechnology
(PCAST)StudyonCreatingNewIndustriesthroughScience,Technology,andInnovation.Thepapersaremeantto
presentissues,stimulatethought,andframediscussion.ThequestionstheyaddresswereprovidedbythePCAST
studyco‐chairsastheagendafortheworkshop.Inpreparingthesepapers,STPIstaffreviewedthecurrent
literatureandhelddiscussionswiththefollowingexpertsinindustryandacademia:
• YungC.Shin,DonaldA.andNancyG.RoachProfessorofAdvancedManufacturing,PurdueUniversity9
• SanjaySarma,AssociateProfessorofMechanicalEngineering,FormerChairmanofResearch&Co‐FounderoftheAuto‐
IDCenteratMIT,MassachusettsInstituteofTechnology
• AlbertLink,Ph.D.ProfessorofEconomics.ScienceandTechnologyPolicy,UNCGreensboro


• DavidAudretsch,DistinguishedProfessorandtheAmeritechChairofEconomicDevelopmentandDirectorofthe
InstituteforDevelopmentStrategiesatIndianaUniversity,IndianaUniversity
• PaulFowler,ResearchDirector&NACFAMWeeklyEditor,NationalCouncilforAdvancedManufacturing

• ChuckWilliams,SeniorVicePresidentofSupplyChainandManufacturinginNorthAmerica,andLukasRuecker,Senior
VicePresidentofStrategyinNorthAmerica,LuxotticaGroup
• LordBhattacharya,ProfessorofManufacturingSystems,UniversityofWarwick

• RichardLester,FoundingDirectoroftheIndustrialPerformanceCenterandProfessorandHeadoftheDepartmentof
NuclearScienceandEngineeringattheMassachusettsInstituteofTechnology,MassachusettsInstituteofTechnology
• WarrenSeering,ProfessorofMechanicalEngineeringandProfessorofEngineeringSystems,MassachusettsInstituteof

Technology
• IrenePetrick,ProfessorofPractice,PennsylvaniaStateUniversity

• MartinCulpepper,AssociateProfessorofMechanicalEngineering,MassachusettsInstituteofTechnology
• LewisBranscomb,ProfessoremeritusofPublicPolicyandCorporateManagement,HarvardUniversity
• BruceBrown,ChiefTechnologyOfficer;R.KeithHarrison,GlobalProductSupplyOfficer;andPaulFox,Corporate
ExternalRelations,Proctor&Gamble
Toprovideaninitialfocusingofoureffortstoaddressthesequestions,STPIfirstlookedintothedefinitionof
“advancedmanufacturing,”asisdiscussedbelow.
WhatIsAdvancedManufacturing?
Severalperspectivesonwhatconstitutesadvancedmanufacturinghavebeenofferedbyleadingexperts,
businesses,andgovernmentorganizations.Thefollowingparagraphslayoutthesevariousperspectivesas
understoodfromdiscussionswithleadingexperts(listedabove)andreviewofliteraturefromtrade,business,and
governmentorganizations.Whileadvancedmanufacturingisvieweddifferentlybydifferentpeople,itprobably
shouldincorporateaspectsofallthefollowingperspectiveswhenconsideringthepublicpolicyquestionsposedby
PCAST.
UseofNewMethodstoProduceNewerorBetterProducts

Someexpertsdefineadvancedmanufacturingasanewwayoftheaccomplishingthe“howto”ofproduction,
wheretheemphasisiscustomizationandscalability,whileadvancingthetechnologiesnecessarytoimprove
capabilities.PaulFowleroftheNationalCouncilforAdvancedManufacturing(NACFAM)definesadvanced
manufacturingasanentitythat:
1


1
DiscussionwithPaulFowlerfromtheNationalCouncilforAdvancedManufacturing.
 DRAFTWorkingPapersVersion040510 ii
 DRAFTWorkingPapersVersion040510
Makes extensive use of computer, high precision, and information technologies integrated with a high
performance work force in a production system capable of furnishing a heterogeneous mix of products in
smallorlargevolumeswithboththeefficiencyofmassproductionandtheflexibilityofcustommanufacturing
inordertorespondrapidlytocustomerdemands.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

AsimilardefinitionwasreportedinaU.S.DepartmentofLabor(DOL)EmploymentTrainingAdministration(ETA)
report,whichdefines“advancedmanufacturing”as“implementingprocessimprovements,increasingquality
controls,andinstallingadvancedroboticsandotherintelligentproductionsystems.”
2
Alongthesamelines,the
CouncilonCompetitivenessemphasizedinitsarticle“U.S.Manufacturing—GlobalLeadershipThroughModeling
andSimulation”thatadvancedmanufacturingmustentailhigh‐performancecomputing(HPC)formodeling,

simulation,andanalysis.
3

ManufacturinginNew(asDistinctfromTraditional)Industries
Otherssuggestadefinitionthatremainsbroadinspectrumbynotfocusingontheuseofparticulartechnologies,
butonmanufacturinginnewandemergingindustries.AreportbytheNewEnglandCouncilandDeloitte
Consulting
4
offersadefinitionthatprovidesadistinctionbetweenthosesectorsthatareseenastraditional
manufacturing(e.g.,automotiveandsteelindustry)andothersectors(e.g.,aerospace,medicaldevices,
pharmaceuticals)inthreeways:(1)volumeandscaleeconomics,(2)laborandskillcontent,and(3)thedepthand
diversityofthenetworksurroundingtheindustry.Largevolumeproductmanufacturers(bothprocessand
fabricationindustries)thatcompetetraditionallybyleveragingscaleandlowcoststructures—andofteninclude
veryadvancedmanufacturingtechnologies—wouldnotbeincludedinthisdefinitionasadvancedmanufacturers.
TheFrontierofAdvancedManufacturing
Someexpertsindicatedthatmakingtheabovedistinctionbetweenadvancedmanufacturingandtraditional
manufacturingisshortsighted,astechnologicaladvancesandimprovementsinmanufacturingoccurinmore
matureortraditionalindustriesaswellasinemergingones.Theyalsochallengedthenotionoffocusingadvanced
manufacturingsolelyonaparticularsetoftechnologies.Intheirview,advancedmanufacturingwasdefinedsolely
byadvancesthatledtodecreasedcostorincreasedproductivity.Thisdefinitionappliestobothexistingproducts
andnewproductsbeingintroducedintothemarketplaceinallindustries.
Mostdiscussantsagreethatanappropriateadvancedmanufacturingdefinitionshouldbedynamicinnaturebe
treatedasmoreofabenchmark.Thatis,thereisaconstantiterationofimprovingmanufacturingfrontiers,which
oftenarecomprisedofpre‐commoditizedprocessesandproducts.Therefore,whatisclassifiedas“frontier”is
constantlychanging,and,likewise,advancedmanufacturingisalwayschanging.
S&T‐BasedManufacturing
Aconcisedefinitionofferedbysomewasthatadvancedmanufacturingismanufacturingthatentailsrapidtransfer
ofscienceandtechnology(S&T)intomanufacturingprocessesandproducts.Intoday’sglobalizedandinformation‐
richenvironment,competitorscanquicklyandeasilycopynewproducts.Duetothespeedofinformation
exchange,theclassificationofcuttingedgetechnologyisdynamicandoftenseenasamovingtarget.Tosustain

operatingonthecuttingedgeofinnovation,itiscrucialtoreducethetimefromresearchanddevelopment(R&D)
toproduction.Thisdefinitioniscorroboratedbya2002reportbytheNationalDefenseUniversitythatdefines

2
SeeAdvancedManufacturingIndustry,U.S.DepartmentofLabor,EmploymentandTrainingAdministration,nodate(circa
2004),availableat />3
See“U.S.Manufacturing—GlobalLeadershipThroughModelingandSimulation,”WhitePaper,CouncilonCompetitiveness,4
March2009,availableat
/>4
See“ReexaminingAdvancedManufacturinginaNetworkedWorld:ProspectsforaResurgenceinNewEngland,NewEngland 
Council,December2009,availableat
/> DRAFTWorkingPapersVersion040510 iii
 DRAFTWorkingPapersVersion040510
 DRAFTWorkingPapersVersion040510 iv
1
2

advancedmanufacturingastheinsertionofnewtechnology,improvedprocesses,andmanagementmethodsto
improvethemanufacturingofproducts.
5


5
AdvancedManufacturingIndustryStudy,NationalDefenseUniversity,2002.
 DRAFTWorkingPapersVersion040510

1
2
3
4

5
6
7
8
9
10
11
12
13
14
15
16
17
TableofContents
Question1.Whatscientificandtechnicaldevelopmentsapplytoawiderangeofadvancedmanufacturing
industries?Whatarethekeyadvancedcutting‐edgetechnologies,relevantacrossmultipleindustriesthat
showthemostpotentialforadvancedmanufacturing? 1‐1
Question2:Whataresomepossiblenewconceptsofadvancedmanufacturingthatmightapplytoawide
rangeofindustries? 2‐1
Question3:WhatistheappropriateroleofGovernmentscienceandtechnologyprogramsandpoliciesin
advancedmanufacturing? 3‐1
Question4:WhatarehistoricalexampleswhereFederalorstatescienceandtechnologyprograms,policies,
oractivitieshaveenhancedadvancedmanufacturing? 4‐1
Question5:WhatFederalGovernmentscienceandtechnologyprogramsorpolicies,ifany,shouldbe
putintoplacetoacceleratethedevelopmentandadoptionofadvancedmanufacturingtechnologiesby
industry?HowmighttheGovernmentencourageincreasedfundingforpre‐competitiveresearch
byindustry? 5‐1
Question6:Whatbroadinfrastructuralimprovementsarecriticalfornewversusexistingenterprises?
Wheredopublic/privatepartnerships(PPP)playacrucialrole? 6‐1
 DRAFTWorkingPapersVersion040510 v

 DRAFTWorkingPapersVersion040510
Question1.Whatscientificandtechnicaldevelopmentsapplytoawiderangeof
advancedmanufacturingindustries?Whatarethekeyadvancedcutting‐edge
technologies,relevantacrossmultipleindustriesthatshowthemostpotential
foradvancedmanufacturing?
1
2
3
4
5
6
7
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Introduction
Thereareclearindicatorsofatransformationintheproductionofgoodsthatwillusherinaneweraof
manufacturing.Thisneweraderivesfrom
• Scientificandtechnologicaldevelopmentsthatarepushingabilitiestomanipulateandconsistently8
produce,especiallyatthemolecularlevel
• Focusedtechnologicaldevelopmentsthatenablesustainablemanufacturing
Thisnewerawilldrawuponandextendtherevolutioninmicroelectronicsandtheinformationtechnologiesthat
employthem.Manufacturerswillimplementincipientabilitiestoconsistentlyperformprecisemanipulationof
materialsatthemolecularlevel,creatingtheemergingprospectofnanoscalemanufacturinginwhichphysics,
chemistry,andbiologyconverge.Inaddition,futuretechnologicaldevelopmentswilldependonabetter
understandingoffundamentalbiologicalprocessesandwillapplytheseprocessestoabroadrangeofproducts
beyondhealth.Thesedevelopmentsareoccurringinahighlyconnectedandglobalizedmarketplacewheretimeto
productandreducedproductioncostsarecrucial.Additionally,thesustainabilityoftheproductionenterpriseis
becominganexplicitrequirementforwhichnewmanufacturingapproachesaswellasimprovedinformation

collection,analysis,anddisseminationcapabilitieswillbeneeded.
ConvergenceattheMolecularLevel
Thetrendtowardincreasinginterrelationshipandconvergenceacrosstraditionalscientificdisciplinesisdrivenby
theneedtoachievenewproductcharacteristics.Thedrivetorealizepropertiesbeyondthoseavailableincurrent
productshaspushedthefrontiersofphysics,chemistry,materialsscience,andbiologyandbegunaconvergence
ofthesedisciplines.Thisconvergenceisnowleadingtoinnovationsatthemolecularscale,atwhichnew
phenomenaemergeandconventionalrulesnolongerapply.
Thereisavastdifferencebetweendemonstratingaconceptinasmallsampleandproducingitinvolumewhilestill
maintainingabsolutecontrolofthemolecularcomposition,morphology,andproperties.Workingatthemolecular
scalerequiresanalyticaltoolsthatanalyzeandsimulatediverseprocesseswithunprecedentedscalesof
granularity,detail,fidelity,andcomplexity.Meetingtheserequirementsdemandssophisticatedinformation
processingcapabilitiesfortheintegrationofproductdesignandproductionprocesses.Itisalsonecessaryto
developandimplementreal‐timeprocesscontrolsforthehighlypreciseexecutionofcomplex,interdependent
processes.Thesenewprocessesandcontrolswilldrawuponsensingandmeasurementthatiswellbeyondthe
currentstateoftheart.
Thetransitiontofabricationofgoodsusingprocessesatthemolecularlevelisusheringaneedtofundamentally
improveupontherigorousmetricsandcontrolsthatthemicroelectronicsindustryintroducedasitshrank
dimensionstothenanometerscale.Inthatindustry,theroadmapsproducedthroughindustryconsensusand
public‐privatepartnershipsenabledtheequipmentandmaterialssupplychaintodeveloptheappropriate
materials,tools,andprocessestocontinueproductdevelopmentattherateofMoore’sLaw.
Thisneweraofmanufacturing,however,facesamoredauntingtaskthanthatfacedbymicroelectronics.Notonly
mustitextendmanufacturingtonanoregimes,itmustalsobringtogetherscientistsandengineersfromdiverse
disciplineswiththeirdifferentterminologies,methodologies,andprocessestoestablishthetechnicalbasisforthe
manufacturingenvironment.
 DRAFTWorkingPapersVersion040510 1‐1
 DRAFTWorkingPapersVersion040510
Implementationofnoveltechnologieswillvarybyapplication,butthedevelopmentofthetechnicalcapabilitiesto
producegoodsemployingthesetechnologieswillbuildoncrosscuttingdevelopmentsintools,equipment,
processes,andanalyticalcapabilities.
1

2
3
1

ISSUE:WhatshouldbetheFederalGovernment’sroleinthedevelopmentofproductionprocessesandrelated4
sensing,measurement,andanalyticalcapabilitiesformolecular‐level,atomicallypreciseproduction.
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

29
30
31
32
33
34
35
36
37
38

Threeexampletechnologyareasinwhichsuchcapabilitiesarebeingdevelopedare(1)next‐generation
optoelectronics;(2)structuralmaterialsbasedonnanocompositematerials;and(3)biomanufacturing.Theseareas
representthescientificandtechnicalchallengesthatneedtobeaddressedtorealizethevalueofproductsbased
onnext‐generationmanufacturing.EachoftheseareasisreviewedinAppendix1‐Atothispaper.
Next‐GenerationMaterials
Expertscharacterizeadvancedmanufacturingas“newwaystomanipulateandmanufactureoldmaterialsorthe
processingofnewmaterialsfornewapplications.”Anexampleofthiscouplingistheinnovativetechniqueofusing
nanophosphatepowderonthecathodeofbatterycellsatA123Systems.Thismaterialitselfisnotinnovative,but
themanufacturingprocessandapplicationofthismaterialisanovelwaytomakethebatterymoreefficientand
morecompetitive.Otherexamplesofadvancedmaterialsincludecarbonnanotubesandadvancedcomposites.
Creationof“metamaterials,”artificialmaterialsengineeredtoprovidepropertiesthatmaynotbereadilyavailable
innature,wasdescribedasagoalofadvancedmanufacturing.Thesematerialsgaintheirpropertiesfromstructure
ratherthancomposition,usingtheinclusionofsmallinhomogeneitiestoenacteffectivemacroscopicbehavior
resultinginchangesinnovelcharacteristicssuchasanegativerefractiveindex,electricalproperties,orstrength.
Potentialapplicationsofmetamaterialsallowsforexpansionofproductsinnovelways.Forexample,
metamaterialshavebeenusedinphotovoltaicmaterialsintheformofanovelthincoatingonthephotovoltaic
paneltoincreasepossibleinstallationenvironmentssuchasdesertsbecausethethincoatingpreventssand
particlesfromscratchingthepanels.Additionalapplicationsofmetamaterialsincludehigh‐resolutionoptical
microscopes,datastorage,nanocircuitsforhigh‐poweredcomputersandsuperlensesthatfocusonobjectstoo

smalltobeseenwithconventionaloptics.
2

Innovativeusesofbothnewandexistingmaterialscreateopportunitiesforcompaniestodevelopnichesand
increasedemandfortheirproducts,whileincreasingcompetitivenessbydecreasingcosts.Anotherexampleisthe
company1366TechnologiesthathasrecentlyreceivedbothARPA‐Eandprivateventurefunding.Usingan
approachofprocessingsiliconinnovelways,1366Technologiesplanstomakethecostofsolarpowercompetitive
withthecostofcoalpower.
BioinspiredManufacturingUsingSelf‐Assembly
Duetotheadvancesatthemolecularlevel,thisneweraofmanufacturingfacesamoredauntingtaskthanthat
facedbymicroelectronics.Whilethetypicalmicroprocessorintegratesgreaterthanahundredmillionnanoscale
electronicparts,miniaturizedsystemsofthefuturewillalsoneedtoincorporatephotonic,mechanical,chemical,
andevenbiologicaldevices.Beyondtheintegratedcircuit,therearedevelopmentstocreatemultifunctional
integratedsystemsthatincorporatesensing,processing,andactivationintoincreasinglysmallpackagesizes,but
mass‐manufacturingofsuchcomplexdeviceshasprovedchallenging.Manufacturingprocessestomass‐produce
usefulmultifunctionalminiaturesystemshavenotyetbeendeveloped.Severalresearchersarelookingtonature

1
ProductiveNanosystems:ATechnologyRoadmap,BattelleMemorialInstitute,2007,discussesthemanytechnology
challengesentailedindevelopingandimplementingatomicallyprecisemanufacturing.
2
KevinBullis,“SuperlensesandSmallerComputerChips,”TechnologyReview,March2007.
 DRAFTWorkingPapersVersion040510 1‐2
 DRAFTWorkingPapersVersion040510
andbiologicalstructurestosolvethisproblem.Naturalsystems,withtheircomplexityandsophistication,exceed
whatcurrentmicrofabricationornanofabricationtechniquescancurrentlyachieve.
1
2
3
4

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

35
36
37
38
39

3

Themassproductionusing“biologicalmachines”isafundamentallynewwayofmanufacturingbecause,innature,
componentsself‐assembletoproducecomplexfunctionalsystems.Theideainthefutureof“growing”an
integratedcircuitorabiomedicalsensorwithadvancedfunctionalityandcomplexitymayaltertheapproachto
manufacturingatthemicro‐andnanoscale.
Asanexample,AngelaBelcherandcolleaguesatMIThaveharnessedthepowerofself‐assemblytoproduce
microscopicbatteriesthatmaybeusedtopowersmallmedicaldevicesorlabsonachip.Theyusedaviruscalled
M13tomaketheanodeofthebattery.Theviruswasgeneticallymodifiedtogeneratestructuredarraysofcobalt
oxidenanowiresontopofasolidelectrolyte.Thiswasthenassembledontoanetchedsiliconsurfacewiththin
bandsofplatinumandcoppertocompletetheconstructionofthebattery.
4

NewApplicationsofThree‐DimensionalPrinting
Three‐dimensional(3D)printingtobuildprototypesandtoaidnewproductdevelopmentandrealizationisnotan
entirelynewconcept.However,3Dprintingisnowbeingappliedtoemergingfieldssuchastissueengineeringand
nanotechnology.Recently,twocompanies,OrganovoandInvetech,havepartneredtogethertobuildthefirst
commercial3Dbioprintertomanufacturehumantissuesandorgans.Thetechnologyoriginatedfromuniversity‐
basedresearchandholdsthepromiseofonedaybeingabletoproduceorgansandreplacementbodypartson
demand.
5

Arecentarticledescribes3Dtissuestructuressuchasmyocardialpatchesbeingformedthroughthepost‐printing
fusionofthebioinkparticlesresemblingtheself‐assemblyphenomenainearlymorphogenesis.

6
3Dprintingisalso
beingemployedtoassistsurgeonswithdifficultproceduresandallowthemtopracticeonrealisticmodelsbuilt
from3DCTscanimages.While3Dprintershavebeensoldsincethemid‐1990s,thequalityhassignificantly
improvedwhilecostshavebeguntocomedown.Z‐Corpcurrentlysells3Dprintersrangingfrom$10,000to
$50,000,dependingonsizeandsophistication.Thecompanyisworkingonbuildingaproductforlessthan$5,000.
Atsuchapricepoint,“DesktopManufacturing”becomesmuchmoreachievable.Somebelievethroughthe
combinationofopeninnovationandtoolssuchas3Dprinters,entrepreneursarepoisedtoacceleratethepaceof
innovation.Other3Dprintingapplicationsincludebuildingmodelsforprosthetics,creatingprototypepartsfor
robotics,andbuildingarchitecturalmodels.
7

SustainableManufacturing
Sustainablemanufacturingreferstotheproductionofgoodsusingprocessesandmaterialsthataredesignedto
minimizetheproduct’senvironmentalfootprint.Sustainabilitygoalsincludeminimizingenergyusageand
materialswaste,monitoringandreducingeffluents,andmitigatingotherenvironmentalimpacts.Sustainability
goesbeyondthesimpleactofproducing:itextendstotheproduct’sexpectedlifetimeuseandthecomplexsystem
ofcomponents,energy,andtransportationrequiredtomaketheproductandbringittomarket.
Traditionalapproachestoreducingemissionshaveoccurredatthepointofemission—thetailpipemodel.
However,sustainablemanufacturingismostfullyrealizedwhensustainabilityprinciplesareappliedatallstepsof
thedesignprocess,frommaterialchoicetowastestreamminimizationandmanagement.Theexpansionof
sustainabilityintotheentiretyoftheproductandproductioncyclewillrequireinnovativeprocessesand
thoughtfulproductdesign.

3
BabakParviz,“TheFutureofManufacturing,”TechnologyReview,September/October2007.
4
LaurenRugani,“Virus‐AssembledMicrobatteries,”TechnologyReview,August2008.
5
OrganovoWebsite: />6

CyrilleNorotteetal.,“Scaffold‐freevasculartissueengineeringusingbioprinting.”Biomaterials30(2009)
7
RachaelKing,“Printingin3DGetsPractical,”BusinessWeek,October2008
 DRAFTWorkingPapersVersion040510 1‐3
 DRAFTWorkingPapersVersion040510
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
TheOECDframeseco‐innovationasaspectrumofnovelprocesses,designs,organizations,andinstitutionsthat
combinetohaveapositiveimpactontheenvironmentalsustainabilityofamanufacturingprocess(seeFigure1‐2).
Amongtheseinnovations,changesinprocessesandproductsrelyheavilyontechnologicaladvances.These
advancesarelikelytovarysubstantiallyfromproducttoproduct;however,improvedsustainabilitywilldrawon
expertisefromavarietyoffields,includingprocessmanagement,mechanicalengineering,andmaterialsscience.


Source:OECDPublicAffairsDivision(2009),“SustainableManufacturingandEco‐innovation:TowardsaGreenEconomy,”OECD
PolicyBriefs,June2009.
Figure1‐1.Eco‐innovation
Duetothecomplexproductionenvironment,sustainabilityrequiresthedevelopmentofsophisticatedproductlife
cycleanalysistoolssothatenvironmentalmanagerscantrackthefootprintofaproductthroughoutthe
distributedproductionsystem.Italsorequiresdataonprocessesandtheireffects,thecollectionofwhichis
beyondthecapabilityofmostmanufacturingfirmstoday.Increasinglydistributedmanufacturingprocessesfurther
complicatetheassessmentandmanagementofprogresstowardsustainabilitygoals.
Whilesustainablepracticesareoftenbeneficialtotheenterpriseandcanevenreducethecostofproduction,their
developmentandimplementationcanentailconsiderableup‐frontcostsandrisks.Moreover,modifyingaqualified
manufacturingprocessmayreduceyieldsorproductperformanceintheshort‐term.Therefore,theremaybea
FederalGovernmentroleindevelopingandincentivizingthetechnologicalmeansforimprovingsustainability,
especiallyinsofarastheyfalloutsidethedirectinterestandcapabilitiesofindividualfirmsandintotherealmof
socialgoods.
8

ISSUE:Needforaccessibleandaffordablemeasurementsystemsandanalyticaltoolsforassessingandmanaging21
sustainabilityacrosstheproductionprocess
22


8
See“SustainableNanomanufacturing—CreatingtheIndustriesoftheFuture,”NationalNanotechnologyInitiativeSignature
Initiative,NSTCCommitteeonTechnology,SubcommitteeonNanoscaleScience,Engineering,andTechnology,February2010,
forarecentperspectiveonthisrole.
 DRAFTWorkingPapersVersion040510 1‐4
 DRAFTWorkingPapersVersion040510
ConclusiononKeyScienceandTechnologyChallenges1
2

3
4
5
6
7
8
9
10
11
12
13
Advancedmanufacturingderivesfromadvancementsintechnologiesandoperationsacrosstheproduction
process.Someoftheseadvancesareintheactualformingoftheproductintermsofprocesses,tools,and
equipment—atlevelsrangingfrominitialrawinputmaterials,throughpartsandcomponents,totheirassembly
intoafinalproduct.Theseadvancesareoftenspecifictothespecificend‐productdomainwhichcanrangefrom
microorevennanoscaledevices(suchasaplanarcomplementarymetal–oxide–semiconductor(CMOS)integrated
circuit(IC)tolarge‐scaleintegratedsystems(suchasacomputerserverthatintegratesmultipleICswithanarray
ofadditionalelectronicandelectro‐mechanicalpartsintoasystemoranaerospacesystemconstructedofhighly
specializedstructuralmaterialswithmassivenumbersofsubsystems).Thefrontiersofproductmanufacturingare
(1)advancesneededtodevelop,employ,andintegratenewmaterialsand(2)advancesintheabilitytointegrate
partsandcomponentsmoreeffectivelyandefficientlyintointermediateandfinalproductswithincreasing
constraintsontime‐to‐product,productcost,andsustainability,withinadistributedvaluechain.

 DRAFTWorkingPapersVersion040510 1‐5
 DRAFTWorkingPapersVersion040510
Appendix1‐A:AdvancedTechnologyManufacturingFrontiers1
2
3
4
5

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

36
37
38
39
40
41
42
43
44

IntegratedOptoelectronics
Photonics,alsoknownasoptoelectronics(OE),isthattechnologyspacewhereinformationsignalscarriedby
electronsareconvertedtophotonsandviceversa(O‐E‐O).Photonstransportinformationintheformof
amplitude,wavelength,andphase—oranycombinationoftheabove.Photonicdevicesareeitheractiveor
passive.Passivedevicesmerelytransporttheinformation‐carryingphotonsfromonelocationtoanother.Active
componentsperformsomefunction—convertelectronsintolight(lasers,displays),convertphotonsintoelectrons
(chargecoupleddevicesensors,avalanchephotodiodes),mergestreamsofdata‐carryingphotons(multiplexors),
separateoutmergedstreamsofdata‐carryingphotons(demultiplexors)andimpartdataonastreamofphotons
(modulators.)
Theapplicationofphotonicscoverssuchdiverseareasasindustriallasers,consumerelectronics,
telecommunications,datastorage,biotechnology,medicine,generalillumination,anddefense.Eachofthese
applicationspaceshasasupplychainandinfrastructurethatstartswithbasicmaterialsandendsatacompleted
product.Alongthischainaresubchainsthatprovidetheindividualcomponentsorsubsystemsthatmakeupthe
finishedproduct.
Akeydynamicinphotonicsistheevolutionfromdiscretephotonicdevicestointegratedsystems.Thisintegration
isdrivenbytheneedforincreasedperformancewhilesimultaneouslyreducingcostandpowerconsumptionto
meettheburgeoningdemandsfortelecommunicationsanddatacommunications—whichthemselvesare
becomingincreasinglyintegrated.
PhotonicIntegrationforTelecommandDatacomm
TelecommunicationsnetworksanddatacentersthatsupportthecommunicationsinfrastructureandtheInternet

willrequireintegratedphotonicstomeetdemandsthatwilloverwhelmthemassiveswitchingcentersthatroute
themessagesanddataaroundthefiberopticnetwork.Thesecenterstypicallycontainthousandsofracksof
electronicrouters,inbuildingsthatcoveracres,andconsumeabout30megawattsofelectricpower.Asnew
mobiledevicesandinternetvideocontentincreasethebandwidthcapacitydemandonthenetwork,theservice
providershavetoincreasethenumberofchannelscarriedbyasinglestrandofopticalfiber.Simplyincreasingthe
electroniccontentofaracktoaccommodateincreasedbandwidthisnotpossiblebecauseoftheassociated
increaseinpowerconsumptionandheatdissipation.Thesolutionliesinphotonicintegration.
9

Photonicintegratedcircuits(PICs)combinemultipleopticandelectro‐opticcomponentsontoachip.Today’sPIC
technologyiscomparabletothatofmicroelectroniclarge‐scaleintegration(LSI)ICsofthe1960s—about200to
300elementsonasinglechip.MostofthePICstodayarehybrid—theyconsistofasiliconsubstratewithanumber
ofmonolithicallyintegratedcomponents,andanumberofcomponentsfabricatedfromothermaterials
mechanically,optically,andelectronicallyconnectedtothesubstrate.PICsrequirecomponentsfabricatedfrom
othermaterialsbecausesilicondoesnotsupportalaser.Technologiesandfabricationtoolsareneededthatwould
supportmonolithicintegrationofsiliconwithothermaterialstoenablePICstomovetohigherlevelsofintegration
andtakeadvantageoftheexistingsiliconCMOSinfrastructure.
Thepriceofincreasedbandwidthisincreasedcomplexityandpowerconsumption.Thesystemrequiresmore
componentstoextractandgroomtheelectricalsignalsfromtheseincreasinglycomplexopticalsignalsandconvert
themintoaformthatelectronicprocessorscanmanipulate.EachO‐E‐Orequiresmanydiscrete,single‐function
opticalcomponents,includinglasers,modulators,wavelengthlockers,detectors,attenuators,wavelengthdivision
multiplexers(WDM)andde‐multiplexers.Inatypicalopticaltransportsystem,eachO‐E‐Oconversionmayrequire
uptohalfadozenoptoelectronicoropticalcomponents,andafullydeployed40‐wavelengthWDMterminalnode
mayuseupwardsof120ormorecomponentsinterconnectedby260ormorefibercouplings.Eachofthesefiber
couplingsrepresentscost,signallosses,andapotentialfailurepoint.

9
BikashKoley,“NetworkArchitectatGoogle,”presentationattheOIDAPhotonicIntegrationForum,October6,2009,Santa
Clara,CA.
 DRAFTWorkingPapersVersion040510 1‐6

 DRAFTWorkingPapersVersion040510
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Theindustryseesthewaytoovercomethiscostandcomplexityhurdleisthroughphotonicintegration.Assuch,
threeclassesofdevicesrepresenttheintegrationinthephotonicsworld.
Theplanarlightwavecircuit(PLC)consistsonlyofpassivedevicesfabricatedfromtransparentmaterialsusing
planartechnology.Itisessentiallyopticalwiringandcanperformsomesignalprocessingbutdoesnotalterthe
signal.TypicallyPLCmaterialsaresilica‐on‐silicon,polymers,andsilicononisolator(SOI).Theindustryhasused
thistechnologywidelyforthelast10years.
Thephotonicintegratedcircuit(PIC)isthesameasaPLCbutalsoincludeson‐chipgeneration,modulation,
alteration,anddetection.Ithasbothpassiveandactivephotonicdevices(InPorGaAs‐based)andtransparentand
opaquesemiconductormaterialswithdifferentbandstructuresanddoping.Semiconductorwaferprocessing
technologiesfabricatetheopticalwaveguidedevices.PICscanbemonolithic,whereallofthedevicesresideinone
die,orhybrid,wherecertaindevicesarephysicallyattachedtogetherontoacommonplatformtofunctionasone

unit.Thistechnologyrepresentsthecurrentstate‐of‐the‐art,andwhereindustryR&Disfocused.
Theoptoelectronicintegratedcircuit(OEIC)isthesameasaPICbutincludeson‐chipelectronicstodrivetheactive
elementsandprovideelectricaloutputs.Itconsistsofphotonicandelectronicdevicescombinedontoonechipand
fabricatedusingsemiconductorprocessingtechnologies.Thisfuturetechnologyisonetheindustryhopesto
achieve.
Becauseofthelargeexistinginfrastructure,siliconwouldbetheidealcandidateforphotonicintegration.Although
researchershavefabricatedmostoftherequiredactiveandpassiveopticalfunctionsinsilicon(Si),the
fundamentalchallengehasbeenthatsilicondoesnotsupportalaser,anessentialcomponentintheopticalworld.
Academicandindustrialresearchershavedevisedcleverapproachestomitigatethisshortcomingofsilicon.For
themostpart,theyhavereliedontheindiumphosphide(InP)materialssystemforthelaser.TheproblemwithInP
istwofold—immatureproductionenvironmentandconcomitantlythelackofasharedcommonproduction
approach.First,thematerialandfabricationinfrastructureisimmature.TypicalwafersizesofInPare3inches,
withleadingedgeat6inches.Siliconfabrication,ontheotherhand,typicallyuses8‐or12‐inchwafers.Six‐inch
technologyforSiismanygenerationsold.BecausethemarketforInPdevicesisrelativelysmall,thetool
infrastructurehasnotbenefitedfromahighlevelofinvestment.Second,InPdeviceshaveevolvedina
manufacturingenvironmentwheretheintellectualpropertyisembeddedintheprocess,ratherthanthedesign.As
aresult,onecannottakeadevicefabricatedinonefacilityandreplicateitusingtheprocessesofanother
fabricationfacility(fab).Again,inthisrespectphotonicintegrationisatthelevelofmaturityofsiliconinthe1960s,
beforeCMOSbecamethetechnologyofchoice.
NotwithstandingthedifficultiesofmonolithicintegrationontheInPplatform,somecompanies,suchasJDSUand
Infinera,havesuccessfullybroughtproductsbasedonmonolithicInPintegrationtomarket.Oclerobelievesitis
well‐positionedforthismarketsegmentbecauseofitsInPfabinCaswellUK.
ThesecondapproachtoPICsistointegrateasmanypassiveandactivecomponentsonasiliconsubstrateas
possible,andthenattachandcouplecriticalnon‐Sicomponentstotheplatform.OneoftheadvantagesofSiasa
platformisthatSiO
2
makesforanexcellentwaveguidematerial,andtheprocessescanbefullycompatiblewith
theexistingCMOSinfrastructure.ThechallengeisinthemismatchofthethermalconductivitiesofInPandSi.As
temperaturechanges,thecomponentsmayshiftslightly,impactingthealignmentoftheopticalpath.Companies
thatfollowthisapproachincludeKotura,Luxtera,andNeoPhotonics.

Potentialroadblocksaheadincludedensitylimits,bothonandoffchip.Withthemassiveamountofwirebonding
requiredfortheseintegratedphotonicdevices,andwithallthewiresrunning10or40GHzsignalsthoughthem,
theyactlikeaphaseantenna,bringingupseriousissuesofelectromagneticinterference.
AnotherkeyimpedimenttoPICdevelopmentisthelackofaneconomicallyviablefoundrybase.Theeconomic
realityisthatmanyIII‐Vfoundriesarestrugglingwithexcesscapacityandno“killerapplication”insightthatwould
drivevolume.Companiestrytolockinwhatlittlecustomerbasetheyhavethroughproprietaryprocessesthatare
notportablefromfoundrytofoundry.
Onthetechnicalside,thelackofarobustmarket,haslimitedthedevelopmentofcomprehensivemodeling
softwareandotherinfrastructureelements.Researchersinterestedinbuildingphotonicintegratedcircuitshaveto
 DRAFTWorkingPapersVersion040510 1‐7
 DRAFTWorkingPapersVersion040510
eithersettleforexcessdiethatfoundriesfabricatedforsomeotherapplication,ortrytocomeupwithadesign
thatsomefoundrycanthenfabricatebutwithnoguaranteethatitwillworkasdesired.Furthermore,thelackof
softwaredesigntoolsandconsistentqualifiedprocessesmeanquickturnaroundisnotpossible.Eveniftheinitial
diesworkasdesired,thereisnoguaranteethatthediesfabricatedonsubsequentrunswillhavecomparable
performance.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

TheOEICwillrequirenewtechniquesandtoolsforincorporatingnon‐siliconmaterialsintotheCMOSprocess.The

challengesaresignificantduetothedifferencesinlatticeconstants,whichcausethreadingdislocations,and
differencesinmeltingpointsofdifferentmaterials.Forexample,theannealingtemperaturefortheCMOS
transistorsourceanddrain,whichisabout1000°C,ismorethan50°abovethemeltingpointofgermanium—the
preferredmaterialfora40Gbpsavalanchegainphotodetector.Notwithstandingthesechallenges,IBMhas
fabricatedatransceivercompletelyinCMOS,includingafibercoupler,6‐channelWDMthatisonly20by70
microns.Eachchannelconnectstoa100‐micronlongmodulator,whichdirectlyconnectstotheelectronicdriver
andadetectorthatisonly10micronslong.Thetotaldevicewithoutaringresonatorassistisonly0.5mmlong;
witharingresonator,itisonly0.1mmlong.
10

NanocompositeStructuralMaterials
Anareaofgrowingimportanceisdevelopmentofnano‐enhancedadvancedcompositesandrelatedstructures.
SignificantdevelopmentsareunderwayintheindustrialscaleproductionofCNTsandincorporatingCNTswithin
traditionalconstituentmaterialsusedtomanufacturefiberreinforcedPMCs.
CNTsarehollowcylindersthatconsistofindividualormultiplewallsofagraphitelatticestructure.Multi‐walled
carbonnanotubes(MWCNTs)aregenerallyeasiertoproduceandlessexpensivetomanufacturethansingle‐
walledcarbonnanotubes(SWCNTs).
11
CNTspossessextraordinarytensilestrengthandexceptionalstiffness.Ona
strength‐to‐weightbasis,CNTsareunmatchedbyanyothermaterial.CNTsalsopossessespeciallyhighthermal
conductivityandstabilitywhilesomevariantsofCNTspossessespeciallyhighelectricalconductivityandchemical
resistance.
FiberreinforcedPMCsrepresentthelargestandmostdiverseapplicationforcompositescomparedwiththose
producedwithmetal,ceramicorothermatrixmaterials.ApplicationsforPMCsarehighlydiverseincluding
sportinggoods,aerospacedefense,andautomotive.WhilePMCshavebeeninusefordecades,theintroductionof
nano‐enhancedPMCsisarecenttechnologicaldevelopmentwhichhaslargescalecommercialpotentialofacross
virtuallyallmajoreconomicsectors(e.g.,publicworks,heavyindustry,energyproduction,powerdistribution,
shipbuilding,consumerproducts,medicalequipment,groundtransportation,commercialaircraft,spaceanda
hostofmilitaryuses).
Carbonnanotubesareofrelativelyrecentorigin,withsingle‐wallCNTsbeingdiscoveredintheearly1990sand

productionprocessesdevelopedsincethattime.ThereforelargescalecommercialuseofCNTsinPMCshasbeen
justgettingunderwayoverthelastfewyearsbeginningwithasmallhandfulofapplications.Anumberof
companiesareactivelyinvolvedwithincorporatingCNTsintovariousconstituentmaterialsthatareusedto
manufacturePMCs.Nano‐enhancedconstituentmaterialscansignificantlyimprovethematerialpropertiesof
PMCsandattendantstructures(e.g.,higherstrengthandlighterweight)byleveragingtheextraordinaryproperties
ofCNTs.ExamplesofthetypesofPMCconstituentmaterialsthatcanbeenhancedbyCNTsincludethermoplastic
andthermosetresins,adhesivesandresininfusedtextiles(knownas“prepregs”)thataresubsequentlyfabricated
intolaminatedandotherPMCstructures.Additionalapproachestonano‐enhancedPMCsincludesincorporating
CNTsintothemanufactureofexistingfibersareusedtoreinforcePMCsaswellasdevelopingentirelyalternative
formsofnewfibersproducedfromCNTs.

10
YuriVlasov,IBMResearch,“Transitionfromtelecommtodatacommtocomputercomm,”OIDAPhotonicIntegrationForum,
October6,2009,SantaClara,CA.
11
SWCNThaveadiameterontheorderof1to3nanometers(nm)

whilethediameterofaMWCNTcanaveragefrom8to10
nms.TheindividualwallthicknessofCNTsmeasuresanatomthickandthelengthofCNTscanreachseveralmillimeters(mm).
 DRAFTWorkingPapersVersion040510 1‐8
 DRAFTWorkingPapersVersion040510
Nano‐enhancedPMCsstandtorevolutionizeadvancedcompositesbyenablingthedevelopmentandmanufacture
ofPMCswithheretoforeunheardofpropertieswithoutthetraditionaltradeoffofmaterialperformance(e.g.,
increasingmaterialstrengthwithoutsacrificingweightreduction).TheamountofCNTsaddedtoPMCstoachieve
optimallevelsofhigherperformancecanrangefrom1to3percentbyvolume.Inaddition,CNTproducersclaim
thattheaddedperformancetoPMCsprovidedbytheirproductscanbeachievedatarelativelylowcostandmay
onlyincreasethepriceofconstituentprepregmaterialby7to10percent.However,thecostofCNTsisnotcheap,
ontheorderof$45perpound.Nano‐enhancedPMCsareanticipatedtoalsospurthedevelopmentofnewclasses
ofcompositesincludingmulti‐functionalmaterials(e.g.,smart,adaptiveandself‐healingstructures).
1

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

32
33
34
35
36
37
38
39

Foruseincompositesthemaintechnicalchallengesarenotthenanotubesthemselves.
12
Whilecommercialscale
productionofCNTsisrelativelynew,thereisalreadyconsiderableCNTproductioncapacityin‐place.Forexample,
asofJanuary2010,thereexistssinglefirmannualproductioncapacityofover200metrictonnes(MTs),andsingle
firmannualcapacityisprojectedtoincreaseto400MTsbeforetheendof2010.
However,large‐scaleuseofCNTsinPMCsisstillintheearlystagesofdevelopmentandfacessignificanttechnical
obstacles.ThegreatestbarriertointegratingCNTsintomanufacturingPMCconstituentmaterialsandassociated
downstreamcompositestructuresisthelackofneededprocessingtechnologies,expertiseandknowhow.
ExamplesincludethenaturaltendencyofCNTstoreagglormerateinresinandprepreg,whichsubsequently
impairshomogeneousdispersionofnanomaterialsandresinviscosity.Theinabilitytoeffectivelycontroluniform
dispersionofCNTsincompositesprocessingcanresultinfailuretomaintaindesiredmaterialpropertyvaluesof
finishedPMCstructures(e.g.,strength,stiffnessandtoughness).Otherbarriersconfrontingwiderscaleuseof
nano‐enhancedPMCs(andCNTsmoregenerally)includesenvironmental,healthandsafetyconcernsaswellasthe
lackofmaterialstandards,referencedataanddesigntools.Therearealternativeapproachesindevelopmentfor
employingCNTsinmanufacturingPMCs,suchasthosebeingdevelopedbyNanocomp,thatareexpresslyaimedat
overcomingtheseobstacles.
Nano‐enhancedPMCsareneverthelesscurrentlybeingcommercializedfordiverseusesinconsumerproducts
(e.g.,sportinggoodsandcasesforlaptopcomputers),renewableenergy(e.g.,windmillblades)andlimitedground
transportationapplications(e.g.,automotiveparts).Howeverproblemsassociatedwitheffectivelyintegrating
CNTswithinexistingPMCmanufacturingprocessesneedtobeovercomeifnano‐enhancedPMCsaretobemore

widelyacceptedintoincreasinglymoredemandingapplicationssuchasaerostructuresusedincommercial
aviation,militaryaircraftandotherhighconsequenceuses.
Biomanufacturing
Biomanufacturingatitsbroadestdefinitioncanbeunderstoodasencompassingallactivitiesthateitherutilize
biologicalprocessestocreateproducts(thatcanbebiologicalornon‐biological)and/orhaveastheirmainproduct
abiologicalsubstance.Productsthatcanbemadeviabiomanufacturingincludepharmaceuticals,fuels,food,
nutraceuticals,biomaterials,andeveninorganicsubstances.
13
Processesthatcanbeconsideredunder
biomanufacturingincludeusing“native”biologicalexpressionsystems,oralteringthosesystemsusinggenetic
engineering,metabolicengineering,andtheprinciplesofsyntheticbiologymorebroadly.Currently,
biomanufacturingismostreadilyidentifiedwiththeproductionofbiopharmaceuticals—theprocessbywhichthey
arefermented,purified,andpackagedanddistributedtotheendcustomer—yetthereareemergingareasof
biomanufacturingthatdeserveattentionandarebrieflymentionedbelow.

12
TheproductionconstraintsforCNTsforcompositesarelessdemandingthanthoseforsuchapplicationsaselectronics,for
whichtheperformancecharacteristicaremoreexacting.
13
Forexample,Dr.BelcheratMIThasgeneticallyengineeredvirusestoattractinorganicmaterialstotheiroutershelltoform
nanowires,batteries,andotherdevices.“ResearchersBuildTinyBatterieswithViruses,”MITNews,April2006,availableat
/> DRAFTWorkingPapersVersion040510 1‐9
 DRAFTWorkingPapersVersion040510
Biopharmaceuticals1
2
3
4
5
6
7

8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

38
39
40
41

TheUnitedStatesisconsideredthegloballeaderinmanufacturingbiopharmaceuticals,anditcurrentlybenefits
fromalarge“installedbase”—forittakes5‐8yearsandfrom$500millionto$1billiontodesign,build,andlicense
abiomanufacturingfacility.Yetbiopharmaceuticalproductionfacilities(includingcontractmanufacturing
organizations)havebeguntomoveoffshore,withfacilitiesoperatinginSingapore,PuertoRico,SouthKorea,and
India.Othercountrieshavelarge‐scaleinitiativestoattractbiomanufacturingtotheircountries,includingthe
UnitedKingdom’sNationalBiomanufacturingCentre.SomeindustryleadersbelievethattheU.S.
biomanufacturingindustryisatthestagethatthesemiconductorindustrywasinthelate1980swhenSEMATECH
andotherpublic‐privatepartnershipsweredevelopedtorevitalizethecapacitytomanufactureintegratedcircuits
withtheUnitedStates.Small‐scalegovernment‐academic‐industrypartnerships,suchasUCBerkeley’sCenterfor
BioprocessOperationsandMIT’sCenterforBiomedicalInnovation,andtheNSF‐fundedNortheast
BiomanufacturingCenterandCollaborative(NBC2),havebeendevelopedtosupportbiomanufacturingwithinthe
UnitedStates.
Severalchallengesinbiopharmaceuticalmanufacturinginclude:
• Optimizingexpressionsystems—productionbasedonlivingorganismsisvariableandcanbeimproved
• Improvingproductandprocesscharacterization
• Streamliningplantdesignandoperations—asthecapitalinvestmentforplantsislargeandhastobedone
inadvanceofdemand(therearecostsforbuildingtooearly—idlecapacity—aswellasforbeingtoo
late—lostsales)
• StrictregulatoryenvironmentrequirementsforprocessvalidationandCertifiedGoodManufacturing
Practices(CGMP)—andchangingregulatoryrequirements
• Workforceshortage
TissueEngineering
Anothermorerecentlydevelopedtypeofbiomanufacturingiswhatisoftenreferredtoas“tissueengineering”—
thisareacanincludetherelatedfieldof“regenerativemedicine”basedontheuseofstemcells.Tissue
engineeringisprimarilyfocusedonthecreationofcomplexbiologicalmaterials,includingbonesandorgans.The

U.S.FederalR&Dcommunityhasprovidedsubstantialfundingfortissueengineering.Theseactivitiesare
coordinatedthroughtheMulti‐AgencyTissueEngineeringScience(MATES)InteragencyWorkingGroup.MATES
definestissuescienceandengineeringas“theuseofphysical,chemical,biological,andengineeringprocessesto
controlanddirecttheaggregatebehaviorofcells.”
14
Someobserversbelievethatthismaybeafutureareaof
manufacturingintheUnitedStates,althoughthereremainsmuchbasicresearchneededontheseareas.Todate,
noprogramshavebeenidentifiedthatspecificallyfocusonthescaleupanddevelopmentofprocessesthathave
beenshowntoworkatthelabscale.However,scaleupisastatedpriorityoftheMATESgroupintheir2007
strategicplan.
15
Althoughseveralcompaniesexistinthisarea,nolarge‐scalerevenueshaveyetbeenattained.The
firstcommercial3Dbioprinter,abletoprintskin,muscle,andshortstretchesofbloodvessels,willsoonbe
releasedtoresearchers.
16

SyntheticBiology
Anotherareathatmayhaveimpactonthefutureofbiomanufacturingisgeneticengineeringor,whenconsidered
asapartofanoverarchingframework,“syntheticbiology.”Ad‐hocgeneticengineeringhasbeeninuseforseveral
decades;thefirstuseofgeneticallymodifiedE.colitomanufacturesynthetichumaninsulinoccurredin1978.But
theadvancementofDNAsequencingandrelatedunderstandingofgeneandproteinfunctionshasmadethisarea

14
Multi‐AgencyTissueEngineeringScience(MATES), />15
AdvancingTissueEngineeringScienceandEngineering:AMulti‐AgencyStrategicPlan,Washington,D.C.,ExecutiveOfficeof
thePresident,June2007, />16
“MakingaBitofMe:AMachinetoPrintOrgansisComingtoMarket,”TheEconomist,February18,2010,availableat
/> DRAFTWorkingPapersVersion040510 1‐10
 DRAFTWorkingPapersVersion040510
ripeforexploration.Recentresearchshowsthatgreenalgaeandgeneticallymodifiedyeastcanproduceproteins

morecheaplythantraditionalsystems,
1
2
3
4
5
6
7

17
andthattheTobaccoMosaicViruscanbeengineeredtorapidlyproduce
avaccineforthequickly‐shiftingnorovirus.
18
Severalgovernmentprogramshavebeenestablishedtosupportthis
typeofresearch,includingDARPA’sAcceleratedManufactureofPharmaceuticals(AMP),DOE’sJointBioenergy
Institute,andNSF’sSyntheticBiologyEngineeringResearchCenter(SynBERC).
19




17
AmberDance,“FromPondScumtoPharmacyShelf”NatureMedicine,vol16No2,010,pp.146–149.
/>18
“Tobaccoplantsyieldthefirstvaccineforthedreaded“cruise shipvirus,”AmericanChemicalSociety,pressrelease,August
18,2009,availableat
/>2762&use_sec=true&sec_url_var=region1&__uuid=3f4c6a40‐bad2‐4959‐8547‐3fdc85dacf49.
19
“CouldMiniLabsandPlant‐BasedVaccinesStoptheNextPandemic?”ScientificAmerican,March1,2010.
/> DRAFTWorkingPapersVersion040510 1‐11

 DRAFTWorkingPapersVersion040510
 DRAFTWorkingPapersVersion040510 1‐12
1 
 DRAFTWorkingPapersVersion040510
Question2:Whataresomepossiblenewconceptsofadvancedmanufacturing
thatmightapplytoawiderangeofindustries?
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

Manybelievethatintoday’sworld,manufacturingadvanceswillderivefrominformationandintegrated
productiontechnologiesthatcreatenewcapabilitiestorapidlyandefficientlydesignandproduceproducts
economically.Beyondtheproductionofspecificproducts,capturedintheterm“productrealization,”
manufacturingisanelementofalargerenterprisethatentailsproductconceptualizationontheoneendand
productdeliverythroughsalesontheother.Theintegrationofmanufacturingwiththedesignanddelivery
processesisitselfafrontierstressingdatacollection,dissemination,andprocessingcapabilitiesandanalytictools
andprocessesforrapidlymakingdecisionsoncomplexissues.Otherconcepts—suchasopeninnovationand
“cloudproducing”—enabletheleveragingofcollectiveintelligenceandfeedbackthroughtheuseofinternet
technologies.

Distributed,RapidlyResponsive,ComplexProductRealization
“Complexproductrealization”referstothetechnologiesandprocessesassociatedwithconceiving,designing,and

manufacturinghighlyintegrated,multi‐componentsystems.
1
Complexproductrealizationisenabledbya
confluenceofradicaladvancesininformationtechnologies,analyticaltools,andthechangesinorganizationsthese
advanceswillenable.Inthisapproach,sophisticatedsimulationsareseamlesslyintegratedwithconceptualand
detaileddesigntools.Thesetoolscanallowcustomers,designersandproductmanagerstolearnandadapt
togetherastheyexperimentinrealtimewithamultitudeofproductconcepts.Intelligentagentsmonitorthe
processandprovideguidanceonoveralldesignstrategy,technicalrisksandopportunities,manufacturingissues,
reliability,andlife‐cyclecost.
Thefoundationofthisproductrealizationenvironmentisimprovinginformationtechnologies—i.e.,the
convergenceofdigitaltechnologiesforvoice,data,andimages,combinedwithincreasingprocessingpower,
networkcapacity,andsoftwareefficiency.Muchofcurrentresearchaimstoleverageemerginginformation
technologiestocoordinatetheactivitiesofdesignteams,managers,andsupplychainplayersastoreduceproduct
cycletimeandlife‐cyclecostwhileincreasingusersatisfactionwiththeresultingproducts.Sophisticated,network‐
baseddesigntoolsthatfacilitateconcurrentoptimizationofcomponentandsubsystemdesignsarealreadybeing
usedinsomeproductareasandareexpectedtodiffusewidelyoverthenextdecade.
Theresultsofthesedesignsasproductsrequiretheirintegrationwithautomatic,flexiblemanufacturing
technologies.Push‐buttonproductionofindividualmachinedpartsfromcompletedcomputer‐aideddesign(CAD)
definitionsisalreadyareality:numericallycontrolledmachineprogramscanbegenerateddirectlyfromCAD
definitions,downloadedintothemachines,andimmediatelyutilizedtocutmetalandformthepart.Analogsexist
forcastandmoldedpartsanddepositionprocesses.TheCADprogramgeneratesadefinitionofthemold,die,or
masterfromthepartdefinitionandprogramsthecodetomachinethemoldormaster,thenthemoldormasteris
madeandthepartiscast.Severalshopsnowuseautomatic,CAD‐basedmanufacturingastheirbasicmethod.
Conceivably,thisautomaticmanufacturingapproachrendersobsoletetraditionalnotionsofalearningcurve.
Designorganizationsseektoexploit“learninginmanufacturingprocesssimulation”beforeanymetaliscut.
Versatilemillsandlathesnowcanmachinetosuchaccuracythatmanyfinishingstepsareeliminated.Various
otherapplicationsofinformationtechnologyarebeingusedtoautomateotheraspectsofthemanufacturing
process(e.g.,materialhandling,parttracking,andequipmentmaintenance),enableon‐lineproblemdiagnosis,
andprovideself‐correctingcapabilitiesattheenterpriselevel.Theseapplicationswillallowforreal‐timetracking
ofmanufacturingflowsacrosstheenterprise,makingcurrent“batchandqueue”operationsmorelikecontinuous


1
RichardVanAtta,etal.,ComplexProductRealization2020:KeyIssueAreas,InstituteforDefenseAnalyses,December15,
1999.
 DRAFTWorkingPapersVersion040510 2‐1
 DRAFTWorkingPapersVersion040510
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

25
26
27
28
29
30
31
32
33
34
35
36
37
38
processcontrolsituations.Theultimateresultcouldbesinglesetuptool‐lessmanufacturingthatiseconomically
efficient,butnotbasedontheneedforeconomiesofscaleoftraditionalmachining.
Single‐unitmanufacturingshouldbeespeciallyadvantageoustoweaponsystemsandother“high‐end”products
thataregenerallybuiltinsmallvolumesrelativetocommercialproductsandarebuiltatlowratesinan
environmentwhereneedschangerapidly.Single‐unitmanufacturingcouldfacilitaterapidreconfigurationofa
designtoaccommodatechangesintherequirements,followedbyaquicksmallproductionrunofthemodified
system.Suchachangewarrantsafundamentalre‐thinkingofhowpartsaredesigned,sincepartbypart
customizationwouldbecomemuchmorepracticalthanbefore.Replacingcomplex,assembledunitswithlarge
machinedcastingsmaybemoreattractivethanbefore.
Torealizethisperspective,asetofoverlappingchallengeswillneedtobeaddressed:
• Logicofknowledgeabstraction:Thereisaneedforproductdefinitioncapabilitiesthatcanrepresentthe
productinfinedetailforpartsdesigners,lessdetailforsystemsengineers,andevenlessdetailforthe
chiefengineer’sperspective.Researchareasincludedatastructuresandintelligentagents.
• Distributed,AdaptiveAlgorithmsforOptimizationofMulti‐DimensionalDesigns:Thedifferentlevelsofthe
designspaceresultintradeoffproblemsthattendtobediscontinuousandillconditioned.Thissuggests
thattheremaybemathematicalpropertiesthatarecharacteristicofthesespaces,andthatsearch

algorithmsmightbecreatedthatcouldexploitthesecharacteristicstoyieldmoreoptimalandmore
robustsolutions.Researchareasincludevisualizationtechnologyand,again,intelligentagents.
• MathematicsandScienceofProductArchitectureandModularity:Theinterconnectionofdesign
challengesmeansthatcomplexproductrealizationwillincreasinglyinvolveintegrating“systemof
systems.”Todoso,itwillbeimportanttoidentifyinterdependentriskdriversandmanagetotalrisk
postureacrossentireplatformsandacrosstime.Keyareasincluderepresentingandvaluingflexibility,
structuringsupplychains,andcostmodeling.
• VirtualCharacterizationandQualificationof“SystemofSystems”ProductsandProcesses:Thephysical
modelsthatunderliecurrentproductrealizationsystemswillneedtokeepupwithnewtechnologies,
whichfrequentlyexceedcustomaryoperatingregimes.Emergingtechnologiessuchas
microelectromechanicalsystems(MEMS),biomechatronics,andnanotechnologywillrequireentirelynew
manufacturingprocessesandprocesscharacterizations.
Increasinglypowerfulcomputers,readilyaccessiblehigh‐speednetworks,andevensocialmediacanprovide
nearlyinstantaneousinformationonproductrequirements,characteristics,andperformancethroughoutthe
“valuechain”fromproductconcepttofinalproduction.Thiscanfacilitate,butalsocreateincreasingdemandfor,
morerapidinformationandresponsivenessthroughouttheincreasinglydistributedproductionsystembothwithin
andamongstfirms.
Distributedsupplyandproductioncanleadtomoregranular,modular,flexible,adaptive,and,hence,responsive
production.Tobeeffective,theseinformationsystemsmustbecapableofcapturingdatafrommultiplesources,
andtransmittingthemacrossthesysteminusableformats.Ifproperlyimplemented,suchasystemcanmatch
customerdemandstosupplieravailabilitytoproductioncapacityanddelivertheproductonschedule—by
providinginformationonpreciselywhatisneededwhenitisneeded.
ISSUE:Developmentandintegrationoftheunderlyinganalyticalcapabilities(algorithms,mathematical39
40
41
42
43
44
45
46

47
representations,logicstructure,etc.)forusebyenterprisesinhighlyresponsive,distributedproduction.
Inaddition,distributedproductionofcomplexcomponentsandsubsystemswithtighttolerancesstresssuppliers’
abilitytomanageandcontrolprocessesandequipment.Externalfactorssuchastemperature,humidity,and
startingmaterialcompositionandmorphologyallcanaffectthequalityoftheendproduct.Internalfactors,such
asmachinecalibration,componentwear,setup,andoperationparametersarelikewiseimportant.Both
environmentschangeovertime,affectingtolerancesandequipmentperformance.Thishighlightstheneedto
developprocessesthatcanbemeasuredandcontrolledinsituandinrealtime.Thesehigh‐performance
productiontoolsmustalsobeaffordableforsuppliersinadistributedproductionsystem.
 DRAFTWorkingPapersVersion040510 2‐2
 DRAFTWorkingPapersVersion040510
Assystemmanufacturersrequireever‐tightertolerances,machininghastotransformfrombeinganoperationtoa
process.Tomaintaintoleranceanduniformityofproduct,themachinistmustknowinrealtimethetemperature
oftheworkpiece,thetemperatureofthetoolhead,thetemperatureofthecoolingfluid,theviscosityofthe
coolant,thecoolantflowrate,thefeedrate,thewearonthetoolhead,amongotherparameters.Toachievereal‐
timemonitoring,aninformationinfrastructure,withintegratedsensors,basedonvalidatedmodelsand
simulationshastobedeveloped.Ineffect,themachiningoperationhastofollowthepathofthesemiconductor
industrybyfocusingonqualifiedprocessesandminimizinghumanintervention.Asonemachineshopproprietor
stated,“Wehavetomovefrommanufacturingtoautofacturing.”
1
2
3
4
5
6
7
8
9
10
11

12
13
14
15
2

Machineshopsareavitalelementofthemanufacturinginfrastructure.Mostmanufacturersofcomplexsystems
nolongersupportanin‐housemachiningoperation.Rather,theyoutsourcetospecialtymachineshopswho
fabricatecomponentstotheirspecifications.IntheUnitedStates,mostmanufacturersrelyontheapproximately
22,000machineshops,whichhavecombinedannualrevenuesof$30billion.Theindustryishighlyfragmented
withnomajorcompanies,andthe50largestgenerateabout15percentofthetotalrevenue.Onlyafewhundred
operationshavemorethan100employees.
3
Assuch,theyareinnopositiontodevelopsophisticatedflexible
manufacturingprocesses.
16 ISSUE:Affordabilityofadvancedhigh‐performancemanufacturingtools,equipment,andprocessesforuseby
enterprisesfordistributed,responsiveproduction.
17
18
19
20
21
22
23
24
25
26
27
28
29

30
31
32
33
34
35
36
37
38
39

LeveragingModelingandSimulation
Traditionally,creatingthescientificinsightneededtoaddressmanufacturingissueshasbeendonethrough
methodsthatrelyheavilyontestinganddemonstration.Whilethisapproachhasbeenverysuccessful,ittakesa
longtimeandisexpensive.Overthepast15years,anewcapabilityhasbeenaddedtotheoryand
experimentationtocreatescientificinsightaboutcomplexphysicalsystems.Withtheadventofveryhigh‐powered
computing,advancedmodelingandsimulationthatisfull‐dimensional,high‐resolution,andbasedonfirst
principalshasprovedinvaluablefordeliveringfasterandmoredetailedinsightsintotheoperationofphysical
systems.
AnexampleisthemodelingandsimulationcentercreatedbytheDepartmentofEnergyOfficeofNuclearEnergy
(NE).
4
TheNEModelingandSimulationHubwillutilizeadvancedmodelingandsimulationcapabilities(e.g.,
computationalfluiddynamics)throughanewmulti‐physicscomputationalcapabilitythatwillprovidepredictive
capabilityforlifeextensionandpowerupratecalculations.After5years,theHubisintendedtoproduceamulti‐
physicscomputationalenvironmentthatcanbeusedbyawiderangeofpractitionerstoconductpredictive
calculationsoftheperformanceofreactorsinthefutureforbothnormalandoff‐normalconditions.TheHub
createsauserenvironmentthatallowsengineerstocreateasimulationofacurrentlyoperatingreactorthatwill
actasa“virtualmodel”ofthatreactor.TheHubwillalsoobtaindatafromthatreactortobeusedtovalidatethe
virtualmodel.Inturn,engineerswillusethevirtualmodeltoaddressimportantquestionsabouttheoperationsof

andsafetybasisforthephysicalreactor.Finally,thecombinationofthevirtualmodelandthephysicalreactorwill
beusedto(1)communicatethepotentialroleofscience‐basedmodelingandsimulationtoaddressnuclearenergy
technologyissuesinthenear,mid‐,andlongtermsand(2)aidwiththedesignandmanufactureofnext‐
generationnuclearpowerplants.ThefirstawardfortheNEModelingandSimulationHubisexpectedtobe
awardedinJune2010.

2
Personalinterviewwithmachineshopproprietor.
3
FirstResearchCorporation,MachineShops,updatedNovember16,2009.
4
See /> DRAFTWorkingPapersVersion040510 2‐3
 DRAFTWorkingPapersVersion040510
MassCustomization1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Oneofthedefinitionsofadvancedmanufacturingreferencestheneedfornewmanufacturingplatformstobe
flexibletorespondtocustomerdemands.Anemergingadvancedmanufacturingconceptsuggestedindiscussions
withexpertsistheabilitytoachievecost‐effective“masscustomization”ofaproduct.Throughadvancesin
complexproductrealizationandsingle‐unitmanufacturing,asdescribedpreviously,masscustomizationis
becomingamoreplausiblereality.Advancedmanufacturingtechniques,suchassolidfree‐formfabrication(often
called“additivemanufacturing”)andlaserprocessing,cancreatecomplex,customproductsandreplacement
partsthatarerequiredtobeproducedquicklyinlowvolumes.
5

Suchadvancesinmanufacturingcouldleadtonewwaysofapproachingpersonalizedmedicineand
biomanufacturingofpharmaceuticals.Somedefinepersonalizedmedicineas“aformofmedicinethatuses
informationaboutaperson’sgenes,proteins,andenvironmenttoprevent,diagnose,andtreatdisease.”

6
Given
limitationsandreducedefficacyofconventionalmedicinesacrossbroadpatientpopulations,manyresearchersare
lookingtowardspersonalizedhealthcarestrategiesandcell‐basedtherapiestobettertargetdiseases.However,
manufacturingtechnologiesfortargetedtherapiesthatmeettheregulatoryandeconomicrequirementsfor
successfulcommercializationarestillinembryonicstages.
Anotherexampleofmasscustomizationthatemergedfromdiscussionswithindustryexpertsisthemanufacturing
ofcustomizableprescriptioneyelenseswithuniquefeatures.Thetechnology,developedbyLuxottica,allowsfor
specialfeaturessuchascoatingsandprogressivelensestobemademorepreciselythroughnewlayering
technologies.Advancesinmanufacturingprocessestocreatedesktopmachineshaveenabledthecompanyto
automatelensmanufacturingforimprovedqualityatalowercost.
OpenInnovationManufacturing
Anotheremergingconceptleveragesthepowerofcollectiveintelligenceandinformationtechnologytocollect
newdesignandmanufacturingstrategiesforproductdevelopment.ArecentarticledescribesaBoston‐based
Company,LocalMotorsInc.,asthefirstopen‐sourceautomotivecompany.
7
LocalMotorsaimstobuildanoff‐
road,butstreet‐legal,vehicletobereleasedinJune2010.ThroughaCreativeCommonslicense,
8
notonlydesign
ideasbutalsodevelopmentandmanufacturingsolutions(mostofwhichwereoff‐the‐shelfcomponents)were
solicitedfromthepublic.Throughwell‐managedcommunityinputaswellastechnologiessuchas3‐Ddesign
softwareandphotorealisticrenderingtechnology,enthusiastsandLocalMotorsemployeesworkedtogetherto
designandbuildacarthat,accordingtothearticle,“putsDetroittoshame.”
Network‐CentricManufacturing
Arecentreport,RationalesandMechanismsforRevitalizingU.S.R&DManufacturingStrategies,arguesthata
majorrequirementforcompetitivenessinmanufacturingisagreateruseofinformationtechnologytomore
effectivelyintegrateallbusinessoperationsinmanufacturingsupplychains.Onemethodofachievingthisgoalis
throughnetwork‐Centricmanufacturing(NCM),definedas:
9



5
GregTassey,“RationalesandmechanismsforrevitalizingUSmanufacturingR&Dstrategies,”JournalofTechnologyTransfer,
publishedonline29Jan2010,availableat />6
SeeNationalCancerInstitute,“DefinitionofTerms,”availableat
/>.
7
ChrisAnderson,“IntheNextIndustrialRevolution,AtomsAretheNewBits,”WiredMagazine,January25,2010.
8
CreativeCommonsisanonprofitorganizationthatworkstoincreasetheamountofcreativity(cultural,educational,and
scientificcontent)in“the commons”—thebodyofworkthatisavailabletothepublicforfreeandlegalsharing,use,
repurposing,andremixing.
9
KennethSabanandJohnMawhinney,“TheImportanceofaBalancedFrameworkinNetworkCentricManufacturing,”DSN
Innovations,availableat /> DRAFTWorkingPapersVersion040510 2‐4
 DRAFTWorkingPapersVersion040510
…the gathering of geographically dispersed organizations via the Internet and information technologies to
fulfill a specific business goal. Such organizations—like Dell, Cisco, Boeing, IBM, and Nike—act more as
designers and system integrators, with a larger percent of manufacturing being done by various
manufacturersintheirsupplychains.
1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

NCMmanagesthemanufactureofproductsthroughouttheirlifecycleswithinanenterpriseinwhichagile
partnersexploitnewcapabilitiesinconnectivity,newskillsincollaboration,andnewstrategiesfornetwork
visibility.
10


Toward“CloudProducing”
OneexampleofNCMwaspresentedinarecentSciencemagazinearticlebyLewisBranscomb.Branscomb
describesaChineseapparelmanufacturer(Li&Fung,aChineseglobalsourcingfirm)thataddressedtheirlow‐
marginproblemwithanapproachtheydescribeas“processorchestrator”.
11
Thecompanydoesnotown
equipment,butbyfocusingonlogistics,theydefineandcustomizetheproductionprocess.Theyworkwithover
12,000suppliersinmorethan40countries,yettheyretainonlyabout14,000employeesoftheirown.
12
Their
relationshipwithpartnerfirmsisbasedonthe“30/30”principle:Li&Fungwillcommittopurchasingatleast30
percentfromapartnerbutwillnotexceed70percentcapacityofthatfirm.Thisensuresthatthepartnerfirmis
viewedassignificant,buttheystillmustgooutsidethenetworktosurvive.Theresultisthateachfirmis
specializedandmustbeabletoinnovate—totakeonnewideas,newvarietiesofskills,andnewproducts.The
assetproductivityofthisarrangementforLi&Fungisveryprofitable.Theyoptimizeonthecollectiveinnovative
capacityoftheirpartnersneededforaspecificproductbyorchestratingthemintoaflexible,agile,andskilled
collaborativesupplychain.
FinalThoughts
Thenewconceptslistedaboveemergedfromourreviewoftheliteratureandinterviewsconductedwithabouta
dozenexpertsfromacademiaandindustry.Whiletheseexpertsgaveexamplesofdifferentnewconceptsand
manyofthemarediscussedabove,oneinsightthatcamefrommostisthatthereisnotechnology“silverbullet”
thatwillresuscitatemanufacturingintheUnitedStates.TheexpertswarnedusthatwhileinvestinginS&Tis
important,itmaybebeneficialtostayawayfrom“buzzword”advanceslike“instantmanufacturing,”among
others.Theadvicegivenwasthatitismoreimportanttoincorporateincrementalbutsystemicchangestothe
manufacturingenterprise.Thisincludesinvestinginearlystagetechnologydevelopment,improvingtheflowsof
knowledgeacrossinterfaces(forexample,throughimprovedpublicprivatepartnerships),bettertrainingof
studentstopreparethemforglobalmanufacturingjobs,andbetterunderstandingandintegrationofcustomer,
manufacturing,andsustainabilityneedsatthedesignphase.Whiletheseconceptsarenotnecessarilyglamorous,
theyarewhattheexpertsbelievewillcreatevalueinthemanufacturingenterprise.




10
BillKessler,EricMittlestadtandJackRussell,InfrastructureinthePossibleFuturesofNetwork‐CentricManufacturing,
NACFAMReport,June2007 />11
LewisM.Branscomb,“ResearchAloneIsNotEnough,”Science,Vol321,August15,2008,availableat
/>12
Li&FungLimitedWebsite: /> DRAFTWorkingPapersVersion040510 2‐5
 DRAFTWorkingPapersVersion040510
 DRAFTWorkingPapersVersion040510 2‐6
1

 DRAFTWorkingPapersVersion040510
Question3:Whatistheappropriateroleof Governmentscienceandtechnology
programsandpoliciesinadvancedmanufacturing?
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

ThenetvalueofgoodsproducedbymanufacturingsteadilyincreasedsincetheendofWorldWarII,butthis
growthappearstohavestalledinthemostrecentdecade.Employmentstatisticsreinforcethispicture,showing
associatedreductionsinemployment,whichdonotappeartofollowtherecoverytrendsofpreviousbusiness
cycles.U.S.manufacturingemploymentpeakedin1979,andemploymentlevelshavefallenby30percentinthe
pastdecade.Whentradeofmanufacturedgoodswithothercountriesisfactoredin,relativecompetitiveness
appearstobeindeclineaswell.In2008,forexample,thetradedeficitformanufacturedproducts,including
advancedtechnologyproducts,was$500billion.
i

Intheearlypartofthepastdecade,thedeclineofthemanufacturingsectorwasseenasanaturalevolutionfrom
anindustrialtoapost‐industrialsociety,andaccordingtosomeexperts,
1

evenapost‐scientificsociety,with
parallelsmadetodecliningemploymentinandincreasingproductivityoftheagriculturesectoratthebeginningof
thetwentiethcentury.Whilecallsformaintainingavibrantmanufacturingbasehavebeenmadeperiodically,
2

othersrecommendedfocusingonthegrowingservicesector.
Intheaftermathofthefinancialandreal‐estatesectorbusts,manyexpertsandpolicymakersareonceagain
lookingtomanufacturingasanewsourceofgrowthandjobs.Theprimaryreasonsofferedarerelatedtoeconomic
strengthandnationalsecurityasexpressedintherecentwritingsofPisanoandShih,
3
Gomory,
4
andTassey.
5

Theseexpertsemphasizethatthemanufacturingsectorproduceswealththroughexports,andprovidesjobsnot
onlytothoseworkinginthemanufacturingsectordirectlybutalsoinothersectors,throughtherippleeffecton
theeconomyingeneral.
ii
Inthedefensesectorespecially,manufacturingisseenasakeystrategicasset.
iii
With
theascentofmanufacturinginothernations,bothasaresultofoffshoringactivitiesandothercountries’domestic
policies,concernsaboutoveralllossofcompetitivenesshavebeenraisedaswell.Someobserverscontendthatas
manufacturingisoffshored,researchanddevelopment,whichistightlylinkedwithmanufacturing,willfollow,and
lossoftheresearchbaseisviewedbythesameobserversasacriticallossfortheU.S.economy.Althoughthere
arethosewhobelievethiscontentionisimmaterial,
6
thereseemstobenearunanimityamongpolicyexpertsthat
somethingneedstobedone.Thechallengenowistoagreeonwhatneedstobedoneandbywhom.

TheU.S.privatesectorhasoperatedlargelyonfree‐marketprinciplesinaglobalizedeconomy,withtheU.S.
Governmentplayingaroleprimarilyinstrategicareaslinkedtothedefenseenterprise.Giventhecomparative
advantagesofferedbysomecountries,suchasChina,inthelatterpartofthetwentiethcentury,privatesector
firmsbeganoffshoringlow‐endmanufacturingactivities.
iv
Proponentsofglobalizationbelievethatthisshiftwas
inevitableandlikelytocontinueinoneformoranother,andthatitisill‐advisedtoerectprotectionistwalls,or
forceU.S.firmsto“bringjobsback.”
7


1
ChristopherHill,“ThePost‐ScientificSociety,”IssuesinScienceandTechnology,24,78(2007).
2
ManufacturinginAmerica:AComprehensiveStrategytoAddresstheChallengestoUSManufacturers,Departmentof
Commerce,2004.
3
GaryPisanoandWillyShih,“RestoringAmericanCompetitiveness,”HarvardBusinessReview,July‐August2009.
4
RalphGomoryonManufacturing,availableat
/>5
GregTassey,“RationalesandmechanismsforrevitalizingUSmanufacturingR&Dstrategies,”JournalofTechnologyTransfer,
DOI10.1007/s10961‐009‐9150‐2.
6
AmarBhide,TheVenturesomeEconomy:HowInnovationSustainsProsperityinaMoreConnectedWorld,2008.
7
SeeManufacturingIndustry,NationalDefenseUniversity,2009;RobertReich,TheFutureofManufacturing,GM,andAmerican
Workers(PartI), />8,2010;HowtoCompeteandGrow:ASectorGuidetoPolicy,McKinseyGlobalInstitute,availableat
 DRAFTWorkingPapersVersion040510 3‐1