AM Equipment for DSCC-PTC SOW v5.pdf

Statement of Work for

Additive Manufacturing Equipment

DLA Land and Maritime, Columbus, OH

[DLA LOGO]

April 2024

Prepared By:

DLA Electronics Product Test Center

DSCC, Building 11, Section 7

3990 E Broad St

Whitehall, OH 43213

SECTION 1

1.0 SCOPE

The Electronics Product Test Center (EPTC) and Mechanical Product Test Center (MPTC), located at DLA Land and Maritime – Defense Supply Center Columbus (DSCC), currently manufactures fixture hardware for various uses within each test lab. This hardware is manufactured in-house using traditional subtractive manufacturing and is used to provide custom fixturing and positioning jigs for devices under test (DUTs), and for augmenting test equipment setup. The current process is limited by the tools and materials available through basic metal machine techniques which does not allow for a rapid and iterative design-build process that is necessary in the laboratories.

The intentions of this project are multi-part: 1) To provide the PTCs with the ability to rapidly produce bespoke fixturing and harnessing to aid in product testing, 2) To develop technical procedures and understanding within the MPTC for mechanical testing of parts created using additive manufacturing technology, 3) To help develop advanced experience in printing with ultra-high-performance thermoplastics so that DLA Land and Maritime has the in-house skill sets to assist future additive manufacturing needs, and 4) To generate high-resolution physical models of DLA-managed parts to help Product Specialists understand particular issues of form, fit, and function when necessary. These objectives help position both the PTCs and DLA for immediate and future success with regards to additive manufacturing.

SCOPE OF WORK TO BE PERFORMED

Contractor shall be responsible for:

a. Installing a state-of-the-art 3D printer.

b. Providing initial material stock.

c. Installing soluble solution washing equipment.

d. Providing a handheld 3D scanner and corresponding software.

e. Providing initial calibration and testing of installed equipment.

f. Providing computing workstations for the installed equipment and part model generation, modification, and preparation.

g. Providing professional training services for SolidWorks software.

h. Providing professional training services for 3D scanner usage.

i. Conducting initial operation and familiarization training of the installed equipment.

j. Providing environmental requirements for installation spaces prior to installation.

k. Providing ongoing support to include necessary parts and labor for a period of not less than one year

The start of work shall be coordinated as to not interrupt the normal operations of the Electronic

Product Test Center. Use of the shipping dock shall be minimized to allow for other normal operations.

Proof of worker’s compensation, general liability, and automobile insurance shall be submitted prior to the start of the work.

1.1. SITE

The hardware shall be installed in, and training conducted in, Building 11, Section 7 located at Defense Supply Center Columbus (DSCC) in accordance with this

Statement of Work. The address is:

Defense Supply Center Columbus

3990 E Broad St

Building 11, Section 7

Whitehall, OH 43213

The contractor shall make arrangements prior to delivery and training to establish base entry location and procedures.

1.1.1. SITE DESCRIPTION

The system shall be installed in Building 11, Section 7 at the Defense Supply

Center Columbus (DSCC) in the Electronics Product Testing Center in accordance with this Statement of Work.

1.2. SYSTEM LAYOUT AND FUNCTION

3D printer shall be installed in a climate controlled indoor working space which contains the required ventilation and power. The minimum door clearance from the dock to the installation room is 40.5” W x 83” H. The washing station shall be installed in a wet lab space with minimum door clearance of 40.5” W x 83” H.

1.3. TECHNICAL POINT OF CONTACT

The technical point of contact for coordinating delivery, training, and service after the award is made shall be:

Nick Bloom nicholas.bloom@dla.mil

(614) 692-1239

1.4. PERIOD OF PERFORMANCE

Delivery and installation of equipment and materials as described by the contract line items below shall be made to the site within 90 days of the award of the contract.

Training shall be conducted within 90 days of the award of the contract. The maintenance and support contract shall be in effect upon delivery of equipment and shall be available for maintenance and support requests initiated within a period of one

(1) year from delivery of the equipment.

1.5. CONTRACT LINE ITEMS

The offeror shall bid the system with separate prices for each contract line item.

Quantities specified are only estimates and shall be designed and verified by the contractor. The Government shall reserve the right to award each contract line item together or separately to match budget allocations with the maximum system capability. If the Government does not award all the contract line items during the initial award, the Government reserves the right to award each remaining CLIN up to

180 days from the initial contract award.

1.5.1. CLIN NO. 0001 3D Printing System

QTY DESCRIPTION

One (1) each Supply and install a new 3D printing system.

Four (4) each User operations/maintenance manuals for the entire system and initial user familiarization and training

One (1) each 3D model slicing software

One (1) each 3D scanned model correction software

1.5.2. CLIN NO. 0002 Support Material Washing Station

One (1) each Supply and install a new soluble support material washing station to include necessary power cord and plug, and drainage hose

Four (4) each User operations/maintenance manuals for the system and initial user familiarization and training

1.5.3. CLIN NO. 0003 Starter Consumable Supply

Twenty (20) ea. Spools of ASA filament

Ten (10) each

Six (6) each

Spools of ESD-safe ABS filament

Spools of Ultem 9085 filament

Fifteen (15) ea. Spools of soluble support material compatible with ASA and ABS

Three (3) each Spools of support material compatible with Ultem 9085

Fifteen (15) ea. 0.010 in. extruder tips compatible with ASA and ABS

Three (3) each 0.010 in. extruder tips compatible with Ultem 9085

Three hundred

(300) each

Low temperature build sheets

Sixty (60) ea. High temperature build sheets

Five (5) each Containers of soluble solution or solution concentrate

1.5.4. CLIN NO. 0004 Maintenance and Support Contract

One (1) year On-site preventative and corrective maintenance contract for the entire system for one year from the date of installation.

1.5.5. CLIN NO. 0005 SolidWorks Training

Four (4) seats Training services for SolidWorks software.

1.5.6. CLIN NO. 0006 3D Scanner

One (1) 3D scanner for capturing part geometry for use in modeling software and for use in measurements.

One (1) 3D scanner geometry capture software.

One (1) 3D scanner inspection software.

1.5.7. CLIN NO. 0007 3D Scanner Training

Eight (8) seats Training services for 3D scanner geometry capture software.

Eight (8) seats Training services for 3D scanner inspection software.

1.5.8. CLIN NO. 0008 Computer workstations

Three (3) Computer workstations for the 3D printer, 3D scanner, and modeling/development of parts in SolidWorks.

VENDORS SHALL PROVIDE SEPARATE PRICING FOR EACH LINE ITEM

SECTION 3

3.0 REQUIREMENTS

3.1. GENERAL REQUIREMENTS

The general requirements cited herein shall apply to any system or equipment proposed by the contractor. The final design of the system and the capability of the designed system to meet the firm performance requirements of this contract are the responsibility of the contractor. Alternate equipment and system architecture may be proposed by the contractor provided all firm performance requirements specified in Sections 1.0 through

1.5 and 3.1 through 3.6 are satisfied by the proposed design. The contractor shall provide all equipment, material, control components, engineering, and labor necessary to provide completely installed systems ready for operation. The system shall be tested by the contractor prior to performance testing by the Government. All equipment (each whole product with its integral software) shall be the manufacturer’s current, commercially designed, and available product. The commercial product must have proven, successful field application for at least one year immediately preceding the issue date of this solicitation. The field experience of each specific equipment product shall have been gained by an identical or previous model to the one being offered. The design of the specific equipment product offered must be fully defined.

3.1.1. MAINTENANCE AND SUPPORT CONTRACT COVERAGE

The maintenance and support contract shall cover all items considered non-consumable and shall include in-person service to repair or replace non-consumable components that have failed. This coverage shall include necessary calibration or adjustments outside of what is considered required for normal use.

3.1.2. MAINTENANCE AND SUPPORT CONTRACT PROVIDER

Maintenance and support provided under the maintenance and support contract shall be provided by the manufacturer of the equipment or by a third party that is qualified by the manufacturer to provide the maintenance and support.

3.1.3. MAINTENANCE AND SUPPORT CONTRACT RESPONSE

Maintenance and support provided under the maintenance and support contract shall be initiated by the provider within 5 business days of request from the Government. The provider shall make all reasonable efforts to minimize the time the equipment is out of service while in the process of repair or maintenance.

3.1.4. EQUIPMENT AND SOFTWARE COUNTRY OF ORIGIN

All equipment and software shall conform to the Buy American Act

(FAR 52.225).

3.2. 3D PRINTER REQUIREMENTS

3.2.1. 3D PRINTER TECHNOLOGY

The 3D printer shall use fused filament fabrication (FFF) technology, known colloquially as fused deposition modeling (FDM®).

3.2.2. 3D PRINTER BUILD VOLUME

The usable build volume of the 3D printer shall be no less than 14 in. x

14 in. x 14 in.

3.2.3. 3D PRINTER EXTRUDER

The 3D printer shall be designed to use at least two (2) extruders so that a model material and support material may be printed interchangeably without unloading/reloading of the materials and/or extruders.

3.2.4. 3D PRINTER MATERIAL COMPATIBILITY

The 3D printer shall be designed for the use of, at a minimum, the following filament materials:

• Acrylonitrile butadiene styrene (ABS)

• Acrylonitrile styrene acrylate (ASA)

• Polyetherketoneketone (PEKK/Antero)

• Polyetherimide (PEI/Ultem)

• At least one material designed to be electrostatic discharge-safe

(ESD-safe)

• At least one dedicated support material

• At least one ABS or nylon material that contains at least 10% carbon fiber

3.2.5. 3D PRINTER SUPPORT MATERIAL REMOVABILITY

The 3D printer shall be designed to use at least one support material which is soluble in either water or a solution designed for the removal of soluble support material without damage to the model material.

3.2.6. 3D PRINTER BUILD CHAMBER TEMPERATURE

The 3D printer shall be designed with an actively heated and temperature-controlled enclosed build chamber capable of maintaining at least 190 °C.

3.2.7. 3D PRINTER EXTRUDER TEMPERATURE

The 3D printer shall be designed with an actively heated and temperature-controlled extruder capable of maintaining at least 480 °C.

3.2.8. 3D PRINTER SOFTWARE

The vendor shall provide software that is compatible with the 3D printer for model slicing and printer operation, if necessary, which shall be installable on a local computer and shall not require access to cloud or

Internet resources to operate normally. The vendor shall also provide software which allows for the use of 3D scans of previously printed parts to produce output files with corrected geometry for future printing.

Designs loaded into any of the software shall not be transmitted from the computer or printer to any cloud-based or remote resource at any time.

3.2.9. 3D PRINTER FILAMENT SPOOL ENCLOSURE HUMIDITY

The 3D printer shall be designed to store loaded model and support filaments in an enclosure with air that is dried, either actively or passively, to a dew point temperature of no greater than -20 °C. This functionality may be provided by a first-party accessory designed for this purpose.

3.2.10. 3D PRINTER FILAMENT SPOOL SWITCHING

The 3D printer shall be designed to be used with at least two spools of model filament and two rolls of support filament and shall contain a mechanism for automatic switching between spools when one becomes empty. The switching of spools of same-material filament must not end the printing process when spool to be switched to is not empty.

3.2.11. 3D PRINTER HAZARDOUS FUMES OUTPUT

The 3D printer shall not output hazardous fumes and any level that requires the use of respiratory personal protective equipment while printing with any of the materials that the printer is designed to print with.

3.2.12. 3D PRINTER POWER REQUIREMENTS

The 3D printer shall use either single-phase 120V AC power at no greater than 30 Amps or 3-phase 208V AC power at no greater than 30

Amps. If the printer is not designed for such sources, power transformers may be provided to meet this requirement.

3.2.13. 3D PRINTER DELIVERY CLEARANCE

The 3D printer and any accessory devices shall be designed to pass through a door which is 40.5 in. W x 83 in. H during delivery.

3.2.14. 3D PRINTER FOOTPRINT MAXIMUMS

The 3D printer shall fit within a maximum footprint of 55 in. x 40 in.

3.2.15. MATERIAL DRYING SYSTEM FOOTPRINT MAXIMUMS

The material drying system, if included to meet these requirements, shall fit within a maximum footprint of 36 in. x 36 in.

3.2.16. POWER TRANSFORMER SYSTEM FOOTPRINT MAXIMUMS

The power transformer system, if included to meet these requirements, shall fit within a maximum footprint of 36 in. x 36 in.

3.2.17. MAXIMUM SOUND LEVELS

The combined sound level produced by the system, to include any accessories used to meet these requirements, shall be less than 85 dBA when measured 12 inches from any point on any equipment provided as part of this contract.

3.3. CONSUMABLE SUPPLY REQUIREMENTS

3.3.1. FILAMENT COMPATIBILITY

Spools of model and support filament shall be designed to be compatible with the 3D printer. Spools of model and support filament shall be new and the contain the largest amount of filament by weight or volume as is commercially available and compatible with the equipment.

3.3.2. FILAMENT DRYNESS

Spools of model and support filament that are susceptible to performance degradation because of atmospheric humidity shall be supplied in packaging that protects the material from atmospheric humidity until use.

3.3.3. FILAMENT COLOR

When color options exist for a filament, the filament shall be supplied in black. When color options for a filament are not available, the filament shall be provided in its natural color.

3.3.4. FILAMENT SUPPLIER

Spools of model and support filament that are supplied as part of this

SOW shall be first-party materials, when possible. Use of third-party materials to satisfy this SOW is acceptable only when materials manufactured and supplied by the 3D printer manufacturer are not available.

3.3.5. EXTRUDER HARDWARE COMPATIBILITY

Filament extruders, hot ends, tips, and other hardware related to the heating and deposition of model and support filament material shall be designed to be compatible with the 3D printer and the model material used.

3.3.6. BUILD PLATE COMPATIBILITY

If used by the 3D printer design, consumable build plates supplied with this SOW shall be designed to be compatible with the 3D printer and shall be compatible with the materials and/or print processes for the materials ordered in this SOW.

3.4. SUPPORT MATERIAL WASHING STATION REQUIREMENTS

3.4.1. WASHING STATION VOLUME

The support material washing station must be designed for the removal of soluble support material from parts no less than the usable print volume of the 3D printer.

3.4.2. WASHING STATION COVER

The support material washing station must be designed with a removable cover to prevent excessive evaporation of washing solution during use.

3.4.3. WASHING STATION NOISE LEVELS

The support material washing station shall be designed such that the noise levels produced during normal operation do not exceed 85 dBA as measured 12 in. from any point on the equipment.

3.4.4. WASHING STATION POWER REQUIREMENTS

The support material washing station shall be designed to use either single-phase 120V AC power at no greater than 20 Amps or single-phase

230V AC power at no greater than 30 Amps.

3.5. 3D SCANNING SYSTEM REQUIREMENTS

3.5.1. 3D SCANNER RESOLUTION

The 3D scanner resolution shall be no greater than 0.0015 in. for any dimension.

3.5.2. 3D SCANNER ACCURACY

The 3D scanner accuracy shall be better than or equal to 0.001 in. +

0.001 in./ft.

3.5.3. 3D SCANNER FORM FACTOR

The 3D scanner shall be designed for handheld use with a maximum weight of 5.0 lbs. The scanner shall not require structural supports or mechanical linkages to determine its relative or absolute orientation.

3.5.4. 3D SCANNER VOLUME

The 3D scanner shall be designed to scan parts with volumes no less than the maximum volume of parts produced by the 3D printer.

3.5.5. 3D SCANNER CONNECTION

The 3D scanner shall use the Universal Serial Bus (USB) for connection to the host computer or store scan data on industry accepted removable media. If removable media is the only way to transfer scanned data from the scanner, a compatible USB removable media reader shall be provided.

3.5.6. 3D SCANNER LIGHT SOURCES

The 3D scanner shall utilize blue light or lasers for its light sources. No red light or lasers will be permitted as a light source for scanning. If eye protection is required for normal operation, three sets of suitable and certified eye protection shall be included with the scanner.

3.5.7. 3D SCANNER GEOMETRY CAPTURE SOFTWARE

The 3D scanner shall be provided with software designed for use with the 3D scanner that is able to capture part geometry with all the requirements into a Standard for the Exchange of Product Data (STEP) file, Initial Graphics Exchange Specification (IGES) file, or another 3D model file type compatible with industry-leading computer aided design

(CAD) software packages.

3.5.8. 3D SCANNER INSPECTION SOFTWARE

The 3D scanner shall be provided with software designed for use with the 3D scanner that is able to use captured part geometry to provide physical measurement functions to include positional, size, and geometric dimensioning & tolerancing (GD&T) measurements. These measurements shall be made at a resolution and accuracy that is supported by the 3D scanner hardware.

3.5.9. 3D SCANNER LAPTOP

The 3D scanner system shall include a laptop computer from a recognized name-brand manufacturer that has hardware specifications sufficient to meet the recommended hardware specifications for both the

3D scanner geometry capture software and the 3D scanner inspection software. The 3D scanner laptop shall have the geometry capture software and inspection software pre-installed. The 3D scanner laptop shall be provided with the power supply designed for the laptop, a carrying case, and a mouse. Administrative/root credentials shall be provided with the laptop.

3.5.10. 3D SCANNER LAPTOP WARRANTY AND SUPPORT

The 3D scanner laptop shall include a warranty and support service which shall cover replacement parts and labor for defects or failures not of the fault of the DLA Product Test Centers. This warranty and support service shall cover the purchased equipment for a period of not less than two (2) years from the date of receipt of the equipment.

3.5.11. 3D SCANNER TRAINING

The vendor shall provide no less than 40 hours of training on operation of the 3D scanner hardware, 3D scanner geometry capture software, and the 3D scanner inspection software. This training shall be conducted at the 3D scanner installation site (the DLA Electronics Product Testing

Center) for up to eight (8) individuals simultaneously.

3.6. SOLIDWORKS TRAINING

3.6.1. SOLIDWORKS TRAINING SCOPE

SolidWorks training shall include no less than 32 hours of hands-on, instructor-led training per seat. The training curriculum shall be previously developed and shall contain only minor deviations from the previously developed curriculum that are necessary to tailor the service to the needs of the Product Test Centers, if necessary.

3.6.2. SOLIDWORKS TRAINING COMPUTERS

Computers for student use during the SolidWorks training shall be provided by the training provider for the purposes of training. These computers shall include any software and example files necessary to complete the SolidWorks training.

3.6.3. SOLIDWORKS TRAINING MATERIALS

Student materials used in the SolidWorks training to include, but not limited to, physical textbooks, digital textbooks, and example files shall be made available to each student at the conclusion of training.

3.6.4. SOLIDWORKS TRAINING CONTENT

SolidWorks training shall include, at a minimum, the following topics as they apply to SolidWorks: Software user interface, sketches, extrusions, fillets, bosses, ribs, revolutions, patterns, symmetry, assemblies, part editing and modifications, views, sections, contours, parameters, and exporting for 3D printing.