Attachment 1_ Experimental Purpose Proposal Instructions.pdf

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Attachment 1 – Proposal Instructions for Experimental Purposes: AM Metals Printer and Material Qualification

1.0 INTRODUCTION

These proposal instructions provide specific guidelines for submitting a proposal for evaluation and potential award. The Offeror must ensure its proposal meets all requirements of these proposal instructions.

The Department of the Air Force (DAF) established the Advanced Manufacturing Program Office (AMPO) within the RSO to scale organic capability. Advanced Manufacturing is targeting cost-effective manufacturing processes for Additive Manufacturing (AM) to address supply chain and mission readiness challenges. The solution seeks to acquire two metal printers of models currently owned by the DAF (EOS, GE M2 Series 5 Concept Laser, Velo3D Sapphire) to complete MMPDS equivalent S-basis dataset for a high strength aluminum alloy, such as A6061-RAM2, A7050-RAM2, or A205, sufficient for structural, non-critical applications, demonstrating an ability to use metal AM technologies to fabricate and develop aerospace parts for flightworthy applications and production support application.

The use of any other printer would not yield results that would be useful for the Government to consider for scaling current printers.

It is important to note, that the Government is not obligated to make any award as a result of these proposal instructions and all awards are subject to the availability of funds and successful negotiations. The Government is not responsible for any monies expended by the Offeror prior to the issuance of an agreement award.

The RSO reserves the right to modify any of the proposal requirements and/or proposal instructions at any time.

2.0 FRAMEWORK FOR EVALUATION & AWARD

Section 2.0 describes the methodology for evaluating the proposal and the subsequent agreement award, should an award be made.

2.1 Evaluation Criteria

The Offeror’s proposed solution for an innovative methodology to mature technology solutions and prepare them to Scale will be evaluated using the following criteria:

Federal Agency: Air Force Program Office: AFLCMC/RO “AM Program Office” RFP Number: FA8684-23-9-R001 NAICS: 541330 - Engineering Services RFP Release Date: August 3, 2023 Proposal Due Date: August 8, 2023 11:59am EST

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• Technical:

o The technical merit of the proposed solution to adequately address the RSO’s stated Objectives and Scope that relate directly to the Technology Focus Areas.

o The demonstrated feasibility of the proposed solution to address the Objectives and Scope shall be at mid-maturity (i.e., objectives are 5 or greater for TRL, MRL, SRL, but disruptive technologies are exceptions)

• Price: Price shall be considered to the extent appropriate, but at a minimum, to determine that the price is fair and reasonable.

Technical reviewers will base their conclusions only on information contained in the written proposal. It cannot be assumed that reviewers are acquainted with the Offeror or any information regarding the Offeror not contained in the proposal. Relevant supporting data such as journal articles, literature, including Government publications, etc., may be included or referenced in the proposal.

2.2 Evaluation of Proposed Line of Effort

Section 3.0 provides details as to the anticipated aspects of this effort’s objectives. This includes Statement of Objectives, Objectives & Anticipated Tasks, Technical Environment Information and Assumptions, Program Management Information and Assumptions, Cybersecurity Risk Management, Information Security Information and Assumptions, Operational Security Information and Assumptions (OPSEC), and Personnel Security.

The evaluators will use the criteria listed in Section 2.1 to evaluate the proposal.

2.3 Agreement Type and Period of Performance

If an award is made the resulting award shall be an agreement via the authority of 10 USC § 4023.

The agreement, if awarded, shall have a base effort with a 15-month period of performance with three separate options described below. The Option can run concurrently if supported and funded.

Deliverable Period of Performance Base MMPDS S-Basis 15-month

Option 1 High Strength Aluminum Part Demonstration, S-basis

Bearing and Shear testing and MMPDS equivalent for elevated tensile testing & Prototype part build

12-month

Option 2 C- & D-basis equivalent room temperature tensile testing, Durability and Damage

Tolerance Evaluation of AM High Strength Aluminum

15-month

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Option 3 Testing on Hot Isostatic Pressed (HIP) High Strength

Aluminum

12-month

3.0 STATEMENT OF OBJECTIVES

The AMPO seeks an innovative solution designed to expand on current DAF capabilities to produce aircraft components via metal additive manufacturing. The desired outcome of this solicitation seeks to acquire two metal printers of models currently owned by the DAF (EOS, GE M2 Series 5 Concept Laser, Velo3D Sapphire) to complete MMPDS equivalent S-basis dataset for a high strength aluminum alloy, such as A6061-RAM2, A7050-RAM2, or A205, sufficient for structural, non-critical applications, demonstrating an ability to use metal AM technologies to fabricate and develop aerospace parts for flightworthy applications and production support application. Experimentation on the selected high strength aluminum alloy shall include testing and evaluation of tensile, fatigue, and physical properties (Young’s and shear modulus, mean coefficient of thermal expansion, thermal conductivity, and specific heat) with Minimum 30 tensile tests per orientation and Minimum 54 fatigue samples, i.e., 9 samples for each stress ratio and level combination (3 stress levels and 2 stress ratios). Draft specifications for powder, heat treatment, and material printed in the selected printer will be developed in the base period. This effort is not intended to be an alloy development effort but is an experimental additive manufacturing evaluation utilizing an available alloy.

This effort has three options. The first is to complete the MMPDS S-basis elevated temperature testing, shear and bearing testing, and process development for a printed Part. The second option is to complete of C-D Basis tensile testing dataset and durability and damage tolerance characterization of a high strength aluminum alloy. The third option is for testing Hot Isostatic Pressed (HIP) aluminum and evaluating equivalency with the material developed in options 1 and/or 2.

The proposal shall set forth an innovative solution that addresses all items outlined in Sections 3.0-3.7. The details regarding the proposed solution shall be provided in the Technical Volume of the Offeror’s proposal. Refer to Section 4.0: Technical Volume for further information.

For this effort and all Options, no Government Furnished Property including, but not limited to, printers, powder, materials, build plates, or other hardware/software will be provided.

3.1 Objectives & Anticipated Tasks

The successful Offeror shall manage all efforts and provide associated reporting for the anticipated tasks included in, but not limited to, the following list:

A. Demonstrate an ability to utilize metal AM technologies to fabricate and develop aerospace parts for flightworthy applications and production support applications. Generate and deliver data necessary to support evaluation and certification of the AM process to fabricate these parts.

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B. Purchase, deliver, and install two (2) metal printers, one at the ATTC-ERR (Moraine, OH) and one at ATTC-MG (Warner Robins, GA). OEM training on the printers shall also be provided at both facilities.

• Item 1 - Printer Delivery: ATTC-ERR, OEM printer training

• Item 2 - Printer Delivery: ATTC-MG, OEM printer training

C. Demonstrate and document the ability to use AM process for high strength aluminum alloys, (i.e., understanding of input materials, evaluation of process parameters including but not limited to powder, speed, hatch, contours, build plate preparation, material preparation, post build-heat treat, and/or final machining and finishing. etc.) and the approaches used to assess and validate the efficacy of the technology.

• A001 – Technical Reports – Studies/Services

D. Demonstrate and document the capability to print and process sound test articles with features that are printed at angles below 45° relative to the build plate. Perform an experiment to establish the relationship between surface roughness and the angle of the printed faces relative to the build plate. The test report and material testing data shall demonstrate an understanding of the metal AM process and support AM utilization to fabricate aerospace components.

• A001 – Technical Reports – Studies/Services

E. Develop, document, and deliver test plans to demonstrate and validate technologies, processes, and techniques presented during the agreement effort, and present results in accompanying test reports. The test plan shall be provided to the USAF for approval prior to beginning testing.

• A002 - Test Plans/Test Procedures

F. Develop, document, and deliver powder characterization data and a powder specification. The powder specification shall include but is not limited to the following powder characteristics:

elemental analysis, particle size distribution, morphology/image analysis, and apparent density. The powder data delivered shall consist of the lots characterized for the consolidated material developed within this effort.

• A001 - Technical Reports – Studies/Services

G. Develop, document, and deliver in a summary test report the ability to print and quantify mechanical properties that achieve the minimum requirements to meet MMPDS equivalent S-basis dataset for the selected high strength aluminum alloy sufficient for structural non-critical applications. Testing to include tensile, fatigue, and physical properties (Young’s and shear modulus, mean coefficient of thermal expansion, thermal conductivity, and specific heat).

Minimum 30 tensile tests per orientation. Minimum 54 fatigue samples, i.e., 9 samples for each stress ratio and level combination (3 stress levels and 2 stress ratios). Triplicate measurements of physical properties as a function temperature from three heats.

• A001 - Technical Reports – Studies/Services

H. Develop, document, and deliver a material specification. The material specification shall include heat treatment cycle requirements and material properties as outlined herein and as agreed upon by the USAF and the contractor.

• A001 - Technical Reports – Studies/Services

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I. Develop, document, and deliver the process operating procedures/specifications. Operating procedures/specifications shall include processes for but not limited to preventative maintenance, machine qualification, powder and build preparation, software/hardware configuration, and process controls along with facility/site requirements such as environmental and safety needs.

• A001 - Technical Reports – Studies/Services

J. Develop, document, and deliver a data and knowledge sharing approach that conveys the metal

AM commercial practices, knowledge, and techniques to the USAF. The intent is to use the program to train current and future USAF personnel on the metal AM process from design (part and process) to final product.

• A003 – Briefing Material

K. Develop, document, and deliver live and/or virtual presentations of the innovative solution and its related data.

• A003 – Briefing Material

L. Develop, document, and deliver a data-sharing approach that positions the Government to recommend application of the solution to Airworthiness Panels and cognizant Government program office engineers. This approach shall also provide a plan for transitioning the innovative process and procedures developed under this effort to the Government via training and demonstrations.

• A003 – Briefing Materials

• A005– Training Materials

M. Develop, document, and deliver the test report(s) to demonstrate and validate technologies, processes, and techniques presented during the contracted effort. Report(s) shall also include lessons learned.

• A001 – Technical Report - Studies/Services

N. Develop, document, and deliver a final technical report describing the outcomes of the above effort and the performance improvement of next generation metal AM technology. This report shall include a before/after or from/to that clearly quantifies the improvements next generation metal AM technology has on currently Air Force capabilities, lessons learned, and details on recommendations for future metal AM technology solutions. Briefing Materials should be a summary reporting processing conditions and testing results.

• A004 - Technical Reports – Scientific & Technical Reports Summary

• A003 – Briefing Materials

O. (OPTION 1)

a. Develop, document, and deliver a summary test report quantifying mechanical properties (elevated temperature tensile, shear and bearing strengths) and establishing the minimum properties according to MMPDS S-Basis or recommended test quantities for a high strength aluminum alloy from the baseline effort to support development of an Air Force prototype part. Determine the as-

Page | 6 printed thicknesses at which tensile mechanical properties deviate from bulk printed mechanical properties.

b. Develop, document, and deliver a test plan that describes the specimen quantities corresponding to the types of testing being performed for AF approval prior to beginning testing.

• A002 - Test Plans/Test Procedures

c. Develop, document, and deliver the process to print a high strength aluminum alloy Air Force prototype part, the processing parameters for the prototype part, and the prototype part. The delivery of the prototype shall include the prototype hardware along with all electronic files associated with producing the prototype including but not limited to the CAD solid model, .STL file, build file, drawings, etc.

• Item 3 - Prototype Part and support files

d. Identify the testing relevant to the part being prototyped, provide a plan for testing, and execute upon approval from the AF.

e. Develop, document, and deliver in a test report pre-/post-processing, non-destructive testing methods that are cost effective, timely, and relevant to the production and characterization of the metal AM components. These shall provide data for process qualification/certification as well as support quality assurance functions. These methods shall be “governed by” or relatable to currently accepted industrial testing standards or practices (ASTM, ISO etc.).

f. Develop, document, and deliver in a test report the surface finish techniques determined from experimentation to reduce stress risers on the finished part and minimize post processing of additively manufactured components.

g. Develop, document, and deliver the prototype test report. The test report shall include the ability to print and the process parameters (including but not limited to powder, speed, hatch, contours, etc.) utilized for the prototype. The report shall include quantification and evaluation of mechanical properties of the functioning prototype from coupons extracted from the part and comparison of those results with the sample testing conducted in the base phase of the program.

h. The OPTION 1 work scope shall include the OPTION 1 scope in Section 3.1 and all of Section 3.2-3.7 of the Statement of Work including deliverables.

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P. (OPTION 2)

a. Develop, document, and deliver a test report and material testing data establishing minimums for an AM processed high strength aluminum alloy, from the baseline effort, according to MMPDS C- and D-Basis for room temperature tensile.

b. Develop, document, and deliver a test plan that describes the specimen quantities

c. Develop, document, and deliver a test report for the MMPDS S-basis equivalent for fracture toughness and da/dN curves for fatigue crack growth rate testing following MMPDS guidance. Testing shall include the impact of machined and as printed surfaces on fatigue, fatigue crack growth, and fracture toughness as well as susceptibility to stress corrosion cracking.

d. Develop, document, and deliver in a test report summarizing secondary materials evaluation on additively manufactured components relevant to the intended use of the part. Examples of secondary materials testing include resistance to wear, general corrosion, and stress corrosion cracking. The compilation of the process and testing data shall be provided in a summary report to the USAF and will be utilized by USAF engineers to evaluate the applicability and support certification processes of metal AM for USAF use.

e. The OPTION 2 work scope shall include the OPTION 2 scope in Section 3.1 and

Q. (OPTION 3)

a. Develop, document, and deliver a test plan that describes the specimen quantities

b. Develop, document, and deliver a test report that includes tensile testing to ascertain equivalence or difference from data generated in base program experimentation and option 2 if executed.

c. Develop, document, and deliver a test report that includes an experiment quantifying the impact of HIP on fatigue of machined samples. Other testing to determine equivalence to non-HIP material includes fatigue crack growth and fracture toughness.

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d. Develop, document, and deliver in a summary test report, testing results for a high strength aluminum alloy, from the baseline effort, that has been Hot Isostatic Pressed (HIP). The compilation of the process and testing data shall be provided in a summary report to the USAF and will be utilized by USAF engineers to evaluate the applicability and support certification processes of metal AM for USAF use.

e. The OPTION 3 work scope shall include the OPTION 3 scope in Section 3.1 and

3.2 Technical Environment Information and Assumptions

The Offeror shall use the following information and assumptions regarding the technical environment.

Additive manufacturing operates within an environment regulated by certain published standards, the modification of which is beyond the scope of this effort. Published standards and regulations the technology solution should follow for project success may include, but are not limited to:

a) ASTM F3301 Standard for Additive Manufacturing – Post Processing Methods – Standard Specification for Thermal Post-Processing Metal Parts Made Via Powder Bed Fusion

b) ASTM F3520 Standard Guide for Additive Manufacturing — Design — Post-Processing for Metal PBF-LB1

c) ASTM F3572 Standard Practice for Additive Manufacturing – General Principles – Part Classifications for Additive Manufactured Parts Used in Aviation

d) ISO/ASTM 52930 Additive manufacturing — Qualification principles — Installation, operation, and performance (IQ/OQ/PQ) of PBF-LB equipment

e) ISO/ASTM 52910 Additive manufacturing — Design — Requirements, guidelines, and recommendations

f) AWS D20.1 Fabrication of Metal Components Using Additive Manufacturing Specification

g) T.O. 34A-1-1 Technical Manual- Additive Manufacturing Qualification of Technicians, Machines and Facilities, Rev 10

h) T.O. 34A-2-1 General Procedures and Process Controls – Metals Additive Manufacturing

i) AMS 7002 - Process Requirements for Production of Metal Powder Feedstock for Use in

Additive Manufacturing of Aerospace Parts

j) AMS 7003 – Laser Powder Bed Fusion Process

k) AMS 7025 - Metal Powder Feedstock Size Classifications

l) AMS 7031 - Batch Processing Requirements for the Reuse of Used Powder in Additive

Manufacturing of Aerospace Parts

m) AMS 7032 – Machine Qualification for Fusion-Based Metal Additive Manufacturing

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3.3 Program Management Information and Assumptions

The successful Offeror shall execute program management responsibilities. The Offeror shall plan to execute a project kickoff no later than 14 days after agreement award at a Government facility or virtually, monthly status meetings where we review the Status Report, quarterly Program Management Reviews (PMR)/Technical Deep Dives and complete meeting minutes.

The first PMR shall be held approximately 3 months after agreement award, and the locations of the PMR/Technical Deep Dives shall be split between a Government, successful Offeror location, and/or virtual. An Integrated Master Schedule (IMS) utilizing MS Project will also be required. In addition, the Offeror shall plan to support recurring and ad hoc technical interchange meetings, site visits, test events, and other engagements at Government and successful Offeror facilities as required and complete meeting minutes.

Any assumption made by the Offeror contrary to this shall be clearly articulated as a term/condition in the Offeror’s proposal.

o A003 – Briefing Materials o A006 – Integrated Program Management Data and Analysis Report (IPMDAR) o A007– Meeting Minutes o A009 – Status Report

3.4 Cybersecurity Risk Management

The successful Offeror shall develop, deliver, and revise cybersecurity Risk Management Framework (RMF) artifacts and activities as described in DoDI 8510.01 and AFI 17-101 for the federal information systems. These activities shall be integrated into the solution/system development life cycle (initial design, development, testing, fielding, operation, and sustainment). The content of the RMF artifacts shall contain the necessary documentation required by the USG Information System Security Manager (ISSM) and Information System Owner (ISO) to successfully achieve and maintain an authorization, following the Assessment & Authorization requirements and processes established by the Authorizing Official (AO).

The successful Offeror shall implement and address RMF and all applicable security and continuous monitoring controls. During the controls selection process, the Offeror shall adhere to the latest versions of DoDI 8510.01 and AFI 17-101, in collaboration with the USG ISSM and ISO. The controls are selected based on data types identified by NIST SP 800-60 vol. 1 and 2, as specified in the signed Information Technology Categorization and Selection Checklist (ITCSC) and AO’s Authorization & Assessment implementation process. The Offeror shall ensure the controls are represented and documented in the System Security Plan (SSP) and Plan of Actions & Milestones (POA&M). The system’s information, documentation, detail, data types, and control selections and implementation will be documented in the System’s RMF package.

The successful Offeror shall conduct and deliver the results of the testing of required/determined security controls to ensure they are implemented correctly, operating as intended, enforcing the desired security policies, meeting established security requirements, effectively addressing cybersecurity risks. The testing results shall include information such as the type, depth, and coverage of the testing, identification of tools and approaches used, frequency, and acceptance criteria, as required to achieve authorization determination.

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The successful Offeror shall provide documentation to demonstrate the implementation of appropriate security controls ensuring the security of the system's information and required operational system connections. This documentation should be maintained throughout the system's lifecycle and contain the information necessary for accepting an information system, IT/OT, or Platform IT (PIT) system, enabling an accurate and timely risk determination.

Additional artifacts may be requested to clarify the system security control status, as assigned, and agreed upon between the contractor and the USG.

The successful Offeror shall deliver all documentation electronically via DoD SAFE to the USG ISSM or ISO for review and approval. Subsequently, the approved documents and artifacts must be uploaded into the system-of-record within the System's RMF Package in Enterprise Mission Assurance Support Service (eMASS) no later than 90 calendar days before the end of the agreement. The documents and artifacts should adhere to the approved format or templates provided by the ISSM, ISO, or Government POC, and must be handled and protected according to the system's classification level.

The successful Offeror shall maintain, revise, and deliver the RMF Package and all system security requirements.

o A010 - DoD Risk Management Framework (RMF) Package Deliverables

3.5 Information Security Information and Assumptions

The successful Offeror shall ensure External Certificate Authority (ECA) digital certificates is obtained by all contractor/sub-contractor personnel who require access to DoD computer networks/systems to perform tasks under the agreement.

The successful Offeror shall ensure a Common Access Card (CAC) is obtained by all contractor/sub-contractor personnel who require access to DoD computer networks/systems and DoD installations to perform tasks under the agreement. The successful Offeror shall provide a list of contractor/subcontractor personnel who require a CAC to the PCO. The successful Offeror shall provide a list of Contractor (and/or subcontractor) personnel who require a CAC and other related artifacts to support the investigation(s). The successful Offeror shall assume that all related artifacts and supporting documentation required as part of this scope be due to the Government within 90 days after any resulting agreement.

An authorized user for the purposes of Basic Safeguarding of Covered Contractor Information Systems (Jun 2016) is limited to U.S. Citizens. The successful Offeror shall ensure non-US Citizens are not given access to data. Authorized users with a privileged or admin role will need NIST 8570 credentials and hold a favorably completed Tier-3 (T3) investigation in accordance with Defense Counterintelligence and Security Agency (DCSA) guideline for access levels.

Access to federal facilities and computer systems require the offeror’s personnel to submit to a federal criminal background check which include an FBI fingerprint check. The offeror’s personnel shall comply with any additional local requirements specific to the facility location, or system, of access.

Additionally, the successful Offeror shall comply with DAF standards for storing, processing, marking, and handling unclassified and/or Controlled Unclassified Information (CUI) and

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The Contractor shall implement security measures for all non-DoD information systems or technology where CUI is processed, stored, or transmitted. The Contractor shall ensure contractor facilities are protected in accordance with CFR 32 Part 117, National Industrial Security Program Operating Manual (NISPOM), and DoDM 5200.01.

3.6 Operational Security Information and Assumptions

The successful Offeror shall ensure OPSEC is incorporated into the appropriate area of the agreement IAW DoD Directive 5205.02E, DoD Operations Security (OPSEC) Program and AFI 10-701 DAF OPSEC Program, to include protection of Critical Information (CI). CI is defined as specific facts about friendly intentions, capabilities, or activities needed by adversaries to plan and act effectively against friendly mission accomplishment.

The Contractor shall support the USG by developing/updating the contractor’s program security / OPSEC Management structure, including relationships with corporate hierarchy and program subcontractors and suppliers.

The Contractor shall support the USG by developing/updating an OPSEC Plan which incorporates development, planning, training, assessment, surveys, and readiness training.

Including the results of the five-step OPSEC analysis Identifying CPI; Analyzing Threats, Analyzing Vulnerabilities, Assessing Risk, and Applying Countermeasures, including those aspects of the foreign intelligence threat that are applicable to the specific agreement.

• A008 – Operations Security (OPSEC) Plan

3.7 Personnel Security

The successful Offeror shall ensure applicable successful Offeror personnel have security clearances at the appropriate level for proper accomplishment of the agreement requirements.

The security clearance shall be obtained in accordance with the DD Form 254, Department of Defense Contract Security Classification Specification. The Offeror shall be able to maintain a collateral level Facility Clearance (FCL), through DCSA, at the onset, and through the lifecycle of the agreement. Successful Offeror personnel whose clearances have been suspended or revoked shall immediately be denied access to classified information and/or CUI and classified items.

IT level positions are defined in DoDM5200.02_AFMAN16-1405, Procedures for the DoD Personnel Security Program (PSP)/DAF Personnel Security 16-1405, Section 3. Some IT systems may require IT-Level I and IT-Level II positions which require T5 and T3 investigations. Some performance of duties, which do not require IT-Levels I or II access, only require a favorably completed Personnel Security Investigation also known as a trustworthiness determination; they do not result in clearance eligibility and are known as a Tier-1 (T1). The Tier-5 (T5) and Tier-3 (T3) investigations are submitted through the contractor’s FSO as authorized by a DD-254. The T1 investigations are submitted through the government Security Manager.

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For successful Offeror personnel whom will require military installation access and/or privilege access to the DAF Cloud-One platform: the successful Offeror shall ensure all personnel, who are authorized users of an information technology system, hold a favorably completed Tier-3 (T3) investigation, or National Agency Check with law and credit (NACLC), or Access National Agency Check and Inquiries (ANACI) with collateral level access and receive a current periodic reinvestigation in accordance with DCSA guideline for access levels. Authorized users with a privileged or admin role will also need proper 8570 credentials.

4.0 TECHNICAL VOLUME

Refer to subsection 6.1 of this document for additional formatting instructions.

The Technical Volume should set forth the Offeror’s innovative solution and shall address all items outlined in Sections 3.0-3.7

There is a strict limit of 20 pages for the Technical Volume.

Content beyond the 20-page limit of the Technical Volume shall not be reviewed by the Government evaluation team.

The Offeror shall include all (if any) assumptions, conditions, or exceptions with any of the work scope, anticipated tasks, or terms and conditions of the Statement of Objectives (SOO) detailed in Section 3.0, the required deliverables detailed in Section 4.5, or the Agreement/Contract Data Requirements List (A/CDRL) in Attachment 5. If no technical assumptions are noted in the Technical Volume submitted with the proposal it is assumed that there are no technical assumptions, and that the Offeror takes no exceptions. It is not the responsibility of the Government to seek out and identify assumptions, conditions, or exceptions buried within the submission. The Government reserves the right to negotiate any assumptions, conditions or exceptions that impact or effect the Government’s rights under the resulting agreement.

4.1 Table of Contents

Include a table of contents in the Technical Volume. The table of contents shall not count against the 20-page limit per Technical Volume.

4.2 Glossary

Include a glossary of acronyms and abbreviations used in the proposal in the Technical Volume.

The glossary shall not count against the 20-page limit per Technical Volume.

4.3 Technical Solution

Describe how the proposed solution addresses the AMPO’s stated objectives in Sections 3.0-3.7.

This section should summarize how the Offeror plans to achieve the stated objectives and identify key results and success metrics that performance can be measured upon. State specific time periods when appropriate and be unambiguous about anticipated results. The technical solution shall count towards the 20-page limit per Technical Volume.

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4.4. Statement of Work

The Offeror shall provide a Statement of Work in response all items outlined in Sections 3.0-3.7.

The proposed technology solution shall include an explanation of how the Contractor will manage the effort, to include addressing all tasks related to Identification, Demonstration, and Transition of technologies, processes, and techniques. The Statement of Work shall include the Contractor’s methodology for assessing risks and issues and for integrating and, where applicable, sourcing enabling technologies along with associated processes and techniques for organic DAF production repair capability. The statement of work shall not count against the 20-page limit per Technical Volume.

4.5. Deliverables

Include a section clearly describing all deliverables, to include schedules and quantities. The successful Offeror shall ensure proper control and coordination of all deliverables as proposed and shall be responsible for timely deliveries. The deliverables shall count against the 20-page limit per Technical Volume.

The Offeror shall assume the Government will review deliverables and notify the successful Offeror of findings within 15 workdays. The successful Offeror shall be prepared to meet with the Government team as necessary to review status and other deliverables.

The Offeror shall assume each required deliverable shall be provided with unlimited rights unless, marked according to section 4.6.

Required Deliverables The deliverables listed below are required deliverables for this effort. The Offeror may propose additional deliverables or slightly alter the deliverables proposed below. However, the deliverables must cover the objectives detailed in Sections 3.0-3.7 and must clearly articulate the proposed rights.

Scope: Base Year

A/CDRL Para. Data Item Title/ DID Description Due Date

A001 3.1.C Technical Report – AM Processes

DI-MISC-80508B/T

(Technical Reports – Studies/Services)

The Contractor shall demonstrate and document the ability to use AM process for high strength aluminum alloys, (i.e., understanding of input materials, control of process parameters including but not limited to powder, speed, hatch, contours, build plate preparation, material preparation, post build-heat treat, and/or final machining and finishing. etc.) and the approaches used to validate the efficacy of the technology.

Draft submission: NLT 120 calendar days after agreement award Final Submission: NLT 180 calendar days after agreement award

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3.1. D Technical Report –

Establishment of Limits for Printable Feature Angles

Studies/Services)

The Contractor shall demonstrate and documents the capability to print and process sound test articles with features that are printed at angles below 45° relative to the build plate. Establish the relationship between surface roughness and the angle of the printed faces relative to the build plate.

The test report and material testing data shall demonstrate an understanding of the metal AM process and support AM utilization to fabricate aerospace components.

Draft submission: NLT 120 calendar days after agreement award Final Submission: NLT 180 calendar days after agreement award

3.1.F Technical Report – Powder Characterization & Specification

Studies/Services)

The Contractor shall develop, document, and deliver powder characterization data and a powder specification. The powder specification shall include but is not limited to the following powder characteristics: elemental analysis, particle size distribution, morphology/image analysis, and apparent density. The powder data delivered shall consist of the lots characterized for the consolidated material developed within this effort.

Draft submission: NLT 270 calendar days after agreement award Final Submission: NLT 365 calendar days after agreement award

Technical Report – Mechanical Properties

Studies/Services)

The Contractor shall develop, document, and deliver in a summary test report the ability to print and quantify mechanical properties that achieve the minimum requirements to meet MMPDS equivalent S-basis dataset for the selected high strength aluminum alloy sufficient for structural non-critical applications.

Draft submission: NLT 120 calendar days prior to the end of the base year agreement period of performance.

Final Submission: NLT 60 calendar days prior to the end of the base year agreement period of performance.

3.1.H Technical Report – Material Specification

The Contractor shall develop, document, and deliver a material specification. The material specification shall include heat treatment cycle

Draft submission: NLT 90 calendar days prior to the end of the base year agreement period of performance.

Final Submission: NLT 30 calendar days prior to the end

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Studies/Services) requirements and material properties as outlined herein and as agreed upon by the USAF and the contractor.

3.1. I Technical Report –

Operating Procedure/Specifications

Studies/Services)

The Contractor shall develop, document, and deliver the process operating procedures/specifications.

Operating procedures/specifications shall include processes for but not limited to preventative maintenance, machine qualification, powder and build preparation, software/hardware configuration, and process controls along with facility/site requirements such as environmental and safety needs

Draft submission: NLT 60 calendar days prior to the end of the base year agreement period of performance.

Final Submission: NLT 30 calendar days prior to the end of the base year agreement period of performance draft submissions

3.1.M Technical Report – Validate Technologies

Studies/Services)

The Contractor shall, develop, document and deliver the test report(s) to demonstrate and validate technologies, processes, and techniques presented during the agreement effort.

Report(s) shall also include lessons learned.

Draft submission: NLT 90 calendar days prior to the end of the base year agreement period of performance.

Final Submission: NLT 30 calendar days prior to the end

A002 3.1.E

Test Plan – Demonstrate & Validate

DI-SESS-81704/T

(Test Plans/Test Procedures)

The Contractor shall develop, document and deliver test plans to demonstrate and validate technologies, processes, and techniques presented during the agreement effort, and present results in accompanying test reports.

The test plan shall be provided to the USAF for approval prior to beginning testing.

Draft submission: NLT 45 calendar days prior to start of planned testing.

Final Submission: NLT 15 calendar days prior to start of planned testing

A003 3.1.J Briefing Materials develop, document, and deliver a data and knowledge sharing approach that conveys the metal AM commercial practices, knowledge, and techniques to the USAF. The intent is to use the program to train current and future USAF personnel on the metal AM

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 Calendar days prior to the agreement period of performance.

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DI-MGMT-81605

(Briefing Materials) process from design (part and process) to final product.

3.1.K Briefing Materials

The contractor shall develop, document and deliver presentations of the innovative solution and its related data.

As requested, Materials to be delivered NLT 7 calendar days prior to the event.

3.1.L Briefing Materials

The contractor shall develop, document, and deliver a data-sharing approach that positions the Government to recommend application of the solution to Airworthiness Panels and cognizant Government program office engineers.

This approach shall also provide a plan for transitioning the innovative process and procedures developed under this effort to the Government via training and demonstrations.

As requested, Materials to be delivered NLT 7 calendar

3.1.N Briefing Materials

The Contractor shall develop, document and deliver a final technical report describing the outcomes of the above effort and the performance improvement of next generation metal AM technology.

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 Calendar days prior to the agreement period of

3.3 Project Kickoff Meeting

The Contractor shall present overall agreement plan and details on deliverable achievement. No more than 10 slides for presentation.

NLT 14 calendar days after agreement award.

Presentation to be delivered three business days prior to the event

3.3 Project Management

Review (PMR)/Technical Deep Dive

The contractor shall provide briefing materials, meeting minutes, and action items for each scheduled event.

The review will consist of the cost, schedule, and performance status updates and any other topics the government identifies as a discussion topic prior to the event.

The Contractor shall provide concise documentation describing progress in implementing scope of work to include descriptions of impacts already achieved

The first shall be approximately 3 months after agreement award;

Subsequent meetings shall be quarterly NLT the15th calendar day of the month.

Materials to be delivered 7 calendar days prior to the event.

Page | 17 and potential future impacts.

Each status report shall not be longer than 15 slides.

A004 3.1.N Technical Report – Final Report

DI-MISC-80048

(Scientific & Technical Reports Summary)

The Contractor shall, develop, document and deliver a final technical report describing the outcomes of the above effort and the performance improvement of next generation metal AM technology. This report shall include a before/after or from/to that clearly quantifies the improvements next generation metal AM technology has on currently Air Force capabilities, lessons learned, and details on recommendations for future metal AM technology solutions.

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 Calendar days prior to the

A005 3.1.L Training Materials

DI-ILSS-80872

(Training Materials)

The contractor shall develop, document and deliver a plan for transitioning the innovative process and procedures developed under this effort to the Air Force via training and demonstrations.

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 calendar days prior to the end of the agreement period of performance.

A006 3.3 Integrated Master Schedule

(IMS)

DI-MGMT-81861C

(Integrated Program Management Data and Analysis Report

(IPMDAR))

The agreement shall provide an Integrated Master Schedule including, but not limited to all subtasks/paragraphs, and DID requirements.

NLT 30 calendar days after agreement award; monthly thereafter NLT 15th calendar day of the month following the reporting period.

A007 3.3 Meeting Minutes

DI-ADMN-81250C

(Meeting Minutes)

The agreement shall provide a summary of discussions, decisions, and/or action items.

NLT 5 calendar days after the event

A008 3.6 OPSEC Plan

Operations Security (OPSEC) Plan (DI-MGMT- 80934C)

Develop/update an OPSEC Plan

NLT 60 calendar days after agreement award

A009 3.3 Status Report

DI-MGMT-80368A

(Status Report)

The Contractor shall provide status updates for work accomplished, upcoming work planned, deviations from the baseline plan, and any risks or concerns.

Monthly, NLT 15th calendar day of each month

Page | 18

A010 3.4 RMF Artifact

DOD Risk Management Framework (RMF) Package Deliverables

(DI-MGMT-82001A)

The contractor shall deliver assessments and artifacts for any required cyber and security certifications required for full fielding of the technology with Government coordination and final approval provided by the Government. The Contractor shall coordinate with the government Security point-of-contact on the appropriate format and templates for approval.

Deliveries shall include a Security Plan, an Assessment and Authorization Project Plan, Plan of Action and Milestones, vulnerability scans, security technical implementation guides, a system assessment, and initial checklist.

Final due NLT 90 calendar days prior to end of the Period of Performance

Item 1 3.1.B Printer Delivery: ATTC-

ERR

Printer Delivery: ATTC- ERR and OEM training

NLT 30 days prior to the end of the Period of Performance

Item 2 3.1.B Printer Delivery: ATTC-

MG

Printer Delivery: ATTC-MG and OEM training

NLT 30 days prior to the end of the Period of Performance

Scope: Option 1

A001 3.1.O.g Technical Report – Surface Finish

Studies/Services)

The Contractor shall develop, document, and deliver in a test report the surface finish techniques to reduce stress risers on the finished part and minimize post processing of additively manufactured components.

Draft submission: NLT 60 calendar days prior to the end of the option agreement period of performance.

Final Submission: NLT 30 calendar days prior to the end of the option agreement period of performance.

A002 3.1.O.b Test Plan – Specimen Quantities develop, document, and deliver a test plan that describes the specimen quantities corresponding to the types of testing being

Draft submission: NLT 45 calendar days prior to start of planned testing.

Final Submission: NLT 15 calendar days prior

Page | 19

(Test Plans/Test Procedures) performed for AF approval prior to beginning testing.

to start of planned testing

3.1.O.d Test Plan – Part prototyped

Procedures)

The Contractor shall identify the testing relevant to the part being prototyped, provide a plan for testing, and execute upon approval from the AF.

Draft submission: NLT 45 calendar days prior to start of planned testing.

Final Submission: NLT 15 calendar days prior to start of planned testing

A003 3.3 Project Kickoff Meeting

The Contractor shall present overall agreements plan and details on deliverable achievement. No more than 10 slides for presentation.

NLT 14 calendar days after agreement award.

Presentation to be delivered three business days prior to the event

3.3 Project Management

Review (PMR)/Technical Deep Dive

The contractor shall provide briefing materials, meeting minutes, and action items for each scheduled event.

The review will consist of the cost, schedule, and performance status updates and any other topics the government identifies as a discussion topic prior to the event.

The Contractor shall provide concise documentation describing progress in implementing scope of work to include descriptions of impacts already achieved and potential future impacts.

Each status report shall not be longer than 15 slides.

The first shall be approximately 3 months after agreement award;

Subsequent meetings shall be quarterly NLT the15th calendar day of the month. Materials to be delivered 7 calendar

A004 3.1.O.a Technical Report – deliver a summary test report quantifying mechanical properties (elevated temperature tensile, shear and bearing strengths) and establishing the minimum properties according to MMPDS S- Basis or recommended test quantities for a high strength aluminum alloy from the baseline effort to support development of an Air Force prototype part.

Determine the as-printed

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 Calendar days prior to the agreement period of performance.

Page | 20

Reports Summary) thicknesses at which tensile mechanical properties deviate from bulk printed mechanical properties.

3.1.O.e Technical Report –

Reports Summary)

The Contractor shall develop, document, and deliver in a test report pre- /post-processing, non-destructive testing methods that are cost effective, timely, and relevant to the production and characterization of the metal AM components.

These shall provide data for process qualification/certification as well as support quality assurance functions. These methods shall be “governed by” or relatable to currently accepted industrial testing standards or practices (ASTM, ISO etc.).

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 Calendar days prior

3.1.O.g Technical Report –

Reports Summary)

The Contractor shall Develop, document, and deliver the prototype test report. The test report shall include the ability to print and the process parameters (including but not limited to powder, speed, hatch, contours, etc.) utilized for the prototype. The report shall include quantification of mechanical properties of the functioning prototype from coupons extracted from the part and comparison of those results with the sample testing conducted in the base phase of the program.

Draft submission: NLT 90 calendar days prior to the end of the agreement period of performance.

Final Submission: NLT 30 Calendar days prior

A006 3.3 Integrated Master Schedule (IMS)

DI-MGMT-81861C

(Integrated Program Management Data and Analysis Report

(IPMDAR))

The agreement shall provide an Integrated Master Schedule including, but not limited to all subtasks/paragraphs, and DID requirements.

NLT 30 calendar days after agreement award;

monthly thereafter NLT 15th calendar day of the month following the reporting period.

(Meeting Minutes)

The agreement shall provide a summary of discussions, decisions, and/or action items.

NLT 5 calendar days after the event

Page | 21

A009 3.3 Status Report

DI-MGMT-80368A

(Status Report)

The Contractor shall provide status updates for work accomplished, upcoming work planned, deviations from the baseline plan, and any risks or concerns.

Monthly, NLT 15th calendar day of each month

Framework (RMF) Package Deliverables deliver assessments and artifacts for any required cyber and security certifications required for full fielding of the technology with Government coordination and final approval provided by the Government. The Contractor shall coordinate with the government Security point-of-contact on the appropriate format and templates for approval.

Deliveries shall include a Security Plan, an Assessment and Authorization Project Plan, Plan of Action and Milestones, vulnerability scans, security technical implementation guides, a system assessment, and initial checklist.

Final due NLT 90 calendar days prior to end of the Period of Performance

Item 3 3.1.O.c Deliver Prototype and Support Files

The Contractor shall…