Attachment 1 - PWS.pdf

PERFORMANCE WORK STATEMENT (PWS)

3D Sand Printer

1.0 DESCRIPTION OF SERVICES/INTRODUCTION:

The Naval Surface Warfare Center Carderock Division (NSWCCD) Code 612 requires award of a fixed price 5-year contract (base year with four one-year options) for purchase of a 3D sand printer with associated machine accessories and services including installation, training, and four years of annual preventative maintenance. This purchase supports the NSWCCD’s Rapid Applied Materials and Processing (RAMP) laboratory.

2.0 BACKGROUND:

The NSWCCD Code 612 performs research and development in the areas of metallic alloy development and metallic production practices. To improve research and development capabilities, the Office of the Secretary of Defense Industrial Base Analysis and Sustainment Program (OSD IBAS) has funded NSWCCD to stand up the RAMP laboratory at the NSWCCD Memphis detachment site. Sand printers are becoming increasingly prevalent in the metal casting industrial base. In order to stay relevant with future research and production goals this equipment is required by NSWCCD C/612 to rapidly design and produce complex sand-casting molds and cores.

3.0 OBJECTIVE:

The contractor shall provide materials and services per this specifications document. Note, as the RAMP laboratory will be still undergoing construction at time of contract award, upon award of contract the Government Technical Point Of Contact (TPOC) for the contract will need to coordinate with the contractor to determine the dates for materials delivery and execution of installation and training services.

3.1 Minimum Specifications, Base Contract:

The contractor shall provide one (1) 3D sand printer designed and configured for printing complex sand casting cores and molds with Furan binder resin, foundry sand, and iron oxide additive. The printer must be capable of printing a sand casting mold with minimum dimensions of 38” x 28” x 19” [L x W x H].

The printer must have a large build platform suitable to printing large mold prototypes:

o Minimum Job Box Dimensions [L x W x H]: 70” x 39” x 27” o Maximum External Dimensions [L x W x H]: 35’ x 12’ x 10’ o Minimum External Dimensions [L x W x H]: 16’ x 8’ x 10’

The printer must operate via a cold hardening epoxy resin binder jetting process:

o Layer height: 200 – 500 µm o Binder System: Furan o Print Media: The printer must be capable of printing using a variety of natural and synthetic sands, including but not limited to:

Natural Sand: Silica, Zircon, Chromite Synthetic: Cerabeads o Additives: Iron Oxide The printer must have an integrated touch screen controller to input 3D CAD models of sand molds and cores. The printer should be able to input CAD files without being connected to the network (e.g., via portable hard drive or similar).

The printer must have a single job box on a motorized roller conveyor on the right side of the printer.

The printer must come with a 3-Sand hopper to support printing with multiple sand types in one mold. At a minimum, the printer must be capable of printing with Zircon or Chromite facing sand followed by Silica backing sand.

Electrical Requirements:

o The printer must be able to operate with 480/3/60 input voltage. If a transformer is required to step down the voltage, this must be included (e.g., 400V).

o The system must come with a 480V uninterruptible power supply (UPS) to ensure system protection from power interruptions and failures.

3D Sand Printer Accessories:

o Integrated desanding units on the left and right side of the printer o If applicable, a transformer to step down input voltage (480/3/60) to 400/3/60.

o Recycling sand separator to reclaim unused sand following printing

The separator should come with all applicable to hoses/connections to hook up to the printer o Industrial vacuum cleaner for cleaning work space and as-printed molds and cores The vacuum should come with all applicable to hoses/connections to hook up to the printer o Semi-automated desanding station to quickly desand the job box o The desanding station should be integrated with the recycling system to facilitate material recycling/reclaim o Additive dosing unit for adding uniform amounts of Iron Oxide additive to the sand mold

3.2 Services Requirements, Base Contract:

3.2.1 Installation and Assembly: The contractor shall:

Provide any resources required for equipment installation including, but not limited to, site preparation guides and equipment installation surveys

Unpack and determine placement of the printer.

Complete all necessary assembly/set up of the printer and associated equipment prior to commencing equipment startup. Assembly operations to include, but not limited to:

o Mount printhead to the printer o Install warning light

Perform equipment leveling, as necessary.

Install all connections as required for operation. Including connecting the printer to power from the government’s electrical drop location(s) and connecting to a compressed air drop.

3.2.2 Initial Startup, Inspection, Demonstration and Acceptance:

The contractor shall be responsible for the initial startup of the machine and all associated equipment supplied under this agreement.

The contractor shall demonstrate to NSWCCD personnel that all key functions are operational prior to equipment acceptance. The demonstration shall at a minimum include performing a single test print. The test print will be inspected by the contractor and NSWCCD personnel to ensure dimensionality and strength, within the specifications called out in the Original Equipment Manufacturer (OEM) specifications. After successful completion of the demonstration phase noted above, the Government TPOC or technical representative will accept the machine.

3.2.3 Training:

The contractor shall provide onsite training to a minimum of two (2) NSWCCD employees or NSWCCD contractors. The training is to be held in Bay 1 at the NSWCCD Memphis Detachment (equipment installation location). The training will be a maximum of 3 days and will cover machine operation and maintenance procedures. The contractor shall provide training handouts and materials for standard machine operation and maintenance procedures. Training must, at a minimum, cover basic operation of the printer including but not limited to: refilling sand and epoxy storage, importing a new print, conducting a print, desanding and cleaning.

The training must also cover standard to preventative maintenance required to maintain optimal performance of the equipment between major preventative maintenance visits from the vendor.

3.2.4 Support:

The contractor shall provide engineering support over the phone as needed to answer technical questions arising for the first twelve (12) months after final acceptance of contract requirements.

Support shall be available Monday through Friday between the hours of 0800 and 1700 Eastern Standard Time (EST/EDT).

3.3 Materials and Services, Requirements Options:

3.3.1 OPTION 1. The contractor shall provide annual Repair and Maintenance Services listed below:

3.3.1.1 Online training

The Contractor shall provide self-paced online training resources to all equipment operators, government employees and onsite contractors. Online training should, at a minimum, include site preparation guides, installation surveys, and best practice articles.

3.3.1.2 Onsite training at vendor location

The Contractor shall provide in-person training at vendor location (TBD) to trained operators of the 3D printer. Training should cover advanced operation of the printing equipment and should be run by trained/certified application engineer(s).

3.3.1.3 Email and phone technical support

The contractor shall provide engineering support over the phone and via email as needed to answer technical questions arising for the first twelve (12) months initiation of contract option.

Support shall be available Monday through Friday between the hours of 0800 and 1700 Eastern Standard Time (EST/EDT).

3.3.1.4 Preventative Maintenance

The Contractor shall perform preventative maintenance (PM), including those services listed below, to maintain the system in optimum performance and working condition, in accordance with manufacturer’s specifications and user-selected operating parameters. Maintenance shall be performed in accordance with the OEM’s recommended engineering and maintenance practices.

The contractor shall furnish all supplies, test equipment, tools, etc., required to conduct PM services within the OEM PM kit.

Preventative maintenance services required are as follows:

o OEM-recommended, routine and preventative maintenance in accordance with the OEM recommended replacement intervals, as described in the Operator’s Manual.

o Cleaning, inspection, and testing/verification of mechanical, electrical/electronics, and printing components.

Adjustment, as necessary, of system parameters to within factory specifications.

Inspection and replacement of worn or broken parts and components in accordance with the

OEM recommended replacement intervals, as described in Operator’s Manual.

Repair of any broken or malfunctioning components and equipment.

Verification of equipment capability with standard test print and examine for strength and dimensional tolerance.

3.3.2 OPTION 2. The contractor shall provide annual Repair and Maintenance Services listed in para

3.3.1, above.

3.3.3 OPTION 3. The contractor shall provide annual Repair and Maintenance Services listed in para

3.3.1, above.

3.3.4 OPTION 4. The contractor shall provide annual Repair and Maintenance Services listed in para

3.3.1, above.

4.0 SPECIAL QUALIFICATIONS: N/A

5.0 GOVERNMENT FURNISHED EQUIPMENT/PROPERTY INFORMATION: N/A

6.0 DELIVERABLES: N/A

7.0 SECURITY REQUIREMENTS: UNCLASSIFIED

8.0 PERIOD, PLACE OF PERFORMANCE AND DELIVERY/SHIPPING:

8.1 Period of performance:

The period of performance for base contract materials delivery and services is twelve (12) months following date of receipt of materials.

The period of performance for Option 1 of the contract is twelve (12) months following date of receipt of materials.

The period of performance for Options 2, 3, and 4 is twelve (12) months following subsequent award of options.

8.2 Place of performance:

The Government TPOC will coordinate with the contractor to schedule the specific date for contractor to conduct installation and training services.

The contractor shall perform contract services in Bay 1, the RAMP lab, of the NSWCCD- Memphis Detachment site.

8.3 Delivery/Shipping:

The Government TPOC will coordinate with the contractor to schedule the specific date for materials delivery.

The contractor shall provide Free on Board (FOB) delivery to the destination, below:

o ATTN: Richard Gins, RAMP Lab Naval Surface Warfare Center, Carderock Division – Memphis Detachment Large Cavitation Channel

3001 Harbor Ave.

Memphis, TN 38113

The contractor shall provide the TPOC with tracking information no later than one day after shipping the 3D sand printer.

9.0 GOVERNMENT TECHNICAL POINTS OF CONTACT (TPOCS):

Primary TPOC:

Richard Gins Code 6120 richard.j.gins.civ@us.navy.mil 301-204-2089

Alternate TPOC:

Joshua Strother Code 6120 joshua.d.strother.civ@us.navy.mil

(240) 281-0104

Memphis Detachment POC:

Justin Rishel Code 892 justin.g.rishel.civ@us.navy.mil

(901) 947-3117 x1104