FY19_-_H9WC08_Rev_6.pdf

Statement of Work for

Binder Jet Sand Printer

Prepared By:

Ryan Fowler

76 CMXG/MXDER

1 SCOPE.

1.1 Scope. The following sets forth the minimum requirements for the procurement of (1) 3D sand printer, with the intention of printing sand molds for the purpose of casting aluminum and magnesium.

The machine shall include all equipment, software, accessories/cosumables, installation and training necessary to provide the full capabilities described herein.

1.2 Specifications.

Salient Characteristics:

• Buildable volume of no less than 800mm x 500mm x 400mm.

• Shall have a layer height of no more than 500 µm.

• Shall use a phenolic or furan type binding system.

• Shall be able to have a magnesium inhibitor selectively applied during printing process.

• Media that is being printed must be capable of withstanding casting processes of light metals

(i.e. aluminum and magnesium).

• Printer must be able to print silica media, ceramic bead media, and any mixture thereof.

• Printer must have the capability of storing enough printable material (sand/ceramic and binder) to complete at least one job box.

• System must include software specific to the system for slicing STL files or converting STL, STEP, or IGES files to a sliceable format by the software.

• System must include software specific to part orientation and packing within the job box.

• System must include software or a subset of above listed software capable of transferring jobs from the slicing/packing computer to the integrated computer within the printer.

• System must include hardware capable of performing the computation and compiling of the above listed software (i.e. PC).

• Printer must include an embedded computer with available operator interface. This computer must not rely on the external PC for performance of printing tasks

• The printing system shall include two job boxes.

• The system shall include a means of moving a job box that is full in a safe manner.

• The printing system shall include a sand reclamation system capable of sieving and separating reusable powder for future builds.

• The system shall include an unpacking station for removing the completed parts from the loose media bed.

• The system shall include a finishing station for fine removal of excess sand by pneumatic blast, sand blast, or other low pressure means.

• The system shall include all necessary cleaning supplies for normal operation.

• The post-processing system shall include means of collecting any dust generated in the finishing steps (i.e. unpacking, fine sand removal, material reclamation.)

• System must be uncrated, assembled, tested and initially operated by OEM personnel in order to prove initial machine operability, per Equipment section of this technical evaluation.

• OEM must provide, at a minimum, two days of specialized training from a qualified representative in order to familiarize MXDER personnel on standard operation, and to help ensure reliable performance and maximum service life

1.3 Installation.

Delivery Schedule. Within 15 days after receipt of award, the contractor shall provide an expected delivery schedule to a government official for approval.

Transportation. The contractor shall provide for covered transportation of the machines from the point of origin to the installation site at Tinker AFB.

Installation Location. The equipment shall be installed in on Tinker AFB, Building 9001, between Post locations AA-20 and BB-20. Within 15 days after receipt of award, the contractor shall provide drawings specifying locations of the utilities required for the sand printer and its accessories. The drawings shall specify equipment dimensions and required clearances, electrical requirements, waste air extraction requirements, compressed air requirements, and (if applicable) chilled water requirements.

Installation Responsibilities. Installation shall be accomplished by an authorized service technician of the equipment. Responsibilities are as listed below:

The government shall provide electrical, and compressed air, to within twenty-five feet of the location of the printer prior to OEM installation. Once the entirety of the printer, and associated subsystems, have been delivered, an OEM certified installation expert shall assemble, connect, and ensure proper performance of the printer.

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1.4 Calibration.

Calibration Requirements. Contractor’s inspection and test equipment utilized in determining conformity of supplies with contract requirements shall have a current valid calibration traceable to the National Institute of Standards and Technology (NIST). This calibration is to have been performed within the established calibration intervals, not to exceed 12 months, unless the contractor maintains sufficient documented records proving continuing accuracy and control throughout the established interval.

2 REQUIREMENTS.

2.1 General. The supplied equipment shall be new and current commercially available models. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogs or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.1.1 New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer and technical POC in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

2.1.2 Measuring and Indicating Device Graduations. All measuring and indicating devices on the equipment shall be graduated in the inch/pound system.

2.1.3 Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification.

Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

2.1.4 Construction. The equipment shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the equipment to its maximum rating and capacity without distortion.

2.1.5 Maintainability. The equipment shall be designed and constructed to permit Maintenance Personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair. Consistent with required maintenance and design of the equipment, the contractor shall provide any special tools required to service the Unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair, or replacement of parts.

2.1.6 Electrical System. The machine shall conform to NFPA 79. The existing source power available at the facility is 480 volts, three phase, 60 hertz. The machine’s electrical system shall be tolerant of fluctuation of ±10 percent. The electrical system shall be complete. This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. In addition, the contractor shall supply full documentation of the electrical requirements of the machine, including voltage and current requirements and any power conditioning requirements.

2.1.7 Arc Flash. All electrical enclosures shall be marked for arc flash hazard per NFPA 79.

2.1.8 Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1.

Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

2.1.9 Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70. The contractor shall furnish all personnel, equipment and materials necessary to connect the fused deposition modeling machine to Tinker AFB provided "rough-in" 480V electrical and compressed air services that are available within twenty-five (25) feet of final connection points.

Contractor furnished transformers and power supplies shall be of the "shielded type" and all electrical work shall be IAW National Electrical Codes (NEC). The contractor shall provide three sets of installation drawings showing a dimensioned top view of the machining cell, along with applicable electric and air requirements fourteen (14) days ARO to enable government lead time of roughed-in utilities. Equipment grounding requirements should be indicated on drawings and the installation of such grounding requirement shall be the responsibility of the contractor.

2.1.10 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be oil and corrosion resistant. Minimum letter and numeral size shall be 3/16 inch or as indicated by industry standards.

2.1.11 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine.

The plate shall contain the following information:

• Points of lubricant application

• Servicing interval

• Type of lubricant

• Viscosity

• Military or Federal Specification for each lubricant (if applicable)

• Size and type of each lubricant filter

2.1.12 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

• Nomenclature

• Manufacturer's name

• Manufacturer's model designation

• Manufacturer's serial number

• Power input (volts, total amps, phase, and frequency)

• Contract Number

• Date of manufacture

2.1.13 Identification Marking of Military Property. An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture.

The application of Human Readable Information (HRI) shall be used in combination with MRI and free text.

2.2 Equipment.

2.2.1 Machine. The printer shall have a job box capable of printing at least 800mm x 500mm x 400mm.

The layer height shall not exceed 500 µm. The binding system shall be either Furan or Phenolic binders. The printer shall be capable of operating with silica sand, ceramic beads, and any combination thereof. The equipment shall be capable of printing a magnesium inhibiting solution for the purposes of creating molds for magnesium castings.

2.2.2 Post Processing: Included in this purchase shall be any binding system-specific required post-processing equipment for the creation of high quality molds, as well as limiting user exposure to chemicals/dust (i.e., hierarchy of controls). This includes, but is not limited to: gloveboxes, ovens, media recycling systems, etc.

2.3 Accessories.

2.3.1 Material Handling. In addition to printer and associated software (see 3.3.2), the printer shall include material and job handling equipment, such as gloveboxes, job box transportation, dust collectors, and material recycling systems. Also included must be a lifting system for the Super-Sack sized sand delivery system.

2.3.2 Consumables. The printer shall include 3300 pounds of sand and 55 gallons of each binder/activator/cleaning solution(s) in order to perform initial acceptance testing of the printer.

2.3.3 Software. The printer shall include the equipment-specific software for STL processing, i.e. slicing, and job-box arrangement. The software shall require no LAN nor internet access in order to operate.

The software shall come preloaded onto a computer capable of running the machine and software concurrently.

2.4 Technical Data. One (1) hard copy and one (1) electronic copy of technical data shall be provided with the machine. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. One (1) set of installation drawings that identify utility requirements shall be furnished fourteen (14) days ARO and the balance of documentation sets delivered with the fused deposition modeling machine.

2.5 Training. After satisfactory completion of acceptance testing of the system, the services of a qualified technician(s) shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life. The courses shall be performed at customer facility and shall be consecutive, 8 hour workdays, between 8:00 am and 5:00 pm, excluding any federal holidays and weekends. All printed training aids shall become property of the government at the end of the course, and be in the English language. As a minimum, 2 days of specialized training shall be provided.

2.6 Warrantee. The printer shall come with a normal commercial 1 year warranty guaranteeing quality of components and workmanship.

2.7 Maintenance Support Services. Following the expiration of the warranty, the OEM shall provide preventative maintenance (PM). The maintenance shall be performed by OEM certified technicians using new or warranteed-as-new parts. The objective of PM is to protect the equipment capability and investment by removing causes of failure, performing routine maintenance, and making adjustments to compensate for normal wear before failure occurs. PM will include labor, tools, parts, materials, equipment, transportation, travel, and all other incidentals. PM shall be performed a minimum of one time per year.

2.7.1 Over and Above Maintenance: O&A is defined as work discovered during the course of performing the repair efforts that is within the scope of the contract and necessary in order to satisfactorily complete the contract. The Contractor shall complete O&A requirements In Accordance With (IAW) Defense Federal Acquisition Regulation Supplement (DFARS) 252.217-7028. PGI 217.77.

2.7.2 Authorization for Repair Actions: Only the Contracting Officer (CO) can authorize repair actions. The COR will coordinate any repair actions with the Subject Matter Expert (SME) and the CO to obtain approval to proceed. The Contractor shall ensure all repair actions have documented CO approval before initiating any repair or ordering parts.

2.7.3 Service report: Immediately upon completion of the maintenance support services, the Contractor shall provide a written Service Report to the SME. Contractor shall provide, by fax or email, the final service report within five (5) business days to the SME. At a minimum, the final service report shall contain the following information:

• name of the company

• requested service date

• contract number

• equipment ID#

• description of services provided

• additional services recommended (if any)

• printed name and signature of technician who performed the services

• printed name and signature of on-site Government SME or COR

• start and completion dates

• complete breakdown of the labor cost (hours and rate)

• materials and parts used

• details of any other charges

• printed name and signature stating only new parts and materials were used

• written verification statement that a performance check to verify operational condition was performed and that the equipment is in working order.

3 SAFETY REQUIREMENTS.

3.1 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the equipment, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

3.2 Safety Guarding. Covers, guards, or other safety devices shall be provided for the point of operation and all other parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.3 Mercury Restriction. The equipment shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.4 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the equipment.

3.5 Lead. Lead and materials containing lead shall not be used on or in the equipment.

3.6 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

3.7 Environmental Protection & Safety: The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health. The Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

3.8 Contractors shall be compliant with Tinker Air Force Base (TAFB) Supplement to Air Force Instruction (AFI) 32-7086, “Hazardous Materials Management”, Tinker AFB procedures per Tinker Air Force Base Instruction (TAFBI) 32-7004, “Hazardous Waste Management”, and Complex procedures per Oklahoma City Air Logistics Complex (OC-ALC) Sup to AFI 32-7086, “Hazardous Material Management” and OC- ALCI 32-101 “Air Quality Record Keeping Procedure”. Publications are available digitally on e- Publishing website at www.e-publishing.af.mil for downloading or ordering.

http://www.e-publishing.af.mil/

3.9 Material Safety Data Sheet/Safety Data Sheet (MSDS/SDS). Upon Government POC receipt of the “No HAZMAT Usage” certification, the requirements of this section no longer apply. The Contractor shall not transport, ship or use any chemical in the performance of this purchase description (PD) on Tinker AFB before written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Contractor shall submit to the Government POC, ten (10) calendar days after contract award date all Material Safety Data Sheets (MSDSs) or Safety Data Sheets (SDSs) and a completed OC-ALC Form 152, MSDS/SDS Information Sheet. The Contractor shall receive approval from the Government POC prior to shipping any chemical, material or substance to Tinker AFB. A copy of the manufacturer MSDS/SDS shall accompany the shipment. Contractor shall comply with the effective dates for SDS requirements in accordance with the Occupational Safety and Health Administrations (OSHA) Hazardous Communication Standard, Title 29, Code of Federal Regulation (CFR) Part 1910.1200. The Government POC will forward all MSDS/SDS submittals to 72 ABW/CEIE for approval. A current manufacturer MSDS/SDS shall be submitted to the Government POC if the Contractor changes manufacturer or vendor for any chemicals that were prior approved. The Contractor shall maintain copies of manufacturer MSDSs/SDSs for all chemicals and MSDSs/SDSs shall be readily accessible at all times by Contractor personnel as well as government employees.

3.9.1 Hazardous Material (HAZMAT): A list of all HAZMAT material must be submitted within 10 days of award. If no HAZMAT will be brought on base or used in performance on this contract, the contractor shall certify “No HAZMAT will be brought on base” or “No HAZMAT Usage” in writing on company letterhead. This certification shall be provided to the Government POC within ten (10) days after award. Upon Government POC receipt of the certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall not store chemicals or hazardous material (HAZMAT) on Tinker AFB. Contractors shall be compliant with HAZMAT management procedures per Oklahoma City Air Logistics Complex (OC-ALC) Supplement to AFI 32-7086, “Hazardous Materials Management”. The Contractor shall maintain a log of all HAZMAT that is used on base. This usage log shall be provided to the Government POC monthly, the last business day of each month, or when the required work is completed. The Government POC will forward the records to the Unit Environmental Coordinator (UEC) no later than the fourth (4th) day of the following month or the first (1st) subsequent business day.

3.9.1.1 Hazardous Waste: If no HAZWASTE will be generated during performance of this contract, the contractor shall certify “NO Hazardous Waste Generation” in writing on company letterhead. This certification shall be provided to the Government POC within ten (10) days after award. Upon Government POC receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall dispose of contaminated solid waste, spent or processed chemical solutions, used rags and hazardous waste in government furnished waste containers located in the shop or area the work is being performed. The Contractor shall notify the Government POC if the required waste containers are not available on site.

3.9.1.2 Discharges: Any discharges into Tinker’s Industrial Waste Treatment Plant (IWTP) or sanitary sewer will be approved and done IAW Tinker Industrial Waste Water Discharge Permit as instructed by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Government POC will submit the required notice of intent documentation to the UEC for 72 ABW/CEIE approval. The Contractor shall maintain records of written approval issued by 72 ABW/CEIE for discharges into IWTP and sanitary sewer.

3.9.1.3 Off-Site Discharges: The Contractor shall provide a letter ten (10) calendar days after contract award date to the Government POC from the POTW that states the POTW is permitted for all pollutants that the Contractor may discharge during the contracted service.

3.9.1.4 Spills: Upon occurrence of any spill that could enter the storm system or cause any harmful environment effects, the Contractor shall immediately call 911 to report the incident.

When possible, the Contractor shall use a base telephone to receive help from Tinker AFB

911. If using a cell phone, the Contractor shall request Tinker AFB 911. The Contractor shall immediately report all environmental violations to the Government POC and UEC.

The Contractor shall provide five (5) copies of a typed or written report about the incident within four (4) clock hours as follows:

One (1) copy to CO, two (2) copies to the Government POC, a copy for UEC and one (1) copy for record. The format of the report shall be left up to the Contractor, but the report shall contain the following information:

1.) Name and contact number of person reporting the spill 2.) Date and time of incident 3.) Location and source of spill 4.) Substance or pollutant spilled 5.) Amount spilled and rate of discharge 6.) Any damages or injuries involved 7.) Extent of area impacted 8.) Potential hazards 9.) Actions taken 10.) Organizations contacted 11.) Remarks Section - that addresses the cause of the spill (e.g. human error, equipment, etc.) and whether 911 was called and which agencies responded.

3.9.1.5 Environmental Training: Upon Government POC receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply.

Contractor personnel performing duties in the service of this PD shall have training that acquaints the person with the details of Resource Conservation Recovery Act (RCRA) regulations in 40 CFR 260 through 279; applicable State Laws and regulations; DoD, Air Force and local requirements. This training can be obtained through creditable training institutions or companies. All training shall be approved by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). RCRA training is available at http://www.natlenvtrainers.com/RCRA-hazardous-waste.htm;

http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000 and http://www.lion.com/Storing-Hazardous-Waste-for-LQGs at the Contractor’s expense. Prior to obtaining training, the Contractor shall provide the name of the training institution or company and course description to the Government POC for approval within ten (10) calendar days after contract award date.

http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000

Once written approval is received from the Government POC, the Contractor shall provide the environmental training certificates for employees performing duties in the service of this PD to the Government POC, within thirty (30) calendar days after contract award date. In addition to the required environmental training, Contractors shall be compliant with Tinker AFB procedures per TAFBI 32-7004, “Hazardous Waste Management”.

4 QUALITY

4.1 Final Inspection/Acceptance: Inspection and acceptance of the equipment and all additional attachments and accessories shall be performed at destination by the contractor, under the supervision of the receiving activity. Inspection and acceptance shall consist of a type and kind;

quantity; condition; operability.

4.2 Inspection and Test. The contractor shall perform or have performed all inspections (examinations and test) required to substantiate that the supplies provided under the contract conform to the technical requirements for the manufacturer’s item(s) specified in the contract. Within 30 days of award, the contractor shall provide a written Final Acceptance Testing Plan for government approval.

Final acceptance of the printer equipment shall not occur until all line items listed in the Final Acceptance Testing Plan have been successfully completed.

4.2.1 Visual/Dimensional Inspections. Any departure from a specified requirement shall be classified as a defect. Any defect shall be cause for rejection of the entire shipment quantity.

4.2.2 End Item Tests. Failure of a sample unit to pass any test shall be cause for rejection of the entire shipment quantity.

4.2.3 Defects. Any defective item discovered by the Government after shipment may be cause for rejection of the entire contract quantity.

ATTACHMENT #4: GOVERNMENT FURNISHED PROPERTY (GFP)

APPENDIX C: SAFETY SPECIFICATIONS

APPENDIX D: GLOSSARY AND DEFINITIONS

APPENDIX E: ENVIRONMENTAL LANGUAGE

APPENDIX H: RELIABILITY CENTERED MAINTENANCE AND VIBRATION SEVERITY CHART