RFQ Attachment - Requirements.pdf

STATEMENT OF WORK/REQUIREMENTS DOCUMENT

Title: Laser-Wire Hybrid CNC Machine Requesting Lab: Engineering Laboratory

I. BACKGROUND INFORMATION

The Production Systems Group (PSG) in the NIST Engineering Laboratory conducts research in metals-based additive manufacturing (AM) to develop and deploy advances in measurement science that will enable rapid design-to-product transformation. The PSG is expanding its repertoire of additive manufacturing research to include hybrid manufacturing; or the combination of additive and subtractive fabrication processes within one machine. The ‘additive’ technology in these hybrid systems typically employ a category of additive manufacturing technologies called ‘direct energy deposition’ (DED), of which there are subcategories based on the type of material being deposited, or the source of thermal energy used to melt and consolidate the material. To make a ‘hybrid’ process, the DED systems are incorporated into traditional subtractive (i.e., metal-cutting) machining centers.

The PSG aims to procure a laser-wire hybrid manufacturing system to be installed at the Additive Manufacturing Research Center (AMRC) at NIST Gaithersburg, Maryland campus. The PSG has identified laser-wire deposition as a target DED process used by key stakeholders in industry and defense. Furthermore, the PSG has identified research objectives that require the dual-wire DED system to be integrated within a 5-axis computer numerical controlled (CNC) subtractive manufacturing machine, programmable utilizing commercial computer-aided manufacturing (CAM) software.

Purpose/Objective:

The purpose of this requirement is to obtain one (1) laser-wire hybrid CNC system to conduct research that will improve the productivity, efficiency, and usability of hybrid manufacturing systems for U.S. industry. Various aspects of hybrid manufacturing research will be conducted with this instrument, including but not limited to: in-situ process monitoring, part surface metrology, part distortion and geometric accuracy metrology, deposition and cutting parameter development and optimization, cutting mechanics and tool wear, and multi-material deposition.

II. SCOPE

The Contractor shall deliver (1) one, fully integrated and operational laser-wire hybrid CNC system delivered to NIST Gaithersburg campus (2) rigging, assembly, and installation of the system by a trained technician (3) testing and validation of system operation (4) training of NIST personnel on programming and safe operation of the system. All are inclusive of FOB Destination delivery, installation, warranty and training.

III. MINIMUM REQUIREMENTS

The Contractor shall provide a system that meets all technical specifications identified below. All items must be new. Used or remanufactured equipment will not be considered for award. Experimental, prototype, or custom items will not be considered.

The use of “gray market” components are not authorized for sale in the U.S. by the Contractor is not acceptable. All line items shall be shipped in the original manufacturer’s packaging and include all original documentation and software, when applicable.

Requirement 1: 5-axis CNC mill Description: Fully enclosed 5-axis CNC milling machine Quantity: 1

A. Technical Specifications:

a. Size Requirements: The product quoted shall adhere to the following size limitations due to NIST space limitations for the required instrument.

i. Max height of delivery crate/pallet: 86 inches

ii. Max width of delivery crate/pallet: 78.5 inches

iii. Max height (installed): 112 inches

iv. Max width (installed): 125 inches wide, not including chip auger, laser chiller, or other accessory components

v. Max depth (installed): 80 inches depth, not including open chamber door or rear clearance

vi. Max depth (installed): 130 inches depth, including open chamber door and rear clearance.

vii. Max weight of installed system not to exceed 6,500 pounds

b. Motion Axes Requirements: The instrument shall include the following motion axes features:

i. Standard 3-axis (XYZ) system with additional 4th and 5th axis rotary tables

ii. Minimum top spindle speed of at least 10,000 rpm.

c. Electrical Integration Requirements:

i. The 5-axis CNC should include any required electrical transformer to integrate with 220 volt 3-phase electrical supply available at the installation site.

d. Additional Requirements:

i. Shall include flood coolant system

ii. Shall include an automatic lubrication system

iii. Shall include carousel tool changer with at least 4 stations

iv. Shall include chip auger

v. Shall include touchscreen controller

vi. Shall include jog pendant

vii. Shall include work offset contact probing system

viii. Shall include 8 additional M-codes for activating auxiliary components

ix. Shall include chiller plate for workpiece

x. Shall include at least one hard copy or downloadable digital file of hardware manual.

Requirement 2: Laser-wire deposition system Description: Dual wire laser deposition head integrated and fully operational within the 5-axis CNC milling machine (Requirement 1 above)

A. Technical Specifications

a. Laser specifications:

i. Laser power: Minimum of 1000 W total power

ii. Laser chiller shall be included, if required for normal operation of the laser. Laser chiller is not required if not necessary for normal operation of the laser.

b. Wire feed specifications:

i. Deposition head and wire feed shall include dual wire capability.

ii. Shall include heated wire (i.e. hot wire) capabilities.

c. Electrical Integration Requirements:

i. The laser-wire deposition system should integrate with 208-volt single-phase electrical supply available in the designated installation site.

d. Omnidirectional wire feed and laser direction: Focused laser energy shall impinge upon the laser and/or workpiece material simultaneously from multiple directions such that material may be deposited by traversing the deposition head along multiple directions (omnidirectional) without reorienting the deposition head.

e. System with integrated laser shall include all necessary laser safety windows and interlocks to be a Class-I laser system.

f. At least one hard copy or downloadable digital file of hardware manual.

Requirement 3: Software Add-on for Deposition Path Planning via CAM Description: Software add-on that integrates with NIST-owned CAM software (MasterCAM)

A. Technical Specifications

a. Contractor shall provide software add-on to integrate with commercial

CAM software MasterCAM.

b. Software add-on shall enable programming of and visualization of laser-wire deposition toolpaths.

c. Laser-wire deposition processes for Requirement 2 shall be programmable via same Computer-Aided Manufacturing (CAM) software used to program subtractive (e.g., milling) operations of Requirement 1.

d. At least one hard copy or downloadable digital file of software operating instructions

IV. PLACE OF PERFORMANCE

The place of performance is the NIST Gaithersburg, Maryland Campus, Building 304 Room 124. Required products shall be delivered to this location and then installation and training shall be performed at the same site.

V. PERIOD OF PERFORMANCE/LEAD TIME

The Period of Performance shall be no longer than 6 months after contractor receipt of order (ARO). Delivery, installation and training shall occur within 6 months ARO.

Installation and training may take place on a different day than delivery, as mutually agreed between NIST and the Contractor.

VI. DELIVERY TERMS

Delivery shall be F.O.B Destination and shall occur in accordance with the period of performance identified above.

FOB Destination means: The contractor shall pack and mark the shipment in conformance with carrier requirements, deliver the shipment in good order and condition to the point of delivery specified in the purchase order, be responsible for any loss of and/or damage to the goods occurring before receipt and acceptance of the shipment by the consignee at the delivery point specified in the purchase order; and pay all charges to the specified point of delivery. The contractor shall deliver all Line Items to:

National Institute of Standards and Technology Shipping and Receiving 100 Bureau Drive, Building 301 Gaithersburg, MD 20899 NIST Technical POC Brandon Lane

VII. INSTALLATION

The system shall be installed by the Contractor and meet contract specifications at a time mutually agreed between NIST and the Contractor within the award maximum period of performance (6 months). Installation, at a minimum, shall include uncrating/unpackaging of all equipment, rigging, set-up and hook-up of the system, demonstration of all specifications, and removal of trash. Onsite installation and demonstration shall be done at NIST, (Gaithersburg, MD- Building 304 Room 124) All installation requirements are identified below:

VIII. TRAINING

The contractor shall conduct training for up to 5 (five) users on-site at NIST. The training shall provide a thorough demonstration of all system/solution functions, maintenance, data administration, and basic troubleshooting.

The training may be completed at a mutually-agreed upon time at the NIST Gaithersburg, MD Campus Monday – Friday during the operating hours of 8 am to 5 pm immediately after installation and demonstration of specifications. Training must be completed at a mutually agreed between NIST and the Contractor within the award maximum period of performance (6 months).Further training requirements are identified below:

A. Training shall include modules on:

a. Operation of all hardware components required for deposition and subtractive manufacturing processes

b. G-code programming including laser-deposition parameter adjustment

c. CAM software programming for machining and deposition operations

B. Contractor shall provide hard copies of manuals covered during training

IX. INSPECTION & ACCEPTANCE

In addition to the inspection and acceptance terms articulated in FAR 52.212-4, the Government shall verify that the ordered equipment has been delivered, installed, and training has been provided per the specifications identified in this document. Verification shall include successful deposition and machining of a metal part using the ordered system in the presence of the NIST COR. Following positive NIST COR verification, equipment and services will be accepted.

X. WARRANTY

The contractor shall provide a commercial warranty for the entire system for a period of a minimum of 1 year. The warranty shall be in accordance with terms in FAR 52.212-4.

XI. PAYMENT SCHEDULE

Advance payment is not authorized. The Contractor shall invoice in arrears according to a negotiated milestone payment schedule. Upon acceptance of milestones and receipt of a proper invoice, payment will be authorized on a NET30 basis.