SOW - Additive Manufacturing System.pdf

Version 05/13/2026

Statement of Work Additive Manufacturing System

SECTION I: Background

The Bureau of Engraving and Printing (BEP) Office of Production Engineering (OPE) supports the design, development, and sustainment of specialized equipment used in United States (US).

currency production. As part of this mission, OPE relies on additive manufacturing capabilities to produce machine components and fixtures that support operational efficiency and continuity across BEP facilities. These components may be prototypes for design validation or final production-ready parts used in an industrial manufacturing environment, requiring high precision, durability, and reliability.

The existing additive manufacturing system located at the Washington DC (DCF) facility has reached the end of its supported life and no longer meets current operational and technical requirements. Limited vendor support, increased maintenance issues, and constrained performance capabilities pose risks to ongoing engineering and production activities. To mitigate these risks and sustain mission-critical operations, BEP OPE requires the procurement of one (1) modern additive manufacturing system to replace the obsolete unit, ensuring enhanced capability, improved efficiency, and alignment with current industry standards.

SECTION II: Purpose

2.1 Product, Service or Outcome Needed.

The contractor shall deliver and install a new industrial-grade additive manufacturing system to support the design and fabrication of both prototype and production components which are integral to the currency manufacturing process.

2.2 Scope of the Product, Service, or Outcome.

- Rapid Prototyping and Production

Outcome Needed:

A. Quickly converting Computer Aided Design (CAD) models to physical parts within hours, minimizing lead times

B. Eliminating traditional processes like engineering drawings, procurement cycles, and market research for machine shops.

C. Avoiding delays associated with answering questions from machine shops or dealing with damaged/lost packages.

D. Creating complex parts that aren’t feasible through conventional methods, such as integrated designs that would typically require multiple assembled components.

E. Prototyping and producing small-scale or one-off parts like a metric flange, InfraRed viewer stands, and test fixtures.

F. Manufacturing parts that would be challenging or costly to machine traditionally, quickly and cost-effectively.

SECTION III: Technical Requirements/Tasks/Outcomes

3.1 Specification Requirements

• Additive Manufacturing System with Large Envelope

• The system shall utilize modular, user-replaceable extrusion nozzles or hotend assemblies available in multiple orifice diameters (e.g., ranging from 0.4 mm to 0.8 mm) to optimize print resolution and build speed based on application requirements.

• Support Material: The system shall utilize an open-material architecture or support third-party material profiles to prevent vendor lock-in. The material delivery system must include continuous feed monitoring (e.g., run-out sensors) and accommodate high-capacity filament spools or multi-spool storage to support continuous, unattended printing for extended durations.

• Build envelope capacity must be at least 400 x 350 x 400 mm.

• Must be compatible with electrical configuration: 230VAC (Volts Alternating Current), 3W, 30Amp

• Uninterruptible power supply (UPS) shall be provided with the system.

• System footprint, including all required operational clearances and ancillary equipment necessary for normal operation, shall not exceed 20 square feet of floor space and shall be suitable for installation within the existing workspace constraints at BEP. Contractor shall provide all dimensional, clearance, and utility requirements necessary to support BEP facility site planning, installation, operation and maintenance activities.

• Compressed air requirement maximum: 120 psi

• Material Delivery: System must support continuous and reliable material feed capability suitable for extended or unattended print operations. The system shall provide sufficient material capacity to support continuous printing and shall include automated or user-manageable material monitoring, changeover, or reload capability to minimize print interruptions during long-duration builds.

• The system shall print within an actively heated chamber environment designed to minimize part warping, improve layer adhesion, and maintain dimensional stability during the printing process. The heated build chamber shall be capable of maintaining a minimum operating temperature of 90° Celsius.

• Vendors must provide software to be able to print 3D. Standard Template Library (STL) or similar files using a BEP computer.

• Support removal cleaning station (water based) needed for the removal of soluble support material must be provided with the following specs:

o Must be compatible with electrical configuration: 220 VAC, single phase, 20Amp o System size shall not exceed the following, 37 (W), 31 (D), 41 (H) in.

o Work envelope size shall be greater than the following: 17 x 13 x 15 in.

o Stainless steel tank and basket o Integrated sink and spray faucet for rinsing of parts o Quick-disconnect, appliance-style plumbing o Fast agitation for quick support removal o Programmable for time and temperature with one touch automated control

3.2 Minimum Performance Requirements

The following represent the salient capability, functional, and performance characteristics that the System shall have or must meet:

A. The System should be capable of producing three-dimensional parts from STL and/or VRML data files and other file types like .3mf and. amf that SolidWorks can export for 3D printing in various types of printers.

B. The build envelope capacity must be at least 400 mm x 350 mm x 400 mm and larger capacities are preferred.

C. Parts produced shall have an overall dimensional accuracy of ±0.25 mm, maximum.

D. Parts shall be able to be machined subsequently using conventional machine tools. In particular, the parts must be able to be threaded internally or externally to produce functional threads.

E. Parts made on this System shall have a minimum tensile strength of at least 30 MPa (per ASTM D638) and should have an impact strength of at least 50 J/m (per ASTM D256).

F. The required System must be able to produce parts with holes, overhangs, or other voids either directly or with the aid of a sacrificial filler material.

G. User shall have some control over build speed and strength (e.g. be able to control “print quality” or material density).

SECTION IV: Installation

4.1 Installation

The Contractor shall supply complete and accurate, site preparation information/drawings in sufficient detail to allow the Bureau to prepare the site. The site preparation information shall include the following information at a minimum: equipment layout (plan and elevation views), floor loading (if applicable), utility requirements, location of utility connections, required clearances around the equipment for operation and maintenance, location of mounting points and bearing area, static and dynamic loading of each mounting point, dynamic loading frequency.

Contractor must supply all equipment necessary to produce the complete functional deliverables and the contractor must include any ancillary part of the equipment that is needed to accomplish the success of the project at contract award.

Contractor shall provide a Turn-Key installation, including all rigging, delivery, and installation for the system. Delivery and installation of the equipment shall occur between 7:00 am and 3:00 pm EST, Monday through Friday, excluding holidays. BEP will provide electrical sources for equipment. Contractor shall, at its own expense, provide and maintain insurance while work on a government installation.

SECTION V: Training

5.1 Training

Contractors shall conduct start up procedures in accordance with manufacturer’s instructions to ensure proper performance. Training shall cover system operation and maintenance. The contractor shall conduct two days of software training, and two days of operating training at BEP facility 602-19A Room for five people from 8:00 am to 4:00 pm CST, Monday through Friday:

excluding holidays. A maximum of five (5) BEP employees shall take part in the training. The Contracting Officer Representative (COR) will make training arrangements with the contractor no less than 30 days prior to training.

5.2 Training Plan

5.2.1 The contractor shall submit for approval a training plan to the BEP.

5.2.2 Two (2) months prior to the start of the training, the contractor shall prepare and deliver to the Contracting Officer Representative (COR), a detailed training plan and schedule. The training plan shall include an hourly breakdown of the subject matter to be covered during each training session. One week prior to conducting a class, the contractor will be informed as to the hours that the training sessions will take place.

5.3 Operator Training

5.3.1 The Contractor shall conduct training classes for the operators of the additive manufacturing system, including any subsystems and supporting equipment.

5.3.2 Training shall be sufficient to adequately prepare the operators to safely run the additive manufacturing system independently while meeting the production requirements.

5.3.3 One (1) operator class shall be provided, lasting two (2) days for up to five (5) BEP Subject Matter Experts (SME) and up to three (3) additional BEP specialists may attend as observers

5.3.4 Contractor shall inform the BEP COR thirty (30) days prior to maintenance to coordinate and schedule maintenance and training. The contractor shall provide all training materials to the COR prior to maintenance for review and approval by the BEP. The training shall be in person. All printed training aids shall be provided for the course, be in English language, and become the property of the Government.

5.3.5 Training personnel shall be qualified representative(s) and be proficient in the English language. Contractors shall provide specialized training to familiarize BEP personnel on the operation of the system, parts, and to help ensure reliable performance and maximum service life, during normal usage.

5.4 Software Training

5.4.1 The Contractor shall conduct training classes for the operators of the additive manufacturing system, including any subsystems and supporting equipment.

5.4.2 Training shall be sufficient to adequately prepare the operators to utilize the software application on the additive manufacturing system independently while meeting the production requirements.

5.4.3 One (1) software training class shall be provided, lasting two (2) days for up to five (5) BEP Subject Matter Experts (SME) and up to three (3) additional BEP specialists may attend as observers

5.4.4 Contractor shall inform the BEP COR thirty (30) days prior to maintenance to coordinate and schedule maintenance and training. The contractor shall provide all training materials to the COR prior to maintenance for review and approval by the BEP. The training shall be in person. All printed training aids shall be provided for the course, be in English language, and become the property of the Government.

5.4.5 Training personnel shall be qualified representative(s) and be proficient in the English language. Contractors shall provide specialized training to familiarize BEP personnel on the software of the system to help ensure reliable performance and maximum service life, during normal usage.

5.5 Instructor Qualifications

5.5.1 Instructors shall create a positive learning environment to facilitate the intellectual development of students. Instructors shall have the following qualifications:

- Capable of developing, managing, and delivering training using classroom and hands-on instruction to attain learning objectives in relation to BEP organizational needs.

- Reviewing training materials considering the students’ backgrounds and course objectives to ensure consistency of quality and accuracy of content.

- Ensure a variety of learning styles can be met by selecting appropriate methods and media for instructional delivery.

- Monitoring participant progress and instructional program effectiveness; establishing and maintaining a learning environment to promote student engagement and participation actively and freely.

- Fluent in English and all training materials shall be presented in English.

- Must have successfully completed training in the craft, of which training will be provided, to a level sufficient to be classified at least at the Journeyman level, Master level preferred.

- Possesses full and detailed knowledge, experience, skills, and proficiency with the subject equipment; capability to configure, set up, trouble-shoot, and make adjustments, or adjust settings, etc.

Shall be considered a SME in the area being covered by the training. Continually updating technical knowledge of equipment and techniques within the subject area

5.6 Training Manuals

5.6.1 Product Manual: The contractor shall provide three (3) copies of the equipment manual.

Manual shall include detailed instructions on the full operations of the equipment. And all deliverables must be in English Language.

5.6.2 Service and Maintenance Schedule: Contractor shall provide manufacturer’s recommended schedule information for service and maintenance of equipment.

SECTION VI: Spare Parts

6.1 Spare Parts Listing

A listing of all parts that the contractor recommends the BEP carry in stock to support the operation of the equipment shall be provided. The listing shall be provided in MS-Excel format.

The listing shall include the manufacturer’s part number, detail description of the part, function, lead-time for delivery, estimated mean time for failure/maintenance, recommended quantity, and unit price.

The contractor shall provide any changes or additions to the original spare parts list prior to delivery of the equipment to BEP.

SECTION VII: Equipment Standards

7.1 Equipment Standards

Equipment to be delivered under this contract shall meet all current U.S. commercial codes and industrial standards, or equally stringent international standards, for manufacturing of high-quality industrial equipment, commercial printing presses and finishing equipment to be utilized within an industrial environment. At a minimum, all equipment shall conform to National Electric Code, NEC, standards.

All equipment delivered to the Bureau shall comply with the attached Safety Requirements, see Attachment 0002 - 75D-07.0-06 EHS Requirements for Large Equipment Purchases.

The following is a list of specific standards that machinery supplied under this contract shall meet:

• All applicable sections of American Conference of Government Industrial Hygienists (ACGIH) (www.acgih.org)

• All applicable documents related to Energy Policy Act of 1992 with specific reference to Executive Order 13123 (www.omb.gov)

• All applicable Occupational Safety and Health Administration (OSHA) standards with specific references to OSHA standards 29 CFR 1910 (www.osha.gov)

• All applicable codes and standards and environmental permitting of U.S.

Environmental Protection Agency (EPA) (www.epa.gov) and District of Columbia (DC) government (www.doee.dc.gov) and State of Texas (TX) government (www.tceq.texas.gov).

7.2 DCF Environmental Health and Safety Contractor Requirements

The contractor shall follow the requirements contained in Attachment 0001 - EHS Contractor Requirements 75D-07.0-04 (DCF). This document is included as an attachment to this contract.

The contractor shall follow environmental health and safety instruction communicated to them by the DCF Environmental Health and Safety representatives.

SECTION VIII: Bureau Acceptance Testing http://www.acgih.org/ http://www.omb.gov/ http://www.osha.gov/ http://www.epa.gov/ http://www.tceq.texas.gov/

8.1 Bureau Acceptance Testing

The contractor shall perform a Bureau Acceptance Test (BAT) in accordance with the requirements notated in the SOW. The contractor shall submit for review and approval four week prior of the BAT, a plan for how they propose to demonstrate compliance with system requirements.

Final version of the test plan will be established after award of the contract. The contractor shall review the preliminary BEP test plan, Attachment 3 – Preliminary BAT Plan and shall submit their detailed plan to the BEP for review.

Final acceptance of the system will occur after the following:

1. Successful completion of the BAT

2. Successful Training of all BEP personnel

3. Successful operation by BEP personnel of the equipment in production for at least twenty

(20) days on three (3) shifts or 480 hours without any problems or failures in full compliance with the requirements within this contract.

SECTION IX: Warranty

9.1 Warranty

Contractor shall provide a one-year warranty on machinery and parts for the system. Warranty period shall begin at the completion of equipment assembly and government acceptance of all equipment. Contractor shall respond to any service call during the warranty period within 72 hours of being contacted by the Bureau representative. Contractor shall provide information regarding who to contact during warranty period.

Contractor should provide warranty certification for all equipment two months before warranty begins. Contractors shall also provide a point of contact for equipment. Point of contact shall be knowledgeable on the operation and maintenance of the equipment.

SECTION X: Options

10. 1 Extended Warranty

The Contractor shall provide an optional extended warranty and maintenance support service for the additive manufacturing system for four (4) additional one-year option periods following expiration of the initial one-year warranty period. The extended warranty shall provide comprehensive coverage for machinery, components, replacement parts, labor, software/firmware updates, and technical support necessary to maintain the system in full operational condition.

During each extended warranty option period, the Contractor shall respond to Government service requests within seventy-two (72) hours of notification by the Bureau of Engraving and Printing (BEP) representative. Support services shall include remote technical assistance, troubleshooting, corrective maintenance, and, when necessary, on-site service support by qualified technicians knowledgeable in the operation and maintenance of the system.

The Contractor shall provide all warranty documentation, points of contact, and service escalation procedures two months prior to the start of each extended warranty period. The Contractor shall also identify any exclusions, consumable limitations, or Government responsibilities associated with warranty coverage. All replacement parts provided under the extended warranty shall be new or OEM-certified components compatible with the installed system configuration.

The Government reserves the right to exercise any or all extended warranty option periods in accordance with contract terms and availability of funding. Exercise of an option period shall not obligate the Government to exercise subsequent option periods.

SECTION XI: Deliverables

11.1 Special Delivery Instructions

Performance / Delivery Period. Contractor shall deliver and install the additive manufacturing system to BEP within nine (9) months of contract award. The period of performance includes one (1) base year and four (4) option years for extended warranty. The anticipated period of performance is 30 August 2026 to 29 August 2031.

11.2 Place / Location of Performance / Delivery

SOW

Deliverable Due Date Deliverable Recipient Deliverable Format

3.2

Design Review Meeting 2 weeks after contract award

Tsega.emshaw@bep.gov PDF, Word, Email

4.1 Site Prep Information contract award Tsega.emshaw@bep.gov PDF, Word, Email

5.1 Product Manuals TBD Tsega.emshaw@bep.gov PDF, Word

5.2 Training Plan 2 months before

training to begin Tsega.emshaw@bep.gov PDF

8.1 Preliminary Bureau

Acceptance Test (BAT)

4 weeks prior to

BAT

Tsega.emshaw@bep.gov PDF, Excel, word

10.1 Warranty Certification Two months

before

Tsega.emshaw@bep.gov PDF, Word

Bureau of Engraving and Printing 14th and C Streets, S.W Washington, DC 20228 602-19A Room

The following DELIVERY information must be provided when scheduling delivery appointments: (1) Name of supplier/manufacturer; (2) Contract/Purchase Order #; (3) Total number of items; (4) Total weight (if applicable), and; (5) Date and time of delivery.

Deliveries to WASHINGTON, D.C. ANNEX BUILDING – (LOADING DOCK ON “D”

STREET SW, BETWEEN 13TH & 14TH STREETS SW):

Vendors must call the appointment hotline at (202) 874-2333 twenty-four (24) hours in advance to schedule approximate delivery times. The hotline is manned from 6:30 am to 2:15 pm Monday through Friday. A voicemail message maybe left after normal working hours. Deliveries are accepted between 8:00 am and 2:15 pm, Monday through Friday, excluding holidays.

Over the road vehicles having an overall height exceeding 12’6” (3.8 meters) empty, or an overall length exceeding 42’ (12.2 meters) cannot be accommodated at our receiving platform.

To resolve any delivery issue, please contact Shipping & Receiving at (202) 874-1149 care of Material Handler/Leader.

11.3 Federal Holidays and Year-End Shutdown

The BEP observes all Federal Holidays outlined by the Office of Personnel Management.

BEP observes the federal holidays that are listed on the Office of Personnel website at:

https://www.opm.gov/policy-data-oversight/pay-leave/federal-holidays/. The Presidential Inauguration Day is applicable only to the Washington, DC Currency Facility.

BEP’s Year End Shutdown Period typically occurs December 25th through January 1st of each calendar year.

Government Holidays:

New Year's Day January 1st Martin Luther King's Birthday Third Monday in January Washington’s Birthday Third Monday in February Memorial Day Last Monday in May Juneteenth June 19th Independence Day July 4th Labor Day First Monday in September Columbus Day Second Monday in October

Veterans Day November 11th Thanksgiving Day Fourth Thursday in November Christmas Day December 25th

Deliveries are not accepted on Federal Holidays unless there are extenuating circumstances and arrangements have been made in advance with appropriate BEP personnel.

SECTION XII: Government Furnished Resources and Information

12.1 EHS Requirements: Contracted services & equipment must be performed in a manner consistent with the following Bureau of Engraving and Printing's (BEP) EMS documents: EHS Contractor Requirements 75D-07.0-04 (DCF) and EHS Requirements for Large Equipment Purchases (75D-07.0-06).

END OF SECTION