Defense Archives - NJII https://www.njii.com/category/defense/ New Jersey Innovation Institute Thu, 01 May 2025 14:21:02 +0000 en-US hourly 1 https://www.njii.com/wp-content/uploads/2020/08/cropped-NJII_icon_red_logo_noBG_square-01-32x32.png Defense Archives - NJII https://www.njii.com/category/defense/ 32 32 New Jersey Innovation Institute (NJII) Announces Sam Gatley as Vice President of Defense Division https://www.njii.com/2025/05/new-jersey-innovation-institute-njii-announces-sam-gatley-as-vice-president-of-defense-division/ Thu, 01 May 2025 14:21:00 +0000 https://www.njii.com/?p=20598 The New Jersey Innovation Institute (NJII), a corporation of New Jersey Institute of Technology (NJIT), is proud to announce the appointment of Sam Gatley as Vice President of its Defense Division. In his new role, ...

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The New Jersey Innovation Institute (NJII), a corporation of New Jersey Institute of Technology (NJIT), is proud to announce the appointment of Sam Gatley as Vice President of its Defense Division.

In his new role, Mr. Gatley will lead NJII’s growing portfolio of defense initiatives, focusing on cutting-edge advancements in technology, workforce development, and applied research to strengthen national security and support the warfighter.

The Defense Division at NJII partners closely with the U.S. Department of Defense, defense contractors, and research institutions to drive innovation in advanced manufacturing, prototyping, and systems integration. Through its work, the division accelerates the development and deployment of critical technologies designed to enhance warfighter effectiveness, improve supply chain resilience, and ensure military readiness. The division also plays a key role in building the next-generation workforce through specialized training programs that prepare individuals for careers in defense manufacturing and technology.

Sam Gatley brings extensive leadership and industry expertise to the position, having worked at the intersection of technology, innovation, and defense throughout his career. His appointment reflects NJII’s commitment to advancing transformative solutions that directly support the needs of the nation’s armed forces.

“We are excited to welcome Sam into this leadership role,” said Dr. Michael Johnson, President of NJII. “Under his guidance, NJII’s Defense Division will continue to expand its impact, driving forward new technologies and manufacturing capabilities that ensure our warfighters have the tools they need to succeed.”

Mr. Gatley will oversee programs that include advanced materials development, additive manufacturing, printed electronics, and modernization efforts critical to the evolving needs of the Department of Defense.

About NJII

The New Jersey Innovation Institute (NJII) is a 501c3 organization wholly owned by the New Jersey Institute of Technology (NJIT). As an independent corporation, NJII is uniquely positioned to be agile, entrepreneurial, and opportunistic. NJII is focused on accelerating technology and fostering innovation in order to have a positive economic impact in New Jersey. To date, NJII has generated over $330M in revenue during its ten years of operation across its divisions (AI/ML, Defense, Entrepreneurship, Healthcare and Learning & Development) and today has a team of 120 staff.

Learn more: https://www.njii.com/about/

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Additively Manufactured Electronics (AME): 3D Printed https://www.njii.com/2025/03/additively-manufactured-electronics-ame-3d-printed/ Tue, 18 Mar 2025 16:47:39 +0000 https://www.njii.com/?p=20460 NJII Defense Printed Electronics staff, located at the Landing 360 COMET Center, have been working with the Institute of Printed Circuits (IPC) Additively Manufactured Electronics (AME) Subcommittee D-67 to establish standards for AME. Standards are used ...

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NJII Defense Printed Electronics staff, located at the Landing 360 COMET Center, have been working with the Institute of Printed Circuits (IPC) Additively Manufactured Electronics (AME) Subcommittee D-67 to establish standards for AME. Standards are used to ensure that printed electronics processes conform to acceptable values. Once standards are published, they can be used to define detailed specifications for inspection, qualification and certification.  In short, standards are the building blocks to increase the manufacturing readiness levels (MRL) of new technology. 

Our team worked on two different IPC task groups; AME Coupons, and the Acceptability of AME Specification. The team developed and printed test coupons with IPC task group members. During regular meetings, the task group reviewed the coupon designs, performed necessary modifications, and worked with IPC to plan future courses of action.  

To date, a suite of 11 different test coupons have been developed to validate AME properties on various equipment types. Some of the factors assessed are: SMT + THT attachment​, Layer bond strength​, Electrical characterization of embedded components (coax, twisted & differential pairs, 3D traces)​, Conductive peel strength​, Moisture and insulation resistance (MIR) ​, Thermal Stress​, and Z-axis registration. Some of these are shown in Figures 1 & 2 below.  

Soon, the task force will be reviewing test methods for printed electronics and the Acceptability of AME Specification. Following the review, documents will be released to other IPC task groups and the public for comments and critique. 

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Advancing Manufacturing: COMET Initiative Welcomes the Stratasys F3300 https://www.njii.com/2025/02/advancing-manufacturing-comet-initiative-welcomes-the-stratasys-f3300/ Wed, 12 Feb 2025 20:49:32 +0000 https://www.njii.com/?p=20384 The Defense Division COMET initiative was established between the US Army – NJIT – NJII to reduce risk in advanced manufacturing. By adding the most advanced equipment to our facility, we can push technical boundaries ...

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The Defense Division COMET initiative was established between the US Army – NJIT – NJII to reduce risk in advanced manufacturing. By adding the most advanced equipment to our facility, we can push technical boundaries through workforce development to ensure that all Army designs repeatably meet stringent specifications. 

The Defense team is excited to share the arrival and installation of the Stratasys F3300 this past December 2024! It joins the current fleet of F900, the Fortus 450 mc, and the F370 CR in our Stratasys cell. Stratasys is an industry leader in Additive Manufacturing (AM) who invented Fused Deposition Modeling (FDM) in 1989. With their first commercial 3D Printer being released in 1992, they have decades of experience and continue to advance their technology. 

The F3300 boasts several improvements including higher throughput resulting in faster print times, a streamlined user interaction including auto calibration for reduced time to start, and, most importantly, a multi-head arrangement.  The multi-head arrangement allows for redundant extruders that reduce the risk of a failed build when a nozzle goes down providing increased uptime, as well as the capability of combining diverse print resolutions and materials within a single build! 

We already have a number of applications for this new capability, and we look forward to discovering even more. If you’d like to learn more about our technology or materials, please reach out to Landing360@NJII.com.

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Kicking Off 2025 with Innovation https://www.njii.com/2025/01/kicking-off-2025-with-innovation/ Wed, 22 Jan 2025 14:59:31 +0000 https://www.njii.com/?p=20333 The Defense Division finished 2024 with a great first week or December at the Defense Manufacturing Conference (DMC) in Austin, TX where we meet with a wide variety of industry and government partners focusing on ...

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The Defense Division finished 2024 with a great first week or December at the Defense Manufacturing Conference (DMC) in Austin, TX where we meet with a wide variety of industry and government partners focusing on improving the Defense Industrial Base (DIB). After a refreshing break over the holidays, we are jumping straight back into meetings and discussions with our partners and industry leaders with our first event of 2025. The 9th Annual Military Additive Manufacturing Summit & Technology Showcase (MilAM) will be held in Tampa, FL from February 11th to 12th, 2025. This event focuses on Additive Manufacturing and how it can be used for the Department of Defense and allies. The importance of the event can be seen by the high level, government speakers that include General Officers from USAF, USMC, US Army, British Army, US Navy as well as Civilians leading Government organizations from the Office of the Assistant Secretary of Defense for Science and Technology (OASD(S&T)) and Defense Logistics Agency (DLA). These leaders will provide guidance and updates on how technology is aiding the warfighter home and abroad. 

Be sure to stop by our booth, #711, to learn more about our Private-Public-Partnership with the US Army, NJIT and NJII to support the COMET Initiative (https://www.militaryam.com/floor-plan

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2024: A Year of Transformation in Advanced Manufacturing  https://www.njii.com/2024/12/2024-a-year-of-transformation-in-advanced-manufacturing/ Mon, 16 Dec 2024 21:16:09 +0000 https://www.njii.com/?p=20233 This year, the advanced manufacturing industry has been a beacon of innovation, adaptability, and resilience, and at the New Jersey Innovation Institute (NJII), we and our partners have been at the forefront of this transformation.  ...

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This year, the advanced manufacturing industry has been a beacon of innovation, adaptability, and resilience, and at the New Jersey Innovation Institute (NJII), we and our partners have been at the forefront of this transformation. 

Pioneering Materials for Extreme Environments 

One of the defining challenges of 2024 has been addressing the need for materials that can withstand extreme environments. From aerospace to defense and energy sectors, the demand for high-performance materials has never been greater. At NJII, our teams are working with leading advanced manufacturing equipment to test new materials, including the work on standards development. Whether part of the ASTM F42 standards for metals additive manufacturing (AM), or developing methods of testing  in IPC subcommittee D-67C-AT for additive manufacturing electronics (AME), the team is pushing technology forward to ensure further adoption.  Organizations are increasingly adopting multi-material solutions to achieve novel applications and performance. This trend is expected to grow as hybrid materials open new possibilities for customized applications. 

Breakthroughs in Additive Manufacturing 

AM continued its evolution this year, with groundbreaking advancements in speed, precision, and scalability. NJII’s state-of-the-art facility was instrumental in testing and validating AM processes for critical applications. A particular highlight was our work in printed electronics to build out training and launching nine AME systems that allowed the team to push the limits of technologies.  By working directly with the original equipment manufacturers (OEMs) NJII has been able to improve workflows and systems, leading to increased capabilities.    For our other focus areas of polymers and metals, the team has operationalized nine and four systems, respectively, providing advanced capabilities in a wide range of materials from low-cost polymers to high strength and heat-resistant metals, such as Inconel 718. The shift toward large-format additive manufacturing has accelerated, enabling the production of larger, complex geometries. Late this year we received our Stratasys F3300, a new, production Fused Deposition Modeling (FDM) system that brings a large build volume, increased speed and repeatability to polymer production. This development is particularly impactful for the defense, aerospace and automotive industries. 

Advancing Digital Twin Technology 

Digital Twin technology has emerged as a game-changer in advanced manufacturing in 2024. By creating virtual replicas of physical systems, manufacturers can simulate, monitor, and optimize processes in real-time. At NJII, we have leveraged Digital Twin technology at the facility and process level to help our partners enhance operational efficiency, reduce downtime, and predict maintenance needs with unprecedented accuracy. This approach has been particularly impactful in sectors like aerospace and energy, where precision and reliability are paramount.  The adoption of Digital Twin technology is expected to accelerate as more companies recognize its potential to drive innovation and cost savings. By combining real-time data with predictive analytics, Digital Twins are enabling manufacturers to stay ahead in a highly competitive landscape. 

Workforce Development: Building Tomorrow’s Talent 

The rapid pace of innovation has underscored the critical importance of upskilling the workforce with hands-on learning. This year, NJII launched multiple training programs focused on developing student talent in advanced manufacturing techniques, digital tools, and quality assurance. These initiatives are not only bridging the skills gap but are also fostering a culture of continuous learning and adaptability.  There is a growing emphasis on integrating soft skills training alongside technical education. As collaboration between humans and machines deepens, skills like problem-solving, adaptability, and teamwork are becoming essential.  During the summer intern program, a multi-disciplinary group of 19 students were tasked with designing a closed reconnaissance system capable of operating in extreme environments. The team was composed of students from a wide range of STEM fields, including mechanical, electrical, chemical, software, and computer engineering, as well as industrial design and human-computer interaction. Their final project, the W.A.R.D.E.N. system (Wireless Assessment Rover with Drone Extended Network) was a closed mesh network comprised of an unmanned ground rover and aerial drone used to conduct reconnaissance. The drone acts as a network extender for the rover and is used to extend the system’s range. The drone can also be used for additional surveillance. Both vehicles also have the ability to carry payloads such as additional batteries, sensors, or supplies. 

Sustainability: Localization and Reduction of Waste 

Sustainability has become a strong benefit of advanced manufacturing. NJII is working with local, small businesses through a NJ State program offered by Commission on Science, Innovation and Technology (CSIT) to support their manufacturing needs. Our team is able to decrease their product development time and reduce the need for shipments from around the globe.  Another benefit from advanced manufacturing is the reduction of waste, this can be seen significantly in metals and electronics. For example, with metals manufacturing when using CNC to mill a part it starts with a block (billet) of metal and is cut away from that block, when parts are complex this can result in a large amount of waste in the form of metal chips. By using metal AM Cold Spray or Directed Energy Deposition (DED) a near net shape can be produced and CNC can be used to remove only a small amount of material to bring the part to tolerance. Within the AME space, electronic components can be reduced in size and using additive manufacturing compared to traditional methods we are reducing waste.  Traditional components would be milled to reduce conductive material, such as copper or silver, therefore placing only the material needed for the conductive trace eliminates wasted material.   

Looking Ahead 

As we look toward 2025, the potential for advanced manufacturing remains vast. NJII is steadfast in the commitment to pushing the boundaries of what’s possible, leveraging cutting-edge technology, fostering collaboration, and driving innovation. Together with our partners, we are shaping a future where advanced manufacturing is not just a tool for production but a catalyst for global progress. 

Thank you to all our collaborators, researchers, and stakeholders who made 2024 a landmark year. Here’s to another year of groundbreaking achievements in advanced manufacturing! 

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New Metal Alloys for Additive Manufacturing: Optimizing Process Parameters for Powder Bed Fusion Using Volumetric Energy Density https://www.njii.com/2024/11/new-metal-alloys-for-am-blog/ Fri, 01 Nov 2024 15:13:22 +0000 https://www.njii.com/?p=20011 One of the promises of additive manufacturing (AM) is that the process parameters can be changed to accommodate a wide range of metal alloys. However, getting started can be daunting.  Typically, researchers will start by ...

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One of the promises of additive manufacturing (AM) is that the process parameters can be changed to accommodate a wide range of metal alloys. However, getting started can be daunting.  Typically, researchers will start by using process parameters that were successful on another alloy with a similar composition. The question though is, “What happens if that fails spectacularly?”

Over the past decade, DEVCOM-AC and New Jersey Institute for Technology (NJIT) researchers have relied on a concept called volumetric energy density (VED)  to help set boundaries on which parameters to change to optimize the density of a new metal. The VED relies on the laser power (Watts), laser scan speed (mm/s), hatch distance (mm) and layer thickness (mm) to calculate how much energy is going into melting the metal alloy within the AM machine, shown below.

VED = P/vhd
P= laser power, Watts
v = laser scan speed, mm/s
h = hatch distance, mm
d = layer thickness, mm

Within the VED construct, if a researcher is limited to having only 1 laser power setting it is still possible for them to vary the VED by changing the laser scan speed (v) or hatch distance (h).  This helps to increase or decrease energy within a certain volume using available equipment.

Once the variations in process parameters have been selected for the design of experiments (DOE), building parts can begin.  To save money on powder, it is recommended that a few small cubes (~15mm – 20mm) be built in various points on the build plate to show the dependency of location.

Once the cubes have been produced and removed from the build plate, obvious defects such as delamination should be noted. Typically, but not always, if the process parameters do not work well for small cubes they will not work well for larger parts.  However, for cubes that remain intact more investigation needs to be done to determine which process parameters produced cubes with the highest relative density.  Density can be measured using the Archimedes Principle or by visually inspecting polished metallurgical specimens and checking for porosity.

Running this DOE several times can confirm the consistency of the results.  Once a researcher is satisfied, the next step would be to produce larger specimens which are properly heat treated to commence other physical and mechanical testing. 

Interested in learning more about how to use Volumetric Energy Density for AM process optimization with NJII Defense?  Contact one of our experts today!

References

Jelis, E., Hespos, M.R., Feurer, M. et al. Development of Laser Powder Bed Fusion Processing Parameters for Aermet 100 Powder. J. of Materi Eng and Perform 32, 7195–7203 (2023). https://doi.org/10.1007/s11665-022-07638-y

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What is Thermal distortion and why is it a problem in additive manufacturing?  https://www.njii.com/2024/10/what-is-thermal-distortion-tools-why-is-it-a-problem-in-additive-manufacturing/ Thu, 10 Oct 2024 20:04:46 +0000 https://www.njii.com/?p=19956 NJII’s Defense Division is at the forefront of Advanced Manufacturing, particularly in the realm of additive manufacturing (AM). Through our partnerships with both public and private defense organizations, we focus on delivering cutting-edge solutions to ...

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NJII’s Defense Division is at the forefront of Advanced Manufacturing, particularly in the realm of additive manufacturing (AM). Through our partnerships with both public and private defense organizations, we focus on delivering cutting-edge solutions to enhance military readiness and national security. 

What is Thermal Distortion? 

Thermal distortion refers to the deformation of a material due to uneven heating and cooling during the additive manufacturing process. This phenomenon is especially common in metal 3D printing, where intense heat from lasers or electron beams is applied to build layers. As the material cools, it can contract non-uniformly, leading to warping or internal stresses. According to research from Penn State University, thermal distortion stems from localized heating and can result in significant dimensional inaccuracies in AM parts. This can impact the mechanical properties of the part, potentially causing defects or failures. 

How Does Thermal Distortion Create Problems for Advanced Manufacturing? 

Thermal distortion poses a significant challenge to the quality and reliability of parts produced via additive manufacturing. In defense applications, where precision and strength are paramount, even slight deviations can render a part unusable. According to the aforementioned study, thermal distortion can lead to cracks, residual stresses, and dimensional inaccuracies. These issues complicate post-processing steps and may result in costly material waste and production delays. Ultimately, this hampers the efficiency of AM in producing high-performance components required in defense applications. 

How Can We Mitigate Thermal Distortion and Produce Better Results? 

Mitigating thermal distortion requires an approach developed by NJIT and the DEVCOM – Armaments Center1, to build small cubes first and ensure that voids and defects are minimized.  This helps to optimize process parameters while reducing the amount of powder that is wasted. With the increase in physical processing studies to build up the materials properties databases, it possible now to use computational tools. 

NJII is committed to leveraging data-driven methodologies and advanced simulation tools to mitigate thermal distortion in additive manufacturing. By integrating these approaches into our Defense Division’s AM processes, we aim to enhance part reliability, reduce material waste, and streamline production. As we continue to refine our techniques, we are confident that our AM capabilities will become even more efficient and robust, ensuring superior outcomes for our defense partners. You can learn more about NJII’s Defense Division by viewing our homepage

  1. Jelis, E., Clemente, M., (Clark) Kerwien, S. et al. Metallurgical and Mechanical Evaluation of 4340 Steel Produced by Direct Metal Laser Sintering. JOM 67, 582–589 (2015). https://doi.org/10.1007/s11837-014-1273-8 

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Tensile Testing Additively Manufactured Metals: The Criticality of Standardized Test Methods https://www.njii.com/2024/09/tensile-testing-additively-manufactured-metals-the-criticality-of-standardized-test-methods/ Wed, 11 Sep 2024 18:33:09 +0000 https://www.njii.com/?p=19831 When working within the rapidly accelerating field of materials engineering, especially for defense applications, knowing the strength of your material is critical. Additive manufacturing (AM), also known as 3D printing, has revolutionized metal production. However, ...

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When working within the rapidly accelerating field of materials engineering, especially for defense applications, knowing the strength of your material is critical. Additive manufacturing (AM), also known as 3D printing, has revolutionized metal production. However, to ensure these materials meet the rigorous demands of defense applications, tensile testing is essential. 

Tensile testing allows engineers to assess how materials perform under stress by stretching them until they break. This process helps identify key characteristics such as tensile strength, yield strength, and ductility which are essential to develop engineering design ‘allowables’. In the Defense Division at New Jersey Innovation Institute (NJII), we emphasize using defined standards to ensure that additively manufactured metals can withstand extreme conditions, such as those encountered in military and aerospace environments. 

Why Tensile Testing Matters in Additive Manufacturing 

Additive manufacturing offers the unique advantage of creating complex geometries that traditional manufacturing methods cannot achieve. But with these new possibilities come new challenges. Metals produced through AM processes, such as laser powder bed fusion or directed energy deposition, often exhibit different mechanical properties compared to conventionally produced metals – even when accounting for similar alloy compositions. Factors such as build orientation, number of parts on a build plate, surface roughness, residual stresses and how the parts are removed from the build plate can affect the final product’s strength and performance.  

Tensile testing provides vital information but performing it in a standardized way, using ASTM E8/E8M, for example, is critical so that the information can reproduced.  Therefore – even before tensile testing starts – it is essential that the metal AM parts be heat treated properly according to their alloy composition and then machined to removed surface defects. For defense applications, performing all steps in the process ensures that components such as missile parts, aircraft frames, or armor materials perform as expected, reducing the risk of failure during critical missions. 

Advancing Defense Capabilities Through Material Science 

At NJII, our focus is on pushing the boundaries of material science for defense. Through rigorous tensile testing, we can verify that additively manufactured metals meet the stringent requirements of defense applications. Whether it’s ensuring that a part can withstand the stresses of high-speed flight or endure harsh environmental conditions, our material engineers work diligently to test and validate these materials. 

By following strict testing protocols, and carefully documenting any deviations, we provide the defense industry with confidence in the integrity and durability of the components we develop. This not only enhances the safety of military personnel, but also strengthens the technological capabilities of our nation’s defense systems. 

NJII’s Defense Division is committed to the development of advanced manufacturing and 3D Printing technologies and techniques. Our flagship COMET Program combines public and private resources to advance workforce development within additive manufacturing and defense technologies. You can read about COMET here. 

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NJII Employee Spotlight: Sam Gatley, Deputy Director of NJII’s Defense Division https://www.njii.com/2024/08/njii-employee-spotlight-sam-gatley-deputy-director/ Thu, 01 Aug 2024 18:52:33 +0000 https://www.njii.com/?p=19677 For this month’s employee spotlight, we’re highlighting Sam Gatley, NJII Defense Division’s Deputy Director! During our interview, Sam discusses how his passion for additive manufacturing began, where and how the idea for the COMET program ...

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For this month’s employee spotlight, we’re highlighting Sam Gatley, NJII Defense Division’s Deputy Director! During our interview, Sam discusses how his passion for additive manufacturing began, where and how the idea for the COMET program originated from, the division’s partnerships, and more. 

Q. I’d love to start by hearing a little bit about your background. How did you get started at NJIT, and how did your role evolve to where it is today? 

A. Yeah, absolutely. About 8-and-a-half years ago, I got an opportunity to be a 3D-printer technician in a physics lab. I was wrapping up my master’s in Science, Technology, and Public Policy and got this opportunity to start collaborating with a lab that was working on a handheld multispectral camera. And this newfangled technology that was just becoming accessible to consumers, 3D-Printing, was on the market, and some of the professors thought it would be a good idea to use it to build housing and kind of rapidly prototype ideas. I had done a little bit of engineering in my undergrad; I didn’t actually finish my engineering degree, I got more of a general studies bachelor’s. But I had enough CAD background that I picked it up quickly, and next thing I knew I was offered a position in the lab. I worked my way up there, turned it into an additive manufacturing lab itself; we founded something we call the ADLAB, short for additive. And it was a way to get going while the Makerspace was getting set up. They had a much bigger goal in mind, so it took a little while for them to become accessible to the rest of the community at NJIT. So, in the meantime, we just bought a few printers and got to work. But a lot of the funding for that lab came from Picatinny Arsenal and the US army. And so I started to get more involved in the grant writing and the reporting, and business development with the army. Then I got to meet Bill Marshall, and he and I took a liking to each other, and I became his Chief of Staff. Long story short, here we are. 

Q. Did you always have an interest in additive manufacturing or did that develop over time? 

A. No, I mean it definitely developed over time, in part because I’m old enough that for much of my life I didn’t know it was a thing! Now I know people who’ve been in the industry for as long as I’ve been alive. I’ve been lucky enough to meet people that were working on 3D printing 30-plus years ago. But it was a really niche field then; million dollar machines that took days for – what we would now look at as – mediocre parts. It was about a decade ago now that the ‘consumer revolution’ for 3D printing became a thing, because a lot of patents expired, so cheaper machines were able to get on the market, and it allowed people to get access to it. And now, I hire people that have been doing 3D printing since they were kids. We actually have an intern this summer, I think he’s in his early 20s; he’s been 3D printing for 10 years. He’s been in 3D printing for longer than I have! 

But I have always been interested in engineering. I went to school initially for mechanical engineering and learned that I wasn’t well suited for the daily work of being an engineer, but I like being around the projects. At the time I was coaching high school basketball and track & field, and I’ve always really liked building teams and helping to facilitate teamwork and collaboration. It took me a while to figure out how to plug that all together, but I joke that nowadays I basically coach engineering. 

Q. What is something about additive manufacturing that people might not know about? 

A. One of the things that we work on out here are 3D printed, additively manufactured electronics. There are people in the industry that may be working for polymer, plastic, 3D printing companies, that aren’t even aware that 3D printed electronics are really a thing. So it’s a pretty early-stage part of the industry. The machines are still very temperamental and getting them to work effectively is still an uphill battle. But I think the promise that they represent – combining the ability to print plastic, metal, ceramics, and electronics – it’s still decades out, but the idea of the Star Trek replicator… maybe! 

Q. The COMET program – How and when did it originate? How has the program developed over the years? 

A. So it’s kind of tough to pick the exact point, but Bill and I were having lunch with one of our army collaborators near Picatinny at the Rockaway Mall. We were looking at the empty Sears building, and we thought “geez, wouldn’t it be cool if we could repurpose this wasted retail space as an additive manufacturing center where we do workforce development, and educate people on the possibilities of the technology”, everything we’re doing now at COMET. 

It was right before COVID that we had the idea. We ended up talking to Sears during COVID. It was actually becoming a site where they were doing COVID tests for the state. They had a date where the state was going to get out of there, and we got to the 11th hour of signing the lease with them to take over the space. But at the last moment, Sears realized “You guys aren’t doing COVID relief. What are you doing?” And they raised the rent on us 10x as we were about to sign the lease. Little bit of a blessing in disguise because I think it was 10 times as big, and it’s been hard enough managing 20,000 square feet let alone 200,000.  

So maybe a month or two later, we were lucky enough to find the listing of the building we’re in now. We rushed out there, basically started negotiating to put an offer in that day, and thankfully we did because the next day 5 more groups wanted to take over this building.  

So, we were able to find that location, but a lot of it was built off work we had done on campus. I ran an internship on campus for four years working on robotics, showing off 3D printing and integrating edge computing into it. That was developed on campus, but in a 2000 square foot room with a couple few-thousand-dollar 3D printers. So, the opportunity to carry those lessons forward into this state-of-the-art facility has been really amazing. 

Q. Where do you see COMET going over the next 5 or so years? Are there any specific prospects that excite you? 

A. One of the things that’s really exciting is the design studio that we’re starting. The Army has worked with us to build out this facility, but they want a developed workforce that knows how to use the equipment. The best way I know how to do that is to put people on the equipment and get them to work. But working on real projects for people that matter, not just toys and made-up things. And so, sometimes that’s in support of the army, but increasingly we’ve had the opportunity to work with startups and small businesses in the state. There are some state programs that help with funding, and other companies are fortunate enough to have cash flow already that they can support this.  

Our facility is well suited to prototyping and low-rate initial production. It’s what we call a high-mix, low-volume manufacturing facility, and I think Mike Van Ter Sluis from NJII had done a study a few years ago showing that a facility like this would be an accelerator to innovation in the state. But it’s not really a money maker on its own. So, the fact that we were able to leverage the resources to do the defense application, but then have excess capacity on the machines, means that now we can be a design studio to help develop those MVPs (minimum viable products), get their ideas out of their head, off napkin sketches, and into the hands of potential investors. We have a pipeline of really great talent from NJIT with their industrial design program, let alone all the engineers and scientists, and so we can support industry in that way. 

These sorts of facilities make sense to address regional workforce needs and industrial needs. We have Northwest Jersey taken care of; we’ve got students commuting over an hour from here. But that’s starting to stretch how far the reach should be. So, figuring out how we might deploy some additional sites to target other industries is something we would be excited to do. And the figuring out how we can network them for defense and for the civilian world, having distributed capabilities like this, so that if a tornado or hurricane comes through or an earthquake or if something more malicious happens, you don’t put all your eggs in one basket. Figuring out how to network manufacturing capabilities like this is something else we’re working on. 

Learn more about the COMET program here 

Q. NJII’s Defense Division works with both private companies and public institutions like the US military. How have those partnerships helped lift our projects and programs, and do you find that these relationships become stronger over time? 

A. Absolutely. Another way I could have answered the question of “how did comet become a thing?” is through a decade of relationship building on my behalf, that built on decades of Bill’s relationship building. Nothing that we do happens overnight, and especially in this space, it feels like it’s built on trust with the people. We have very good relationships with Picatinny Arsenal, but also at the joint base and increasingly with the other branches of the DoD. All of this really relies on working with industry as well. Our role, the way we see it, is as an integrator between the academic efforts that happen at NJIT or other universities, the industrial partners we have, and the DoD, and kind of aligning those interests so that we get the most bang for our buck when we work together. 

Another thing that we did before COMET was the ADAPT program, and I was the project manager on that. We brought together a dozen small businesses, about a dozen faculty members from NJIT and a couple people from the University of Delaware to work with Picatinny Arsenal on some interesting technology and try to accelerate the development from the lab to get it in the field as soon as possible. And on that, it was really built around in team building. So, if you’re a big prime, like Raytheon or a Booz Allen, you might have divisions that can all work together to build final products, or you have people in your supply chain. These were small businesses, though, that kind of tackled one slice of a product on their own. So, we had, a battery company, software, a 3D printing electronics company, an antenna company, and separate from that a testing company. So together, if they’re properly aligned, they can do the development that typically only primes could do. 

It’s also been kind of the inspiration for our internship. We had 20 interns that had 12 different majors working together last year. We tried to teach and expose the interns to that way of working while they’re young, so that they can learn these lessons early and really apply them through their whole career. My goal is for them to have fun this summer, and if you don’t find this work fun, you’re on the wrong job. 

Q. Working daily operations at Landing 360, what are the most common challenges that come about on a day-to-day basis, and what kind of work do you find yourself enjoying the most? 

A. We’ve been in this building for over two years now and it doesn’t really feel like any one day is like the other. We’ll have days where we all have to chip in, clean up the facility, put furniture together and receive equipment. Recently we hosted a meeting for the state effort around the CHIPS Act Notice of Funding Opportunity 3 Response, with ideation sessions with high level people from the DoD. Then it’s teaching 20 year olds how to do 3D printing or giving a tour of the space to FIRST Robotics Clubs in high school. One of the things that I think makes it so exciting is how varied the work is. And since we kind of view ourselves as that systems integrator, we need to understand what other people in this space are doing to properly align those efforts.  

And so that’s really fun, but also challenging. It requires kind of a high level strategic vision of what we’re trying to do and merging the priorities of NJIT and NJII and DEVCOM Armaments Center; keeping all of those interests in mind while then executing tactically day-to-day. But one thing that’s cool about additive manufacturing is you can get your ideas out of your head and into your hands quickly at relatively low cost. So, you’re able to kind of try something, assess it and reiterate. For better or worse, we have applied that methodology to just about everything we’re doing. 

Q. You are an employee of both NJII and NJIT. Does this affect your job significantly in any way? Do you find yourself working more with one than the other? 

A. Yeah, it does. One of the things that’s funny about this is that I supervise NJII staff members and employees, but because I’m actually paid by NJIT, I don’t always know the processes that you have to go through. Like, I’ve never actually filled out a timesheet or gotten a paycheck from NJII. But the benefit of being between both organizations is that I really understand the processes on both sides of the house; who to talk to, what portals to access, what forms to fill out, how “the sausage” is made on both sides. So, I’m able to get things to effectively move back and forth. There’s a huge benefit to us being able to act as an academic effort at times, put it in grants, and engage with people that way. Then at times move a lot faster. Being able to engage with the government and industry at the speed that they operate at as NJII, but then also leverage the academic resources of NJIT, it really opens up a lot of opportunities. 

Q. What do you enjoy most about working for NJII? 

Oh, my favorite thing about my job is how many interesting people I get to work with. I get to work with young people at the beginning of their career. I often joke with them or other people I’m talking to: They don’t realize what’s supposed to be hard, and I put problems in front of them that I think are damn near impossible, and they just breeze through them in a day. I also put problems in front of them that I think are trivial and it takes them a week to figure out, so it’s always exciting to see what’s going to be challenging on that front. But then I also get to work with people from the state or the federal government, industry, etc. Additive manufacturing is a pretty small industry at this point, so it’s amazing how many people I know in that space. 

And recently, Bill arranged for us to lead an ideation session at Fort Gregg Adams on advanced manufacturing and how the Army will use it in the next upcoming decades. I was lucky enough to actually lead that third day ideation session and report out to several acting generals. That was just an amazing opportunity.  

The post NJII Employee Spotlight: Sam Gatley, Deputy Director of NJII’s Defense Division appeared first on NJII.

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New Jersey Innovation Institute Hosts Ribbon Cutting Ceremony for COMET Initiative https://www.njii.com/2024/07/njii-hosts-ribbon-cutting-ceremony-for-comet-initiative/ Tue, 23 Jul 2024 11:23:56 +0000 https://www.njii.com/?p=19635 Newark, NJ – [July 23, 2024] – New Jersey Innovation Institute (NJII) proudly announces the successful ribbon cutting ceremony for the COMET Initiative, held at the NJII Advanced Manufacturing Center, Landing 360. The event marked ...

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Newark, NJ – [July 23, 2024] – New Jersey Innovation Institute (NJII) proudly announces the successful ribbon cutting ceremony for the COMET Initiative, held at the NJII Advanced Manufacturing Center, Landing 360. The event marked a significant milestone in advancing collaborative innovation, workforce development and technological development.

Dr. Michael Johnson, President of NJII, delivered the opening remarks, emphasizing the importance of the COMET Initiative in fostering innovation and industry collaboration. “The COMET Initiative represents a major step forward in our mission to drive technological advancement and economic growth,” said Dr. Johnson. “We are excited to drive positive impact on the industry and the community though this initiative.”

Dr. Atam P. Dhawan, Senior Vice Provost for Research at the New Jersey Institute of Technology (NJIT), concluded the remarks on behalf of NJIT President, Dr. Teik Lim, by highlighting the academic and research contributions to the initiative. “NJIT is proud to support the COMET Initiative, which will provide our students and faculty with unparalleled opportunities to engage in cutting-edge research and development,” said Dr. Dhawan.

Distinguished guest speakers included Paul Manz, Chief Technology Officer JPEO Armaments and Ammunition who offered comments on behalf of Maj. Gen. John T. Reim, Commanding General of Picatinny Arsenal and Joint Program Executive Officer for Armaments & Ammunition. Mr. Manz highlighted the critical role of innovation in national defense and shared Major General Reim’s sentiment, “The collaboration between NJII and Picatinny Arsenal through the COMET Initiative is a testament to our shared commitment to advancing technological capabilities for our armed forces.”

Mr. Christopher Grassano, Director of the U.S. Army Combat Capabilities Development Command (DEVCOM) Armaments Center, also spoke at the event, stressing the importance of partnerships in driving research and development. “The DEVCOM Armaments Center is proud to be a key collaborator in the COMET Initiative, which will undoubtedly lead to groundbreaking advancements in armament technologies,” said Mr. Grassano.

“The COMET initiative represents a significant milestone in our journey towards solidifying New Jersey’s position as a leader in innovation across the nation,” said Congressman Kean. “This facility embodies our state’s commitment to excellence, our dedication to fostering talent, and our leading force in technology and innovation. With this initiative, we’ll have positive impacts across New Jersey, such as boosting the local economy and creating more high-tech jobs.”

Final comments were offered by Stephen Luckowski, OSD MII Program Manager. He reflected on the value of partnerships and the importance of advanced manufacturing to the Department of Defense. He stated, “The partnership with NJII and NJIT promises to provide capabilities in workforce training that go beyond what is achievable in the classroom alone. I am extremely excited that COMET will help produce scientists and engineers skilled and upskilled in advanced manufacturing and advanced materials, that understand how to solve DoD’s technical challenges, bringing a new generation of workers to support the needs of the nation.”

Following the enthusiastic remarks was a group ribbon cutting ceremony and unveiling of the equipment floor. Both guided and self-guided tours allowed attendees live demonstrations and interaction with subject matter experts.

The COMET Initiative is designed to foster collaboration between industry, academia, and government to drive innovation in critical technology areas. The initiative aims to create a dynamic ecosystem that supports the development of new technologies and the commercialization of innovative solutions.

For more information about the COMET Initiative and NJII, please visit: https://www.njii.com/defense/new-comet-overview/.

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