IRONWALKER

Objective: The objective of this topic is to conduct applied research to an innovative capability for a deployable, and user-friendly manufacturing system that integrates Artificial Intelligence (AI) and Augmented Reality (AR) to enhance advanced additive and subtractive machining capabilities. This system will provide each operator with AI-driven advanced manufacturing expertise and AR-based work instructions to train, certify, and guide them in operating complex machinery for the production of air, ground, and maritime components. Description: This effort will explore, design, and evaluate an innovative manufacturing capability that combines Artificial Intelligence (AI) and Augmented Reality (AR) to enhance advanced additive and subtractive machining operations. As a part of this feasibility study, the proposers shall address all viable overall system design options with respective specifications that enable rapid deployment, ease of use, and minimal training burden while maintaining the precision and repeatability required for air, ground, and maritime component production. The research will focus on integrating AI-driven advanced manufacturing expertise with AR-based work instructions to guide operators through the full lifecycle of production—from setup and calibration to machining, quality assurance, and certification. The system shall leverage modular, transportable platforms suitable for forward-deployed or austere environments, with consideration for integration into both manned and autonomous (e.g., bipedal robotic) operations in future phases. Proposers shall detail specification for key system attributes, including but not limited to: AI Capability: Real-time adaptive guidance, error detection, and optimization based on operator input and environmental factors. AR Work Instructions: Interactive overlays for step-by-step tasks, safety checks, and certification pathways. Machining Integration: Compatibility with advanced additive and subtractive manufacturing processes using multiple metal and composite materials. Deployment and Sustainment: Footprint, power requirements, portability, and environmental resilience. Cybersecurity and Data Management: Secure handling of operational data, digital twin integration, and compliance with DoD cybersecurity requirements. Keywords: Artificial Intelligence; Augmented Reality; Additive Manufacturing; Subtractive Machining; Advanced Manufacturing; Human-Machine Teaming; Operator Training; Expeditionary Manufacturing; Deployable Manufacturing; Digital Work Instructions; CNC Machining; 3D Printing; Autonomous Manufacturing; Field Repair; Point-of-Need Production CMMC Level: Level 1