centers of excellence update quality

8/13/2019 Centers of Excellence Update Quality

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Additive Manufacturing Centers of Excellence

An update to the Quality approach

James Curtis Taylor (BSME, MBA)Morris Technologies, Inc.

Rapid Quality Manufacturing, Inc.


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Abstract:

Today, several leading prototyping and rapid manufacturing companies are

setting up new organizations to address the explosive interest in productionlevel additive manufacturing of metals. Progressive companies are educatingtheir customers on the design to the process benefits of additivetechnologies like DMLS (Direct Metal Laser Sintering EOS). Thiseducation and new product development has lead to requests for validatedprocesses for longer term production. Current customer requirements aredriving additive manufacturing companies to invest in new processes and

validation tools in support of ISO and customer specific standards. Thispresentation will share learnings / case studies from two of these leadingcompanies (Morris Technologies, Inc. and Rapid Quality Manufacturing, Inc.)

The collaboration between initial product prototyping and longer termproduction is important when addressing the best value equation for productsthat fit the new digital production journey. Production processes and

validated methods of manufacturing will be key entry hurdles once designsare proven. Manufacturing Centers of Excellence will be developed toprovide these new supply chains across key industries including Aerospace,Medical and Dental.


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1. STATUS OF ADDITIVE MANUFACTURING IN PROTOTYPEAND PRODUCTION ENVIRONMENTS

1.1.Status of additive prototyping / manufacturingThe preface to this paper High volume additive manufacturing of finishedproduction parts a quality approach was released in 2007. At that timetwo charts were presented from the 2006 Wohlers Report as an evaluation ofthe state of the industry at that time. It is important to reflect and comparethe same two charts two years later.

The industrial sectors that are using additive manufacturing worldwide can beseen in figure 1.0 below:

Figure 1.0 Industries utilizing additive manufacturing.

One finds that there continues to be a broad use of the technology acrossmultiple industries. Figure 2.0 shows the range of applications of additivemanufactured parts across all sectors.

The industries that Morris Technologies and Rapid Quality Manufacturing

serve are aerospace and medical / dental subgroups. Comparisons from 2006show a 0.6% and 0.8% increase respectively.


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Figure 2.0 Current applications of additive processes.

As additive manufacturing technologies continue to grow, more and moreservice providers are using this technology for the production of finishedproducts vs. prototypes. The term Rapid Manufacturing or DigitalManufacturing is now a standard topic among service providers within theindustry. Rapid Manufacturing is defined as the direct production of finishedgoods from an additive system. Rapid manufacturing has continued to growsince our last paper and now represents 14.9% of the additive manufacturingmarket. This represents an increase of 5.3% over the last two years.

The intent of this follow-up paper is to update our audience on the currentstate of the Morris Technologies, Inc. (MTI) and Rapid QualityManufacturing, Inc. (RQM) businesses related to additive manufacturing ofmetals. This information will be based on utilizing the EOS M270 DMLS Direct Metal Laser Sintering system.


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2. GENERAL EXPLANATION OF AREAS TO BE DISCUSSED2.1 Evaluation of prototype to production products: In this section we

will look at how MTI and RQM evaluate one off products to identify what wecall production opportunities.

2.2 Process learnings with DMLS metal products: In this section wepresent several areas of learnings that are known within the industry anddiscuss the improvements this has made in our pilot production efforts.

2.3 Validation learnings relating to process variables and productionflow: In this section we will discuss two systems that MTI / RQM are usingto build technical databases. These systems support metal powder andmechanical property requirements.

2.4 Evaluation of e-RP learnings relating to longer term productionsystems: In this section we will update the audience on our Magics e-RPbeta testing and launch along with our newest supporting software fromSoluminaTM. This will also include a schedule update on our ISO progressand system definition.

2.5 Detail RQMs goal of becoming The Manufacturing Center ofExcellence for North America relating to additive metals: We willdiscuss our focus on metals strategy. This will include new partnerships

with key customers within and between industries.

2.6 Define next steps of collaboration in our relationship with EOS: Here we will reconfirm our 5 year relationship with EOS as an e-manufacturing partner and recommit our goal of open collaboration.

2.7 Another company is born: In this section we will introduce a newcompany. MicroTek Finishing, LLC. is a company born from the leadershipof Morris Technologies and Best-In-Class. We will discuss this new ventureas a separate entity and a collaborative partner with RQM, Inc.

2.8 Summary: In this area we summarize our current plans of expansionvs. our quality approach to additive metals manufacturing. We will alsodiscuss our opportunities and focus areas moving forward.


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3. EVALUATION OF PROTOTYPE TO PRODUCTION PRODUCTS3.1 As products are quoted for customers they are evaluated against many

criteria. Primarily there are two types of products that MTI / RQM evaluateon a daily basis. There are typically new products / new designs or productsthat are currently being evaluated for new production supply chains vs.traditional methodologies.

A sample product life cycle is shown in Figure 3.0 below. This shows saleslevels vs. time. MTI is structured for Introduction (prototyping) and RQM isstructured for Growth (Higher Volume Manufacturing).

Figure 3.0 Example of Product Life Cycle.

3.2 Prior to entering the manufacturing environment for DMLS productsan assessment needs to be completed to evaluate the effectiveness of the

traditional design vs. DMLS capabilities and know secondary capabilities.The base M270 DMLS system can replace and even improvemanufacturability when the product is designed to the known capabilitiesand shortfalls.

Figure 4.0 below presents a simple visual of this process. New customerproduct designs or traditional products end up in either group A (OK to


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produce vs. current DMLS process) and group B (OK to produce butrequires potential design changes and a secondary operations analysis).

Figure 4.0 DMLS Production Evaluation.

The point is that a proper evaluation with the customer must be made upfront to ensure that the most cost effective and best quality approach is taken.

At this stage in the evolution of DMLS we have seem many early adopters toDMLS recognizing the importance of this phase where other customers areonly interested in evaluating a direct replacement approach.

P

P

P

P

P

P

P

P

P

P P

P

P

P

P

PP

OK via Current DMLS ProcessOK with Modified Product Design

and Secondary Operations

P

P

POTENTIAL NEW PRODUCT DESIGNS

Group AGroup B

P

CURRENTLY PRODUCED TRADITIONAL PRODUCTS


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4. PROCESS LEARNINGS WITH DMLS METAL PRODUCTS4.1 Over the last 5 years MTI / RQM have developed intellectual propertyrelated to how to best utilize DMLS capabilities and support structureoptimization to effectively build new products and current products. As we

move from prototyping to production runs (ie. Batch Processing) we havedeveloped proprietary techniques to improve build quality, reduce scrap andincorporate support structures for secondary operations. We will look atthree of these techniques.

4.2 Support Aids when dealing with internal stress: Longer build spans inDMLS creates an opportunity for spring due to internal stresses caused bythe sintering process. Until appropriate secondary stress relieving processescan be completed it is possible to hold critical locations by using spansupports.

A generic support aid is shown below in Figure 5.0.

Figure 5.0 DMLS Support Aids Span Supports.

4.3 Powder removal optimization: When dealing with internal cavities thatcontain internal and external tubes you may have to create a new powderremoval path that can be welded shut post powder removal but prior tostress relief.

Span Support Aid


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A generic powder removal hole is shown below in Figure 6.0.

Figure 6.0 DMLS Powder Removal Ports.

4.4 Secondary operations / tooling fixture optimization: To improve buildspeed and secondary operations it is possible to integrate tooling fixtures intoDMLS builds. In many situations this can lead to a reduction in build timeand improved machining cycle times.

A generic integrated tooling fixture is shown below in Figure 7.0 below.

Figure 7.0 Integrated Tooling Options.

Powder Removal Hole

Location Holes


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The key point in this section is to think in a more integrated manor to ensurethat the entire process is reviewed prior to parts being produced. This isthe power of the prototype vs. production culture between MTI and RQM.

We work together across companies to ensure the best possible set-up priorto the larger volume manufacturing phase.

5.VALIDATION LEARNINGS RELATING TO PROCESSVARIABLES AND PRODUCTION FLOW

5.1 RQM Coupon: The ASTM standard E8 Standard Test Methods forTension Testing of Metallic Materials gives a range of criteria and severalspecific examples for specimen size and shape. Both rectangular and roundcross sections can be used. We chose a round coupon because it is easier tomachine in a repeatable fashion to a high degree of precision. RQM chosethe smallest gage length possible to reduce cost of producing specimens, and

we verified process capability through several tests and statistical analysis. Itis important to save time and costs in creating these destructive tests, and atthe same time ensure high statistical confidence in both the specimens andtest procedures. Long term, it will be necessary to derive a correlationbetween as-built specimen geometries and final machined geometries to saveeven more time and cost. By doing this it will allow us to have real timeprocess controls alongside each production build.

RQM and MTI are participating in the newly created ASTM committeeF42 on Additive Manufacturing Technologies to ensure that we areinputting our learnings and following new procedures related to additivemetals coupon development and testing.

5.2 Initial Tensile Learnings - With an MTS tensile / fatigue testing systemin house, it has been possible to map out mechanical properties according tobuild orientation and location, as well as machine-to-machine variation. It isessential to understand all these competing variables in order to ramp up into

full production. Understanding how the different build parameters interactwith each other and impact quality allows us to develop proper controlstrategies. Mapping out the properties for each machine also enables us tostart matching machines to a master, which will be critical for high volumebuilds across several machines and over a long period of time.


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In figure 8.0 below we show an example of a tensile testing report fromRQMs internal MTS tensile testing system.

Figure 8.0 Example Tensile Data (4 Samples).

5.3 Variability and Secondary Processing - The DMLS process yields aproduct that is anisotropic (directionally dependent) due to its deposition inlayers. The tensile properties in the vertical build direction versus horizontalbuild direction differ by 10-20% out of the machine. Through a combinationof thermal processing it is possible to obtain a material that is much morehomogenous and isotropic (homogeneity in all directions). With RQMsproprietary heat treating solution, we have been able to obtain tensileproperties that differ by only 3-4% in transverse directions (both 0.2% offsetyield and ultimate tensile strength).

Figure 8.10 below shows comparison graphs of MP1 CoCr yield and ultimatetensile results pre and post secondary thermal processing (horizontal and

vertical samples). Figure 8.20 shows how ductility can be improved with thisprocess.


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Figure 8.1 Pre and Post Thermal Processing of MP1 CoCr (YS and UTS)

Figure 8.2 Pre and Post Thermal Processing of MP1 CoCr (Elongation)

RQM has started at temperature testing due to specific aerospace customerrequirements. Samples that have been thermally processed show goodmaterial characteristics at higher temperatures. This is providing ourcustomers more confidence to utilize final products in more and more high

temperature environments.

Figure 9.0 below shows one of RQMs 1stat temperature tensile tests.


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Figure 9.0 RQMs 1stat temperature Tensile Sample (CoCr MP1).

The key in this area is that individual build coupons will have to be producedfor each production build, heat treated, mechanically tested, and resultsdocumented. The results will also have to be archived based on customerrequirements.

5.4 Chemical Analysis - Another process control involves continuousmonitoring of chemical composition of powder. RQM has measured powdercomposition directly after the receipt of new powder, and throughout severalbuild cycles. With the correct controls in place, it is possible to keep thecomposition of the powder homogenous throughout its life cycle, even whenfiltering back through the system. Over time oxidation builds up, but this is

1800F


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easily detected and can be controlled within a limited range based on itsknown effects on the build integrity and physical properties.

5.5 Particle Size Analysis - Another Validation measure that RQM iscurrently using in its process is particle size measurement and tracking. This

study has primarily been conducted with MP1 CoCr materials with other newmaterials coming on line at MTI. The reason for this testing is to evaluate theparticle size of virgin materials vs. materials that have cycled through theprocess multiple times. We find in our testing that the process creates largerparticles that fuse with smaller particles thereby increasing the nominalparticle size within a powder bed.

Figure 10.0 below shows a sample from RQMs Malvern Mastersizer 2000report for a virgin MP1 CoCr material.

Figure 10.0 Example Particle Size Distribution (MP1 CoCr Powder).


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5.7 Cycles RQM will be pulling powder samples with each build. We willdevelop a database of powder lot traceability along with particle sizedistributions within and between builds and powder beds.

Figure 11.0 below shows a picture of a nominal size particle bed of virgin

MP1 CoCr materials.

Figure 11.0 Example Particle Size (MP1 Virgin Materials).

Figure 12.0 below shows a sample of removed powder (200 mesh sieve

>74microns) with a nominal particle size of 57um (lower limit of 15um andupper limit of 180um) created after one 120 hour production run.

RQM sieves powder beds after each build in an effort to reducecontamination variability due to these larger particles. This is just the firststage of controls and more automated systems are being developed.


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Figure 12.0 Example Particle Size (MP1 10X Cycles).

6. EVALUATION OF E-RP LEARNINGS RELATING TO LONGERTERM PRODUCTION SYSTEMS

6.1 RQM was the 1stcompany in North America to begin using Magics e-RP in the tracking of production batch products through the DMLS process.

The initial beta development of the product took place during the 1sthalf of2008.

The objective of the e-RP system for RQM was to establish a new method

for DMLS production batch and coupon evaluations to trace position,orientation and support structures of individual serialized production parts.

Figure 13.0 below provides an example of the visualization screen that iscurrently being developed for the next revision of Magics e-RP.


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Figure 12.0 Magics e-RP Visualization (next generation).

To date our system is not only capturing valuable data on specific projects butalso R&D projects. Due to the ongoing collaboration approach thatMaterialise and RQM are taking, additional features are coming on-line fasterthan originally expected. These new features will allow other additivemanufacturing companies to quickly accelerate their production systems to anew higher level of performance and traceability.

Magics e-RP has focused at the build level but is expanding its dataassociations to include secondary processing criteria, materials traceability andmore detailed customer / job information.


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RQM is expanding its internal e-RP production system to include a newsoftware package from SoluminaTM(iBASEt). This will be a fully integratedsystem approach to file management, purchase order requirements, customer

work definition, work order tracking, Magics e-RP, customer specificrequirements, accounting and quality inspection integration.

iBASEt has been a leader of high-tech software solutions and services since1986. iBASEt currently has two divisions: SoluminaTMand Federal Systems.

The SoluminaTMsoftware solution streamlines and integrates functions acrossthe product development life cycle from engineering to the supplier network.

This experience in Aerospace Defense, Nuclear, Medical Devices, Industrialand Shipbuilding is unmatched in the industry.

RQM plans to utilize iBASEts experience in complex and stringent processrequirements to support its Aerospace and Medical additive manufacturingbusinesses.This alignment of systems (SoluminaTMand Magics) will allowRQM to complete both its AS9100 Revision C and ISO 13485 certification in2009.

Figure 13.0 below provides an example of the type of integration thatSoluminaTMcan provide.

Figure 13.0 SOLUMINATMProcess Management Cycle.


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The key in this area is two fold:

1)To ensure a Quality approach to finished product additive manufacturing,a company must ensure that all traceability and configuration managementobjectives are met and

2) Customer specific requirements must be integrated into vendor processes.This effort can be huge when you begin to evaluate the level of detail thataerospace and medical companies require prior to vendor qualification.

7. RQMS GOAL OF BECOMING THE MANUFACTURINGCENTER OF EXCELLENCE FOR NORTH AMERICARELATING TO ADDITIVE METALS

7.1 When RQMs business plan was created in October 2006, the goal wassimple. Build on the success of Morris Technologies to focus on one additivemetals manufacturing technology in support of future high volumeproduction using the M270 DMLS platform.

RQMs initial objectives were the following:

1) Develop secured facilities to allow for a production vs. prototype cultureto be developed.

2) Continue to build a collaborative e-manufacturing partnership with EOS.3) Partner with customers to evaluate Aerospace, Medical and Dental

production opportunities with key customers and key productlines.

4) Expand facilities to include requirements for secondary operations andvalidation of the process.

5) Develop the quality systems necessary to deliver all ISO certifications bythe end of 2009.

6) Develop RQM into the preferred Center of Excellence for additivemetals manufacturing across multiple industries within North America.

7)

Evaluate initial product opportunities with a quality approach.8) Complete internal validation of the EOS M270 platform to develop thenecessary high focus variables that must be controlled (SPC) to enablequality finished products.

9) Utilize 5 years of DMLS experience to drive out waste from the currentEOS process that would allow for more efficient production on the M270platform.


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10)Continue to promote additive technologies by being an active member inorganizations like ASQ, SME, ASTM and ISO.

In the following section we will discuss key customer projects and productsfrom section 3.0 above.

7.2 Key customer projects / products: RQMs mission is to becomeThe additive manufacturing Center of Excellence for metals. RQM doesnot target one industry but rather multiple industries. This helps withproduct diversification and it allows for expedited learnings. Each arearequires different methodologies and levels of certifications, quality andlogistics. In the areas below we will briefly discuss product developmentsacross each industry. Some areas we are not able to go into details due to theconfidentiality of the products.

AEROSPACE PRODUCTION

RQM has been working with three confidential aerospace customers since

2007. This work flows from upstream prototype and evaluation projects atMTI and focuses on both process and pilot production batch processing.Detailed product designs can not be shared at this time.


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MEDICAL PRODUCTION

RQM has been working with three confidential medical customers starting in2008. The product focus is both instrumentation and surgical implants. This

work has flowed from MTI operations and organically through RQM. Finalproduct designs are in development and biocompatibility and toxicity testing

plans are being developed with our customers.

DENTAL PRODUCTION

RQM started dental production January 1st, 2009. We are teaming up with

Diadem Digital Solutions (www.diadem-ids.com) and 3M ESPE on theexpansion of our production in 2009. RQM is also working on several newproducts relating to larger frameworks. We are now working with 7 differentdental labs (as of March 1st, 2009) and plan to add more labs each month in2009.


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JEWELRY and FINE ART PRODUCTION

RQM has been in product development with a leading additive manufacturingartist (Anthony Tammaro of Philadelphia, PA). The initial design of themetal flexure bracelet shown above was given to RQM as a new testproduct. By collaborating with our customer we were able to simplify thedesign and allow for a more cost effective product.

This product is currently being used in gallery events and will soon be on salein a line of products to be released by Anthony later this year. The next

generation of products will include precious jewels.

8. DEFINE NEXT STEPS OF COLLABORATION IN OURRELATIONSHIP WITH EOS.

8.1 Morris Technologies (MTI) along with RQM have been e-manufacturing partners with EOS form the start of DMLS. MTI was the firstcompany in North America to have a DMLS machine and has been the beta

site for multiple material launches.

RQM has continued in this spirit by providing manufacturing feedback toEOS on items such as:

1) Powder bed monitoring and evaluation2) Build parameter optimization and learnings


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3) Sharing examples of quality systems and processes required for productvalidation

4) Dental process improvement (porosity)5) Sharing of validation learnings (process control strategies)6) General customer requirements that will impact future EOS equipmentRQM is committed to continuing the partnership that was created during ourinitial business plan development in 2006. Our goal is to continue tocollaborate with EOS to ensure that we are following all necessary equipmentrequirements and processes in the creation of quality finished parts.

In support of this commitment RQM recently participated in an internal EOSsummit on EOS Quality Standards for Metals and Plastics. We arecommitted to becoming Quality Certified through EOS by 2010. This willnot only give EOS confidence in our abilities with DMLS but will also giveour customers confidence in our overall quality standard.

9.ANOTHER COMPANY IS BORN9.1 Effective June 1st, 2009 MicroTek Finishing, LLC will start operationsnext to the RQM facility located in West Chester, Ohio (Point at UnionCenter). MicroTek will have proprietary licensing of the MMP process forNorth America.

MMP, which stands for Micro Machining Process, is a proprietarysuperfinishing method that delivers consistent, repeatable results using finelycontrolled automated processes. MMP uses highly engineered finishingmedia in combination with catalysts and a mechanical process to create asystem that can precisely remove from as little as 1 um to as much as 40 um

while achieving more finely controlled surface finishes than other methods.Unlike other finishing processes that use an acid attack, MMP does not leaveany contamination on the part being processed, and it doesn't leave the part

susceptible to hydrogen embrittlement.

The roughness of any unprocessed surface can be described by a combinationof undulation, primary roughness, and secondary roughness. MMP is uniquein its ability to target specific components of this roughness, enabling it toremove a specific portion of the roughness and leave the rest if that is more


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desirable. This unique capability allows MMP to fine tune the resultingsurface finish for specific applications.

The MMP process has limitations on the size of parts it can process, but thereis no universal rule of thumb since the geometry of the part factors into thedecision. MMP can process an extremely wide range of materials, with thenotable exception of Aluminum.

MicroTek Finishing, LLC is the exclusive provider of MMP services in theUnited State, Canada, and Mexico. While the initial facility is well positionedto serve a broad range of industries in the Midwest, as the company expandsits business in North America, it will open additional facilities in otherstrategic locations.

RQM plans to utilize MicroTek Finishing in the production of finishedDMLS parts produced on the EOS M270 DMLS platform. Currently we areworking on unique geometries within aerospace, medical, dental and jewelry.The location of MicroTek Finishing, LLC next to RQM will allow forconfidential applications and projects to be developed with key customersin a controlled environment.

10.SUMMARY10.1 RQM completed its facility expansion in October 2008. RQM nowhas a total of 17,000 sq ft of space and an additional 2000 amps worth ofpower in the facility. We also took the opportunity in 2008 to expand ourfacilities to both primary and secondary systems including an overall upgradeof HVAC. All of this expansion was completed in preparation of growth insecondary operations at RQM in 2009 / 2010.

Currently RQM is outsourcing the majority of our secondary CNC Milling,Lathe, Wire EDM and Hole Drilling operations to Morris Technologies. Weare evaluating our longer term and larger batch production requirements for

2010. Once this is complete in the 4th

quarter of 2009, we will beginadditional capital equipment expansion at RQM in Bay 2 of our expansion.

The goal of RQM was to take additive metals manufacturing to the next level ofproduction capability and production quality. We hope to have more detailedcase studies to share with SME and organizations who are interested inproduction quality parts on the EOS M270 DMLS platform (www.eos.info).


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We will continue to be very transparent in our approach of these objectives.Our goal is to continue to take a conservative, long term, Quality Approachto our activities.

The term Quality Approach to us means:

1) All production products are produced with final quality objectives inmind.

2) All equipment high focus variables that impact quality are identified andcontrolled.

3) All Quality Management Systems are in place to ensure ISO AS9100 RevC and ISO 13485 (including customer specific requirements).

4) All items that impact quality are quickly shared with our equipmentmanufacturer (EOS).

5) We openly participate in industry events to continue to promote additivetechnologies for current and new product designs within the Aerospace,Medical and Dental industries.

Our focus for the rest of 2009 will we be the completion of our pilotaerospace / medical production runs, dental production expansion, jewelryproduct development, ISO certifications and validations in support of full

production capability in 2010. We look forward to another strong year ofgrowth.


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_______________

Wohlers, T.T. (2008) Wohlers Report 2008, Wohlers Associates, Inc.

Quick MBA Website ( www.quickmba.com ) July 7th, 2008

Morris, G. 2008. Greg Morriss Website[on-line]. [Accessed 20th

, December 2008].Available from World Wide Web: ( www.morristech.com )

Liechty, Eli 2008. [RQM Internal MTS Report] October 20th

, 2008

Liechty, Eli 2008. [RQM Internal MTS Report / Tensile Flyer] April 20th

, 2009

ASTM, ( www.astm.org/index.shtml ) - April 20th

, 2009

Banks, Laura 2008. [RQM Internal Malvern Report] September 17th, 2008

Byers, R.W. 2009. [Personal communications] January 5 th, 2009.

Lenaerts, K. and Moss, J. 2008 [Personal communication] June 15th, 2008.

Van Espen, J. 2009 [Personal communication] March 23rd

, 2009.

SoluminaTM

website ( www.solumina.com ) December 12th

, 2008

Diadem Digital Solutions ( www.diadem-ids.com ) January 7th, 2008

3M ESPE ( www.3m.com ) October 20th, 2008

Trilliant Surgical LTD ( www.trilliantsurgical.com ) January 15th

, 2009

Anthony Tammaro ( www.anthonytammaro.com ) January 23rd

, 2009

Morris, Wendell. 2009 [Personal communication] January 26th

, 2009.

EOS Website ( www.eos.info ) March 2nd, 2009

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