Whether it’s developing new products, reducing costs, or increasing accessibility, innovations in manufacturing stand to improve the lives of companies and consumers alike. Georgia Tech recently took another step toward ensuring those innovations make it from lab to market with the launch of a Modular Pilot Scale Roll-to-Roll Manufacturing Facility. 

“As researchers develop new materials, one of the key aspects we’re missing is how to make them at scale. This is a major oversight because if we can’t make them at scale, we can’t transition from basic research to commercialization,” said Tequila Harris, a professor in the George W. Woodruff School of Mechanical Engineering. “With this new facility, we can prove our discoveries beyond lab-scale studies — and can go from materials innovation to product development at scale.”

Led by Harris, the new facility is the result of a partnership between the Georgia Tech Manufacturing Institute(GTMI), the Strategic Energy Institute, and the Woodruff School. As a pilot facility, it will serve as a testbed for scaling up manufacturing research open for Georgia Tech researchers as well as academic, government, and industry partners around the world.

“The larger vision I see at Georgia Tech involves innovation in manufacturing for large-scale industries,” said Georgia Tech’s Interim Executive Vice President for Research Tim Lieuwen at the facility’s unveiling event on Sept. 19. “It’s crucial that we’re innovating in basic science and technology, but we also need to be innovating in large-scale manufacturing.”

Roll-to-roll (R2R) manufacturing transforms flexible rolls of substrate materials, such as paper, metal foils, and plastics, into more complex, transportable rolls upon coating the surface with one or more fluids, such as inks, suspensions, and solutions, which are subsequently dried or cured on the base substrate. Its high yield and efficiency make R2R an ideal method for the sustainable, large-scale production of components for solar cells, batteries, flexible electronics, and separations — all industries that have expanded in Georgia in recent years.

“As a state institution, we’re ultimately here to serve our state,” said Lieuwen, who is also Regents’ Professor and David S. Lewis Jr. Chair in the Daniel Guggenheim School of Aerospace Engineering. “We’re seeing Georgia emerge as the national leader in terms of recruiting corporate investments in this space and in industries that will be served by this facility.”

Roll-to-Roll Innovations

The R2R process is similar to the production of newspapers, where a large roll of blank paper goes through a series of rollers printing text and photos. “The roll-to-roll aspect is the process of using a specialized tool to force fluid onto a moving surface,” says Harris. It’s one of the fastest-growing methods for producing thin film materials — photovoltaics used in solar cells, transistors in flexible electronics, and micro-batteries, for example — at a large scale. 

Harris’s group works to develop novel manufacturing tools, with a particular focus on understanding and improving the dynamics of thin film manufacturing to increase efficiency and minimize waste. Her group is particularly interested in slot die coating, an R2R technique where a liquid material is precisely deposited onto a substrate through a narrow slot. With the new pilot facility, researchers like Harris will be able to take their work to the next level.

“Slot die coating on a roll-to-roll can handle the broadest viscosity range of most coating methods. Therefore, you can process a lot of different materials very quickly and easily,” says Harris. “It’s one of the fastest-growing technologies in the U.S. — and currently, this is the most advanced modular pilot scale facility at an academic university in the United States.”

“Georgia Tech is way ahead of the curve in terms of our facilities,” says GTMI Executive Director and Regents’ Professor Thomas Kurfess. “This will grow our capability in the battery area, membranes, flexible electronics, and more to allow us to support the development of new technologies.”

“As technologies around cleantech continue to advance at an unprecedented pace, pilot manufacturing facilities provide a critical bridge between innovative benchtop research and commercial-scale production and manufacturing,” says Christine Conwell, interim executive director of the Strategic Energy Institute. “We are excited about the opportunities this R2R facility will provide to the Georgia Tech energy community and our industry partners.”

As artificial intelligence continues to transform countless areas of society, the Georgia Tech Research Institute (GTRI) is applying it to another critical area: disaster management. 

GTRI is leading the development of an integrated artificial intelligence response hub for Southwest Georgia to help communities streamline disaster management and logistics. The hub aims to enhance resilience and response efficiency of these communities, potentially saving lives and reducing economic losses. GTRI is collaborating in this effort with the Southwest Georgia Regional Commission (SWGRC), a regional planning agency that serves 14 counties and 44 cities in Southwest Georgia. The SWGRC focuses on ecosystem building in the areas of manufacturing in food production, manufacturing start-ups, supply chain logistics and workforce development. 

“This will be a centralized platform that key stakeholders in Southwest Georgia can use to manage various disruption scenarios,” said GTRI Senior Research Engineer Francisco Valdes, who is leading this project.

This project is one of several initiatives undertaken by Georgia Artificial Intelligence in Manufacturing (Georgia AIM), a $65 million federal grant awarded to Georgia Tech and a coalition of partners across the state, including the Georgia Tech Manufacturing Institute.

Read the full story on the GTRI website >>>

Professor Horacio Ahuett Garza from the Tecnológico de Monterrey recently settled into the Georgia Tech Manufacturing Institute (GTMI) community as a visiting scholar. Ahuett is a leading faculty member in the Mechanical Engineering and Advanced Materials Department at Tecnológico de Monterrey located in Monterrey, Mexico. He earned his mechanical engineering masters and doctorate from Ohio State University more than 25 years ago. Ahuett will be interacting with Georgia Tech faculty to explore research areas in Smart Manufacturing and Industry 4.0.

“My home university has 30 campuses across Mexico with the main campus being in Monterrey—where I was born. I’ve known professor Tom Kurfess, executive director of GTMI, for more than 20 years. He has a faculty appointment at Tecnológico de Monterrey similar to a distinguished professor due to an agreement with Georgia Tech,” said Ahuett. “We’re both involved with advanced manufacturing but in different countries with similar processes. However, the facilities at Georgia Tech are far more advanced, such as the Advanced Manufacturing Pilot Facility (AMPF) operated by GTMI. Some of our graduate students periodically come to participate in research at Georgia Tech.”

Ahuett, who has ample manufacturing research experience, was extended an invitation to visit Georgia Tech this spring. He is using this visit as a sabbatical to further his understandings and learn more about new advanced manufacturing topic areas.

He recently attended The Hershey Company lecture at GTMI presented by Will Bonifant, vice president of the US and Canada supply chain, and Chris Myers, vice president of engineering at Hershey. The topic was modernizing a century-old, iconic snacks company leveraging Industry 4.0 digital and technology solutions.

“Today, Hershey provided a good understanding of smart manufacturing and how Hershey uses its fast access to data to make quick decisions that are implemented inside the factory and its processes,” said Ahuett. “They deployed smart manufacturing processes to use fewer resources, reduce waste, yet make factory equipment changes in a timely manner and safe manner to deliver targeted product quantities based on customer demand.”

Ahuett indicated that the proliferation of sensor technology and corresponding data can be used to benefit manufacturing by reducing waste, saving energy, and generally making companies more agile with better use of resources in factory settings. One example would be understanding performance parameters for tooling where you generally know the life cycle of a cutting tool and are able to measure the tool’s degradation in real time so that you can make plans to replace the tool at the best time to minimize your downtime of that tool versus waiting for it to break unexpectedly and shut down the process.

His strongest research interest during his GTMI visit is the topic of digital twins.

“The topic of digital twins is not new -- it has been around for at least 40 years. A good example is that during the Apollo moon missions NASA had digital twins. They had instruments on earth that replicated the instruments sent on the moon missions so they could simulate actions [using data] on earth that would occur on the actual spaceships,” said Ahuett.

“The concept of digital twins generates confusion. The first impulse is to think of a digital image as the twin of a physical entity. In principle, the digital twin simulates the behavior of the physical twin to model and make predictions. Not all processes can be modelled in real time, but some can which provides beneficial information in a timely manner given how fast computer processors are today. Today, we have more and better tools that use data to give us greater insights.”

Ahuett will be working with robots and co-robots in collaboration with Kyle Saleeby, research engineer at GTMI, to help automate accurate measuring during a manufacturing process. A piece of their research project will be building models so a part’s characteristic data can be tracked and stored in a digital twin that represents a specific instance of each part manufactured and which will also include external data associated with the manufacturing of the part.  

“I’m hoping my sabbatical at Georgia Tech will help me develop new competencies, new skills, and new knowledge on critical topics. I want to move research further in some areas and part of being here is to figure out some things that I didn’t know before with the help of GTMI,” said Ahuett.

The Novelis Innovation Hub at Georgia Tech organized a "AI Applications Workshop" on June 8, 2023. This hybrid event took place on the Georgia Tech campus and brought together a diverse group of participants, including over 50 scientists and engineers from Novelis, as well as faculty members, scholars, and administrators from Georgia Tech. The main purpose of the workshop was to identify synergies between the areas of interest and needs within Novelis and the research and capabilities of Georgia Tech faculty in the fields of artificial intelligence (AI) and machine learning (ML). The aim was to explore how the two organizations could collaborate effectively in leveraging AI/ML technology. Through presentations and discussions, potential areas of interest aligned with Novelis's objectives were identified, focusing on machine learning for system modeling, diagnostics, and prognostics in manufacturing systems, materials informatics, digital engineering including digital twins, model-based system engineering, and the integration of AI/ML. The open discussion session focused on collaboration opportunities to accelerate discovery, development, and optimization of materials and manufacturing processes of relevance to Novelis. The desired outcomes of the event were to define follow-up actions, specifically focusing on developing collaborative proposals and statements of work (SOWs) between Novelis and Georgia Tech. By facilitating this collaborative environment, the workshop aimed to foster meaningful partnerships and to enable the exchange of industry needs and academic research expertise, ultimately paving the way for future collaborations and advancements in AI applications. More photos from the event >>.

Novelis Innovation Hub >>

From airplanes to soda cans, aluminum is a crucial — not to mention, an incredibly sustainable — material in manufacturing. Since 2019, Georgia Tech has partnered with Novelis, a global leader in aluminum rolling and recycling, through the Novelis Innovation Hub to advance research and business opportunities in aluminum manufacturing.

Novelis and the Georgia Institute of Technology recently co-hosted the 19th International Conference on Aluminum Alloys (ICAA19). Held on Georgia Tech's campus, this event brought together the brightest minds in aluminum technology for four days of intensive learning and networking.

Since its inception in 1986, ICAA has been the premier global forum for aluminum manufacturing innovations. This year, the conference attracted over 300 participants from 19 countries, including representatives from academia, research organizations, and industry leaders.

“The diverse mix of attendees created a rich tapestry of knowledge and experience, fostering a robust exchange of ideas,” said Naresh Thadhani, conference co-chair and professor in the School of Materials Science and Engineering

ICAA19 featured 12 symposia topics and over 250 technical presentations, delving into critical themes such as sustainability, future mobility, and next-generation manufacturing. Keynote addresses from leaders at the Aluminum Association, Airbus, and Coca-Cola set the stage for insightful discussions. Novelis Chief Technology Officer Philippe Meyer and Georgia Tech Executive Vice President for Research Chaouki Abdallah headlined the event, underscoring the importance of Novelis’ partnership with Georgia Tech.

Marking the fifth anniversary of the Novelis Innovation Hub at Georgia Tech, Hub Executive Director Shreyes Melkote says that “ICAA19 represents a prime example of the close collaboration between Novelis and the Institute, enabled by the Novelis Innovation Hub.” Melkote, a professor in the George W. Woodruff School of Mechanical Engineering, also serves as the associate director of the Georgia Tech Manufacturing Institute.

“This unique center for research, development, and technology has been instrumental in advancing aluminum innovations, exemplifying the power of partnerships in driving industry progress,” says Meyer. “As we reflect on the success of ICAA19, we remain committed to strengthening our existing partnerships and forging new alliances to accelerate innovation. The collaborative spirit showcased at the conference is a testament to our dedication to leading the aluminum industry into a more sustainable future.”

When it comes to manufacturing innovation, the “valley of death” — the gap between the lab and the industry floor where even the best discoveries often get lost — looms large.

“An individual faculty’s lab focuses on showing the innovation or the new science that they discovered,” said Aaron Stebner, professor and Eugene C. Gwaltney Jr. Chair in Manufacturing in the George W. Woodruff School of Mechanical Engineering. “At that point, the business case hasn't been made for the technology yet — there's no testing on an industrial system to know if it breaks or if it scales up. A lot of innovation and scientific discovery dies there.”

The Georgia Tech Manufacturing Institute (GTMI) launched the Advanced Manufacturing Pilot Facility (AMPF) in 2017 to help bridge that gap. 

Now, GTMI is breaking ground on an extensive expansion to bring new capabilities in automation, artificial intelligence, and data management to the facility. 

“This will be the first facility of this size that's being intentionally designed to enable AI to perform research and development in materials and manufacturing at the same time,” said Stebner, “setting up GTMI as not just a leader in Georgia, but a leader in automation and AI in manufacturing across the country.”

AMPF: A Catalyst for Collaboration

Located just north of Georgia Tech’s main campus, APMF is a 20,000-square-foot facility serving as a teaching laboratory, technology test bed, and workforce development space for manufacturing innovations.

“The pilot facility,” says Stebner, “is meant to be a place where stakeholders in academic research, government, industry, and workforce development can come together and develop both the workforce that is needed for future technologies, as well as mature, de-risk, and develop business cases for new technologies — proving them out to the point where it makes sense for industry to pick them up.”

In addition to serving as the flagship facility for GTMI research and the state’s Georgia AIM (Artificial Intelligence in Manufacturing) project, the AMPF is a user facility accessible to Georgia Tech’s industry partners as well as the Institute’s faculty, staff, and students.

“We have all kinds of great capabilities and technologies, plus staff that can train students, postdocs, and faculty on how to use them,” said Stebner, who also serves as co-director of the GTMI-affiliated Georgia AIM project. “It creates a unique asset for Georgia Tech faculty, staff, and students.”

Bringing AI and Automation to the Forefront

The renovation of APMF is a key component of the $65 million grant, awarded to Georgia Tech by the U.S. Department of Commerce’s Economic Development Administration in 2022, which gave rise to the Georgia AIM project. With over $23 million in support from Georgia AIM, the improved facility will feature new workforce training programs, personnel, and equipment. 

Set to complete in Spring 2026, the Institute’s investment of $16 million supports construction that will roughly triple the size of the facility — and work to address a major roadblock for incorporating AI and automation into manufacturing practices: data.

“There’s a lot of work going on across the world in using machine learning in engineering problems, including manufacturing, but it's limited in scale-up and commercial adoption,” explained Stebner. 

Machine learning algorithms have the potential to make manufacturing more efficient, but they need a lot of reliable, repeatable data about the processes and materials involved to be effective. Collecting that data manually is monotonous, costly, and time-consuming.

“The idea is to automate those functions that we need to enable AI and machine learning” in manufacturing, says Stebner. “Let it be a facility where you can imagine new things and push new boundaries and not just be stuck in demonstrating concepts over and over again.”

To make that possible, the expanded facility will couple AI and data management with robotic automation.

“We're going to be able to demonstrate automation from the very beginning of our process all the way through the entire ecosystem of manufacturing,” said Steven Sheffield, GTMI’s senior assistant director of research operations.

“This expansion — no one else has done anything like it,” added Steven Ferguson, principal research scientist with GTMI and managing director of Georgia AIM. “We will have the leading facility for demonstrating what a hyperconnected and AI-driven manufacturing enterprise looks like. We’re setting the stage for Georgia Tech to continue to lead in the manufacturing space for the next decade and beyond.”

Work done by Georgia AIM (Artificial Intelligence in Manufacturing) is translating into success stories across the state. Recently, these success stories framed another achievement: Helping to host Vice President Kamala Harris as she kicked off her Economic Opportunity Tour in Atlanta at the end of April.

The multi-state tour was designed to showcase ways the Biden-Harris administration has built economic opportunity, supported communities, and is investing in traditionally underserved areas. Georgia AIM is an example of this, as it helps to expand technology training, job opportunities and advances for manufacturing across the state. Along with Georgia AIM, the Georgia Minority Business Development Agency Business Center (Georgia MBC), and Southeast Business Hub, programs of Georgia Tech’s Enterprise Innovation Institute, also attended the event at the Georgia International Convention Center, near Hartsfield-Jackson Atlanta International Airport.

“This event was a great opportunity to introduce the vice president to the work of Georgia AIM,” said Donna Ennis, co-director of Georgia AIM, which works to drive adoption of AI in U.S. manufacturing. “We were founded as part of the federal government’s Build Back Better plan. It’s important for her to see how we are putting the grant to work to deliver equity in artificial intelligence for manufacturing in Georgia.”

Prior to the arrival of Vice President Harris, attendees could visit tables set up in the entry hall and learn about a number of organizations, from banks to nonprofits to governmental agencies, that are working to level the playing field for underserved Georgians. Attendees included representatives from the Environmental Protection Agency, Rise, and Brunswick Job Corps Center.

The Georgia AIM table, staffed by Ryan Scott, the community engagement manager, and Kyle Saleeby, research engineer with Georgia Tech Manufacturing Institute (GTMI), was a popular stop, thanks to the tabletop “cobot” showing how robotics can be used in manufacturing and an array of 3-D printed industrial materials.

The program featured a conversation with Harris and financial literacy and business advice podcasters Rashad Bilal and Troy Millings, from Earn Your Leisure. The podcast has an audience of about 2 million people, a majority of whom are Black. Harris spoke to the crowd of approximately 400 people about the administration’s focus on access to capital for minority small businesses and entrepreneurs.

“One of the compelling reasons for me to start this tour now,” Harris said, “is to ask all the leaders here for help in getting the word out about what is available to entrepreneurs and small businesses. Because we are in the process of putting a lot of money in the streets of America.”

Some of those funds have gone to Enterprise Innovation Institute programs, including $65 million for Georgia AIM.

Georgia senators Jon Ossoff and Raphael Warnock and Rep. Nikema Williams also spoke at the event. Prior to the event, they joined Harris at the Russell Innovation Center for Entrepreneurs(RICE), a partner project with Georgia AIM. RICE is developing a mobile lab with researchers at the University of Georgia College of Engineering that will showcase AI-based technologies to communities across the state.

“It was exciting to hear first-hand about the administration’s commitment to equity in small businesses and entrepreneurship,” Ennis said. “It dovetails perfectly with the commitment of the programs of the Enterprise Innovation Institute.”

Naiya Salinas and her instructor, Deryk Stoops, looked back and forth between the large screen on the wall and a hand-held monitor.

Tracing between the lines of code, Salinas made a discovery: A character was missing.

The lesson was an important, real-world example of the problem-solving skills required when working in robotics. Salinas is one of a half-dozen students enrolled in the new AI Enhanced Robotic Manufacturing program at the Georgia Veterans Education Career Transition Resource (VECTR) Center, which is setting a new standard for technology-focused careers.

The set-up of the lab was intentional, said Stoops, who designed the course modules and worked with local industry to determine their manufacturing needs. Then, with funding from the Georgia Tech Manufacturing Institute's (GTMI) Georgia Artificial Intelligence in Manufacturing (Georgia AIM) project, Stoops worked with administrators at Central Georgia Technical College to purchase robotics and other cutting-edge manufacturing tools.

As a result, the VECTR Center’s AI-Enhanced Robotic Manufacturing Studio trains veterans in industry-standard robotics, manufacturing modules, cameras, and network systems. This equipment gives students experience in a variety of robotics-based manufacturing applications. Graduates can also finish the 17-credit course with two certifications that carry some weight in the manufacturing world.

“After getting the Georgia AIM grant, we pulled together a roundtable with industry. And then we did site visits to see how they pulled AI and robotics into the space,” said Stoops. “All the equipment in here is the direct result of industry feedback.”

Statewide Strategic Effort

Funded by a $65 million grant from the federal Economic Development Administration, Georgia AIM is a network of projects across the state born out of GTMI and led by Georgia Tech’s Enterprise Innovation Institute. These projects work to connect the manufacturing community with smart technologies and a ready workforce. Central Georgia received around $4 million as part of the initiative to advance innovation, workforce development and STEM education in support of local manufacturing and Robins Air Force Base.

Georgia AIM pulls together a host of regional partners all working toward a common goal of increasing STEM education, access to technology and enhancing AI among local manufacturers. This partnership includes Fort Valley State University, the Middle Georgia Innovation Project led by the Development Authority of Houston County, Central Georgia Technical College, which administers the VECTR Center, and the 21st Century Partnership.

“This grant will help us turn our vision for both the Middle Georgia Innovation Project and the Middle Georgia STEM Alliance, along with our partners, into reality, advancing this region and supporting the future of Robins AFB,” said Brig. Gen. John Kubinec, USAF (ret.), president and chief executive officer of the 21st Century Partnership.

Georgia AIM funding for Central Georgia Technical College and Fort Valley State focused on enhancing technology and purchasing new components to assist in education. At Fort Valley State, a mobile lab will launch later this year to take AI-enhanced technologies to underserved parts of the state, while Central Georgia Tech invested in an AI-enhanced robotics manufacturing lab at the VECTR Center.

“This funding will help bring emerging technology throughout our service area and beyond, to our students, economy, and Robins Air Force Base,” said Dr. Ivan Allen, president of Central Georgia Technical College. “Thanks to the power of this partnership, our faculty and students will have the opportunity to work directly with modern manufacturing technology, giving our students the experience and education needed to transition from the classroom to the workforce in an in-demand industry.”

New Gateway for Vets

The VECTR Center’s AI-Enhanced Robotics Manufacturing Studio includes FANUC robotic systems, Rockwell Automation programmable logic controllers, Cognex AI-enabled machine vision systems, smart sensor networks, and a MiR autonomous mobile robot.

The studio graduated its first cohort of students in February and celebrated its ribbon-cutting ceremony on April 17 with a host of local officials and dignitaries. It was also an opportunity to celebrate the students, who are transitioning from a military career to civilian life.

The new technologies at the VECTR Center lab are opening new doors to a growing, cutting-edge field.

“From being in this class, you really start to see how the world is going toward AI. Not just Chat GPT, but everything — the world is going toward AI for sure now,” said Jordan Leonard, who worked in logistics and as a vehicle mechanic in the U.S. Army. Now, he’s upskilling into robotics and looking forward to using his new skills in maintenance. “What I want to do is go to school for instrumentation and electrical technician. But since a lot of industrial plants are trying to get more robots, for me this will be a step up from my coworkers by knowing these things.”

Whether it’s typing an email or guiding travel from one destination to the next, artificial intelligence (AI) already plays a role in simplifying daily tasks.

But what if it could also help people live more efficiently — that is, more sustainably, with less waste?

It’s a concept that often runs through the mind of Iesha Baldwin, the inaugural Georgia AIM Fellow with the Partnership for Inclusive Innovation (PIN) at the Georgia Institute of Technology’s Enterprise Innovation Institute. Born out of the Georgia Tech Manufacturing Institute, the Georgia AIM (Artificial Intelligence in Manufacturing) project works with PIN fellows to advance the project's mission of equitably developing and deploying talent and innovation in AI for manufacturing throughout the state of Georgia.

When she accepted the PIN Fellowship for 2023, she saw an opportunity to learn more about the nexus of artificial intelligence, manufacturing, waste, and education. With a background in environmental studies and science, Baldwin studied methods for waste reduction, environmental protection, and science education.

“I took an interest in AI technology because I wanted to learn how it can be harnessed to solve the waste problem and create better science education opportunities for K-12 and higher education students,” said Baldwin.

This type of unique problem-solving is what defines the PIN Fellowship programs. Every year, a cohort of recent college graduates is selected, and each is paired with an industry that aligns with their expertise and career goals — specifically, cleantech, AI manufacturing, supply chain and logistics, and cybersecurity/information technology. Fellowships are one year, with fellows spending six months with a private company and then six months with a public organization.

Through the experience, fellows expand their professional network and drive connections between the public and private sectors. They also use the opportunity to work on special projects that involve using new technologies in their area of interest.

With a focus on artificial intelligence in manufacturing, Baldwin led an inventory management project at the Georgia manufacturer Freudenberg-NOK, where the objective was to create an inventory management system that reduced manufacturing downtime and, as a result, increased efficiency, and reduced waste.

She also worked in several capacities at Georgia Tech: supporting K-12 outreach programs at the Advanced Manufacturing Pilot Facility, assisting with energy research at the Marcus Nanotechnology Research Center, and auditing the infamous mechanical engineering course ME2110 to improve her design thinking and engineering skills.

“Learning about artificial intelligence is a process, and the knowledge gained was worth the academic adventure,” she said. “Because of the wonderful support at Georgia Tech, Freudenberg NOK, PIN, and Georgia AIM, I feel confident about connecting environmental sustainability and technology in a way that makes communities more resilient and sustainable.”

Since leaving the PIN Fellowship, Baldwin connected her love for education, science, and environmental sustainability through her new role as the inaugural sustainability coordinator for Spelman College, her alma mater.  In this role, she is responsible for supporting campus sustainability initiatives.