Pathway to validation: Fieldmade in DISCMAM’s final phase

• Insights from Fieldmade on the key PBF-LB capabilities supporting the integration and validation of the DISCMAM solutions.

As DISCMAM enters the final six months of the project, the consortium is focusing on its final validation phase. On the Powder Bed Fusion Laser beam (PBF-LB) side, Fieldmade is leading the integration and validation of the DISCMAM solutions within its NOMAD®03 portable metal Additive Manufacturing system.

We spoke with Nils Knofius, Head of Digitalisation, and Tobias Rønneberg, Head of Quality at Fieldmade, to discuss the key capabilities being demonstrated, the role of secure digitalisation and what successful implementation and validation could mean for the future of on-site metal Additive Manufacturing. The objective is to demonstrate how advanced digitalisation, secure communication, in-field testing and data-driven quality assurance can support reliable on-site manufacturing operations for spare parts production.

The objective is to demonstrate how advanced digitalisation, secure communication, in-field testing and data-driven quality assurance can support reliable on-site manufacturing operations for spare parts production.

Key capabilities under validation

One of the key capabilities currently being validated is digitisation of parts using semi-automatic hardware and easy software. As explained by Nils Knofius, “If we can get this going, we will achieve higher consistency of the input data used to create design 3D files. This makes the approach more efficient (less back and forth) and increases the quality 3D models and as a consequence of the produced parts”.

Another important aspect of the validation is sending Technical Data Package (TDP) and quality data for parts securely via the cybersecure digital thread to the NOMAD®03, enabling the company to rely on reach-back functionalities. This means that not all activities surrounding on-site manufacturing need to be performed in the field, as certain engineering tasks can instead be carried out at a centralised location.

For Fieldmade, this also represents an important step towards interoperability with wider defence digital ecosystems. “This brings benefits in terms of leveraging expertise and potentially relying on a more advanced digital infrastructure. Furthermore, it lightens the load of the operators on-site”, noted Tobias Rønneberg.

Advancing digital qualification for on-site production

One of the most important innovations being validated within DISCMAM is the concept of digital qualification for on-site manufacturing. According to Fieldmade, this remains one of the main challenges for wider adoption. “If we can improve on that this is a major step ahead since it will significantly increase the part portfolio that can be produced on-site with confidence”, added Tobias Rønneberg.

Traditional quality assurance methods often rely on sending parts to specialised labs or testing centres, which defeats the purpose of on-site manufacturing. Alternatively, visual inspections performed by equipment operators can only identify surface-level defects and remain highly dependent on individual judgement.

To improve the current situation, DISCMAM is exploring the use of robust and easily transportable equipment for in-field testing and in-process sensors capable of capturing sufficient quality-related data directly during production.

The objective is to provide greater confidence in manufactured components while reducing dependence on traditional testing procedures.

As Nils Knofius explains:

“For Fieldmade the key is of course that we are ready to easily integrate with the digital military platforms and infrastructure. Normally this is a cumbersome process for SMEs. By now having the possibility to test our system with a compliant digital communication pathway makes us future proof and interoperable with the wider defence ecosystem”.

What would make this validation a real step forward?

The final validation phase will focus on demonstrating how these capabilities perform outside controlled factory environments and in the entire workflow.

A key objective for the DISCMAM partner will be benchmarking digital qualification methods against traditional laboratory testing approaches. “Based on first results we are quite confident that we will be able to show that we are close to laboratory testing insights (of course a fully equipped lab will always have some sort of edge)”, highlighted Tobias Rønneberg.

This would represent a significant step forward, as it would make the production of critical components in the field becomes a realistic option. It would also provide a viable pathway for large Original Equipment Manufacturers (OEMs) to make part of their portfolios available for deployed production of their spare parts.

Ultimately, this would contribute to increased resilience, improved system uptime and greater operational readiness for allied forces, addressing one of the most pressing challenges in modern defence logistics.

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