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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Verification, Calibration, and Validation Approaches in Modeling the Mechanical Performance of Metallic Materials
Presentation Title SURGE Ahead: Rethinking Qualification for Additive Manufacturing
Author(s) Andrew Detor
On-Site Speaker (Planned) Andrew Detor
Abstract Scope The DARPA SURGE (Structures Uniquely Resolved to Guarantee Endurance) program is redefining qualification paradigms in additive manufacturing (AM) by shifting from machine-focused efforts to part-specific life prediction. Traditional AM qualification demands exhaustive process optimization and materials testing – often requiring months and millions of dollars for critical parts. SURGE proposes a disruptive alternative: leverage high-fidelity data captured during fabrication to assess mechanical performance and predict part life at the point of production. This approach requires integrating in-situ sensing, advanced modeling, uncertainty quantification, and novel validation strategies to establish confidence in part performance without prior machine pedigree. The program ultimately aims to enable distributed, on-demand AM of critical components across heterogeneous machines and operators. This talk will introduce SURGE’s technical vision and verification framework and highlight recent results from teams executing on the program.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Modeling and Simulation, Other

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