HPC4Mfg Advances State-of-the-Art for American Manufacturing

By Tiffany Trader

March 9, 2017

Last Friday (March 3, 2017), the High Performance Computing for Manufacturing (HPC4Mfg) program held an industry engagement day workshop in San Diego, bringing together members of the US manufacturing community, national laboratories and universities to discuss the role of high-performance computing as an innovation engine for American manufacturing.

Keynote speaker Thomas Lange, 36-year veteran of Procter & Gamble (P&G), the manufacturing company well-known in HPC circles for their Pringles success story, engaged the room with a dynamic recounting of the history of manufacturing in the United States. Lange, an industry consultant since leaving P&G in 2015, emphasized the importance of infrastructure and logistics to the rise of American manufacturing. Throughout the last two centuries, he noted, manufacturing success was tied first to waterways (P&G), then to railroads (Sears), to the interstate-highway network (Walmart), and moving into the present day, the Internet (Amazon).

Tom Lange

“Manufacturers have to innovate how we do our thing or we will diminish,” said Lange. “It’s that simple. It’s not just about regulations and cheap labor off-shore; it’s about innovating how we do what we do, not just what we make. And it turns out innovating manufacturing at scale is too expensive to just try it and see what happens. That is the issue; it’s too big; it’s too expensive to mess with.”

The HPC4Mfg program was launched by the Department of Energy in 2015 to directly facilitate this innovation by infusing advanced computing expertise and technology into the US manufacturing industry, where it “shortens development time, guides designs, optimizes processes, prequalifies parts, reduces testing, reduces energy intensity, minimizes green house gas emissions, and ultimately improves economic competitiveness,” according to HPC4Mfg program management. Advancing innovative clean energy technologies and reducing energy and resource consumption are core elements of the program.

Lori Diachin, HPC4Mfg Director

“The HPC4Mfg program has really been designed for high-performance computing and [demonstrating] the benefits to industry,” said HPC4Mfg Director Lori Diachin. “You see a lot of ways that it’s impacting industry in the projects we have now, and these impacts range from accelerating innovation, facilitating new product design, and upscaling technologies that have been demonstrated in the laboratory or at a small scale.”

HPC4Mfg began with five seedling projects and has since implemented three solicitation rounds. (Awardees for the third round are due to be announced very shortly). It is now executing a $8.5-9 million portfolio at Lawrence Livermore, Lawrence Berkeley, and Oak Ridge National Laboratories (the managing partner laboratories for the program). The program is in the process of expanding across the DOE national lab space to include access to computers and expertise at other participating laboratories.

Currently, there are 27 demonstration projects (either in-progress, getting started or going through the CRADA process) and one, larger capability project with Purdue Calumet and US Steel (to develop the “The Virtual Blast Furnace”). The projects get access to the top supercomputers in the country: Titan at Oak Ridge, Cori at Berkeley, Vulcan at Livermore, Peregrine at NREL, and soon Mira at Argonne National Lab.

HPC4Mfg is sponsored by the DOE’s Advanced Manufacturing Office (AMO), which is part of the Office of Energy Efficiency and Renewable Energy. The AMO’s mission is to “partner with industry, small business, universities, and other stakeholders to identify and invest in emerging technologies with the potential to create high-quality domestic manufacturing jobs and enhance the global competitiveness of the United States.”

HPC4Mfg proposal submissions by industrial sector (Source: HPC4Mfg)

High-impact manufacturing areas, such as the aerospace industry, automotive, machinery, chemical processing, and the steel industry, are all represented in the participant pool.

“We aim to lower the barriers, lower the amount of risk that industrial companies have in experimenting with high performance computing in the context of their applications,” said Diachin of the program’s vision and goals. “From our perspective, the status of the industry is that some large companies have a lot of access to HPC. They’re very sophisticated in how they use it. On the flip side, very few small-to-medium-sized companies really have the in-house expertise or the access to compute resources that they need to even try out high performance computing in the context of their problems.

“On the DOE side, we do have a lot of expertise and we have very large-scale computers and so we’re able to bring to bear some of those technologies in a large array of different problems, but I think it’s a challenge – and I’ve heard this many times – for industry to understand how do they get access to the expertise that’s in the DOE labs. What is that expertise? Where does it live? They can’t really track everything that’s going on in all the national labs that the DOE has. And so this program is really designed to help reduce those barriers and create that marriage between industry-interesting challenges and problems and HPC resources at the laboratory.”

In terms of disciplines, computational fluid dynamics is a very widely needed expertise, also materials modeling and thermomechanical type modeling, but there are a wide variety, according to Diachin.

From Concept to Project: Airplanes, Lightbulbs, and Paper Towels

After submitting a concept paper, followed by a full proposal, successful projects receive about $300,000 from the AMO to fund the laboratory participation in the project. The industrial partners are required to provide at least a 20 percent match to the AMO funding. This is usually in the form of “in kind time and effort” but industrial partners can also provide a cash contribution.

Diachin emphasized that concept papers need not identify a particular lab or PI as collaborator, explaining, “You just need to tell us what your problem is and describe it in a way that we understand what simulation capabilities are needed and what’s the impact that you envision being able to achieve if you’re successful in this demonstration project.  The technical merit review team will evaluate each concepts paper for relevance as a high performance computing challenge, appropriateness for partnership with the national laboratories, and its ability to have national scale impact and be successful.  And if you haven’t identified a principal investigator at the national lab, we’ll identify the right place and team from the DOE lab complex to get this work done; this matching process is really a unique feature of the program.“

For a given round, the program typically receives about 40 concept papers from which the program office selects about 20 to go forward to full proposal state. From that they select around 10 to be fully-funded. The proposals are evaluated on how well they advance the state-of-the-art for the manufacturing sector, the technical feasibility of the project, the impact to energy savings and or clean energy production, relevance to HPC, and the strength and balance of the team.

“We are really looking for a strong partnership between the DOE lab and the company,” Diachin told HPCwire. “We’re looking for evidence that there were in-depth discussions as part of the proposal writing process and that there’s a good match in terms of the team.”

Building community and workforce is another important goal here, and the AMO funds about 10 student internships to work on the HPC4Mfg program each year.

In her talk, Diachin highlighted several projects. The LIFT consortium in collaboration with the University of Michigan and Livermore is working to predict the strength of lightweight aluminum lithium alloys produced under different process conditions. Implemented in aircraft designs, the new alloys could save millions of dollars in fuel costs.

SORAA/LLNL: GaN crystal growth

The SORAA/Livermore team is working to develop more efficient LED lightbulbs by modeling ammono-thermal crystal growth of gallium nitride to scale up the process. The goal is to reduce production costs of LED lighting by 20 percent. Project partners say the new high-fidelity model will save years of trial-and-error experimentation typically needed to facilitate large-scale commercial production.

Energy savings in paper-making is the focus of the Agenda2020 Technology Alliance (a paper industry consortium) in collaboration with Livermore and Berkeley. The goal of this project is to use multi-physics models to reduce paper rewetting in the pressing process. The simulations will be used to optimize drying reducing energy consumption by up to 20 percent (saving 80 trillion BTUs and $250 million each year).

In another paper-related project, P&G and their lab partner Livermore are using HPC to evaluate different microfiber configurations “to optimize the drying time while maintaining user experience.” The project resulted in the development of a new mesh tool, called pFiber, that reduces the product design cycle by a factor of two for smaller numbers of fibers and processing cores, and by a factor of eight for higher fiber counts using a larger number of cores.

This P&G project also illustrates the return on investment for the laboratories. The example represents the largest non-benchmark run done with the Paradyn code at Livermore. “These are very challenging problems that the industry is putting forward that are stretching the capabilities and making our capabilities at the national labs more robust,” said Diachin.

One area that is receiving a lot of attention is additive manufacturing, which is broadly used among multiple industry sectors and thus fits with the role of HPC4Mfg to foster high-impact innovation. “It’s a very hot topic for modeling and simulation, both to better understand the processes and the properties of the resultant parts,” said Diachin.

A collaboration involving United Technologies Research Center (UTRC), Livermore and Oak Ridge is one of the projects studying this industrial process. Their focus is on dendrite growth in additive manufacturing parts. UTRC is one of those companies that has a lot of sophisticated modeling and simulation experience, Diachin explained. “They came to the table with some models that they had in hand that they could run in two dimensions, but they weren’t able to take into three dimensions, so the collaboration is taking the models that they have and looking at implementing them directly in a code at Livermore called AMP and running that to much larger scale. At the same time, at Oak Ridge, there are alternate models that can be used to model these processes, so they are developing these alternate models and then they will compare and contrast these different models to understand the process better. So it’s a very interesting approach.”

Once the projects create these large-scale models in partnership with the labs, there can be a need to then down-scale the applications to employ them in industrial settings. This is where reduced order modeling comes in. “This can be a very nice use of the resources and expertise at the labs,” Diachin told HPCwire. “The way reduced order models often work is you run very large-scale, fine-resolution, detailed simulations of a particular phenomenon and from that you can extract basis vectors from a number of different parameter runs. You can then use those basis vectors to create a much smaller representation of the problem – often two to three orders of magnitude smaller. Problems that required high-performance computing can then be run on a small cluster or even a desktop and you can do more real-time analysis within the context of the parameter space you studied with the large-scale run. That’s a very powerful tool for process optimization or the process decisions you have to make in an operating environment. “

HPC4Mfg focuses on manufacturing right now, but the concept is designed to be scalable. “We get a lot of concept papers that are very appropriate for other offices potentially within the Department of Energy and we have been informally socializing them. With the next solicitation we’re going to make that more formal. Jeff Roberts from Livermore National Lab has been working with Mark Johnson at the AMO and others to really expand the program into a lot of different areas,” said Diachin.

The program runs two solicitations per year, in the fall and in the spring. The next funding round will be announced in mid to late March with concept papers due the following month. After the announcement, the HPC4Mfg program management team will be conducting webinars to explain the goals of the program, the submission process and answer any questions.

Announced Projects:

Spring 2016 Solicitation Selectees

Fall 2015 Solicitation Selectees

Seedlings

Subscribe to HPCwire's Weekly Update!

Be the most informed person in the room! Stay ahead of the tech trends with industy updates delivered to you every week!

AMD Epyc CPUs Now on Bare Metal IBM Cloud Servers

April 1, 2020

AMD’s expanding presence in the datacenter and cloud computing markets took a step forward with today’s announcement that its 7nm 2nd Gen Epyc 7642 CPUs are now available on IBM Cloud bare metal servers. AMD, whose Read more…

By Doug Black

Supercomputer Testing Probes Viral Transmission in Airplanes

April 1, 2020

It might be a long time before the general public is flying again, but the question remains: how high-risk is air travel in terms of viral infection? In an article for the Texas Advanced Computing Center (TACC), Faith Si Read more…

By Staff report

ECP Milestone Report Details Progress and Directions

April 1, 2020

The Exascale Computing Project (ECP) milestone report issued last week presents a good snapshot of progress in preparing applications for exascale computing. There are roughly 30 ECP application development (AD) subproj Read more…

By John Russell

Russian Supercomputer Employed to Develop COVID-19 Treatment

March 31, 2020

From Summit to [email protected], global supercomputing is continuing to mobilize against the coronavirus pandemic by crunching massive problems like epidemiology, therapeutic development and vaccine development. The latest a Read more…

By Staff report

What’s New in HPC Research: Supersonic Jets, Skin Modeling, Astrophysics & More

March 31, 2020

In this bimonthly feature, HPCwire highlights newly published research in the high-performance computing community and related domains. From parallel programming to exascale to quantum computing, the details are here. Read more…

By Oliver Peckham

AWS Solution Channel

Amazon FSx for Lustre Update: Persistent Storage for Long-Term, High-Performance Workloads

Last year I wrote about Amazon FSx for Lustre and told you how our customers can use it to create pebibyte-scale, highly parallel POSIX-compliant file systems that serve thousands of simultaneous clients driving millions of IOPS (Input/Output Operations per Second) with sub-millisecond latency. Read more…

Pandemic ‘Wipes Out’ 2020 HPC Market Growth, Flat to 12% Drop Expected

March 31, 2020

As the world battles the still accelerating novel coronavirus, the HPC community has mounted a forceful response to the pandemic on many fronts. But these efforts won't inoculate the HPC industry from the economic effects of COVID-19. Market watcher Intersect360 Research has revised its 2020 forecast for HPC products and services, projecting... Read more…

By Tiffany Trader

Pandemic ‘Wipes Out’ 2020 HPC Market Growth, Flat to 12% Drop Expected

March 31, 2020

As the world battles the still accelerating novel coronavirus, the HPC community has mounted a forceful response to the pandemic on many fronts. But these efforts won't inoculate the HPC industry from the economic effects of COVID-19. Market watcher Intersect360 Research has revised its 2020 forecast for HPC products and services, projecting... Read more…

By Tiffany Trader

Weather at Exascale: Load Balancing for Heterogeneous Systems

March 30, 2020

The first months of 2020 were dominated by weather and climate supercomputing news, with major announcements coming from the UK, the European Centre for Medium- Read more…

By Oliver Peckham

Q&A Part Two: ORNL’s Pooser on Progress in Quantum Communication

March 30, 2020

Quantum computing seems to get more than its fair share of attention compared to quantum communication. That’s despite the fact that quantum networking may be Read more…

By John Russell

DoE Expands on Role of COVID-19 Supercomputing Consortium

March 25, 2020

After announcing the launch of the COVID-19 High Performance Computing Consortium on Sunday, the Department of Energy yesterday provided more details on its sco Read more…

By John Russell

[email protected] Rallies a Legion of Computers Against the Coronavirus

March 24, 2020

Last week, we highlighted [email protected], a massive, crowdsourced computer network that has turned its resources against the coronavirus pandemic sweeping the globe – but [email protected] isn’t the only game in town. The internet is buzzing with crowdsourced computing... Read more…

By Oliver Peckham

Conversation: ANL’s Rick Stevens on DoE’s AI for Science Project

March 23, 2020

With release of the Department of Energy’s AI for Science report in late February, the effort to build a national AI program, modeled loosely on the U.S. Exascale Initiative, enters a new phase. Project leaders have already had early discussions with Congress... Read more…

By John Russell

Servers Headed to Junkyard Find 2nd Life Fighting Cancer in Clusters

March 20, 2020

Ottawa-based charitable organization Cancer Computer is on a mission to stamp out cancer and other life-threatening diseases, including coronavirus, by putting Read more…

By Tiffany Trader

Kubernetes and HPC Applications in Hybrid Cloud Environments – Part II

March 19, 2020

With the rise of cloud services, CIOs are recognizing that applications, middleware, and infrastructure running in various compute environments need a common management and operating model. Maintaining different application and middleware stacks on-premises and in cloud environments, by possibly using different specialized infrastructure and application... Read more…

By Daniel Gruber,Burak Yenier and Wolfgang Gentzsch, UberCloud

[email protected] Turns Its Massive Crowdsourced Computer Network Against COVID-19

March 16, 2020

For gamers, fighting against a global crisis is usually pure fantasy – but now, it’s looking more like a reality. As supercomputers around the world spin up Read more…

By Oliver Peckham

Julia Programming’s Dramatic Rise in HPC and Elsewhere

January 14, 2020

Back in 2012 a paper by four computer scientists including Alan Edelman of MIT introduced Julia, A Fast Dynamic Language for Technical Computing. At the time, t Read more…

By John Russell

Global Supercomputing Is Mobilizing Against COVID-19

March 12, 2020

Tech has been taking some heavy losses from the coronavirus pandemic. Global supply chains have been disrupted, virtually every major tech conference taking place over the next few months has been canceled... Read more…

By Oliver Peckham

[email protected] Rallies a Legion of Computers Against the Coronavirus

March 24, 2020

Last week, we highlighted [email protected], a massive, crowdsourced computer network that has turned its resources against the coronavirus pandemic sweeping the globe – but [email protected] isn’t the only game in town. The internet is buzzing with crowdsourced computing... Read more…

By Oliver Peckham

DoE Expands on Role of COVID-19 Supercomputing Consortium

March 25, 2020

After announcing the launch of the COVID-19 High Performance Computing Consortium on Sunday, the Department of Energy yesterday provided more details on its sco Read more…

By John Russell

Steve Scott Lays Out HPE-Cray Blended Product Roadmap

March 11, 2020

Last week, the day before the El Capitan processor disclosures were made at HPE's new headquarters in San Jose, Steve Scott (CTO for HPC & AI at HPE, and former Cray CTO) was on-hand at the Rice Oil & Gas HPC conference in Houston. He was there to discuss the HPE-Cray transition and blended roadmap, as well as his favorite topic, Cray's eighth-gen networking technology, Slingshot. Read more…

By Tiffany Trader

Fujitsu A64FX Supercomputer to Be Deployed at Nagoya University This Summer

February 3, 2020

Japanese tech giant Fujitsu announced today that it will supply Nagoya University Information Technology Center with the first commercial supercomputer powered Read more…

By Tiffany Trader

Tech Conferences Are Being Canceled Due to Coronavirus

March 3, 2020

Several conferences scheduled to take place in the coming weeks, including Nvidia’s GPU Technology Conference (GTC) and the Strata Data + AI conference, have Read more…

By Alex Woodie

Leading Solution Providers

SC 2019 Virtual Booth Video Tour

AMD
AMD
ASROCK RACK
ASROCK RACK
AWS
AWS
CEJN
CJEN
CRAY
CRAY
DDN
DDN
DELL EMC
DELL EMC
IBM
IBM
MELLANOX
MELLANOX
ONE STOP SYSTEMS
ONE STOP SYSTEMS
PANASAS
PANASAS
SIX NINES IT
SIX NINES IT
VERNE GLOBAL
VERNE GLOBAL
WEKAIO
WEKAIO

Cray to Provide NOAA with Two AMD-Powered Supercomputers

February 24, 2020

The United States’ National Oceanic and Atmospheric Administration (NOAA) last week announced plans for a major refresh of its operational weather forecasting supercomputers, part of a 10-year, $505.2 million program, which will secure two HPE-Cray systems for NOAA’s National Weather Service to be fielded later this year and put into production in early 2022. Read more…

By Tiffany Trader

Exascale Watch: El Capitan Will Use AMD CPUs & GPUs to Reach 2 Exaflops

March 4, 2020

HPE and its collaborators reported today that El Capitan, the forthcoming exascale supercomputer to be sited at Lawrence Livermore National Laboratory and serve Read more…

By John Russell

Summit Supercomputer is Already Making its Mark on Science

September 20, 2018

Summit, now the fastest supercomputer in the world, is quickly making its mark in science – five of the six finalists just announced for the prestigious 2018 Read more…

By John Russell

IBM Unveils Latest Achievements in AI Hardware

December 13, 2019

“The increased capabilities of contemporary AI models provide unprecedented recognition accuracy, but often at the expense of larger computational and energet Read more…

By Oliver Peckham

TACC Supercomputers Run Simulations Illuminating COVID-19, DNA Replication

March 19, 2020

As supercomputers around the world spin up to combat the coronavirus, the Texas Advanced Computing Center (TACC) is announcing results that may help to illumina Read more…

By Staff report

IBM Debuts IC922 Power Server for AI Inferencing and Data Management

January 28, 2020

IBM today launched a Power9-based inference server – the IC922 – that features up to six Nvidia T4 GPUs, PCIe Gen 4 and OpenCAPI connectivity, and can accom Read more…

By John Russell

Summit Joins the Fight Against the Coronavirus

March 6, 2020

With the coronavirus sweeping the globe, tech conferences and supply chains are being hit hard – but now, tech is hitting back. Oak Ridge National Laboratory Read more…

By Staff report

University of Stuttgart Inaugurates ‘Hawk’ Supercomputer

February 20, 2020

This week, the new “Hawk” supercomputer was inaugurated in a ceremony at the High-Performance Computing Center of the University of Stuttgart (HLRS). Offici Read more…

By Staff report

  • arrow
  • Click Here for More Headlines
  • arrow
Do NOT follow this link or you will be banned from the site!
Share This