As additive manufacturing (AM) continues to rapidly reshape the manufacturing landscape, one engineering firm has emerged as a leader in accelerating this transformation. The Barnes Global Advisors (TBGA), based in Pittsburgh, PA, acts as the largest independent AM consultancy, providing specialized expertise across materials, systems, process economics, digital, supply chain, sustainability life cycle assessments, workforce development, and advanced manufacturing strategy.

Neighborhood 91 officially opened in October 2022 and is now home to a dynamic ecosystem of leading manufacturers, researchers, and institutions, all focusing on AM advancement and adoption.

“We are a team of experienced professionals who can balance the technical and the strategic.  We turn data into information and information into insights, so the strategy is informed by data,” said the company’s founder, John E. Barnes.

Barnes and his team at TBGA are not only leading AM strategies but also driving tangible initiatives that strengthen the industry’s infrastructure. One example of this is Neighborhood 91, a pioneering effort to build a robust and efficient AM supply chain.

The concept of Neighborhood 91 was born from a collaborative discussion between Barnes and Christina Cassotis, CEO of Pittsburgh International Airport, who sought to transform 200 acres of airport land into an innovation campus. Barnes proposed creating a supply chain model campus focused on AM to leverage Pittsburgh’s existing strengths in manufacturing, materials science, and 3D printing. This vision quickly resonated with key stakeholders, paving the way for a strategic partnership that would transform the idea into reality.

Neighborhood 91 officially opened in October 2022 and is now home to a dynamic ecosystem of leading manufacturers, researchers, and institutions, all focusing on AM advancement and adoption.

“Within two hours of Pittsburgh, we have printer manufacturers, powder production, complementary manufacturing, and prestigious universities. From a workforce standpoint, this region is known for manufacturing. I said that if we consolidated that into a 200-acre campus focused on production, not on research, we would have an interesting model. No one else was doing that,” Barnes said.

Neighborhood 91 is designed to foster collaboration to link the supply chain to accelerate production delivery times, which reduces costs and increases operational efficiency. TBGA’s active participation in Neighborhood 91 not only strengthens local economic growth but also elevates Pittsburgh’s role in the global AM landscape.

Addressing critical industry gaps

Beyond its contributions to Neighborhood 91, TBGA continues to address broader industry challenges through strategic partnerships and initiatives aimed at advancing AM technology and adoption.

A longtime member of America Makes, TBGA is playing an integral role in efforts to develop rapid, cost-effective qualification processes for AM materials. The Delta Qualification projects are crucial for ensuring the reliability and performance of 3D-printed components used in various industries.

“We’ve participated in multiple projects with America Makes. We created a team to lead the Red Team for the government in the Delta Qualification effort. We saw the need and knew it was aligned to our values because this is at the core of what we do,” Barnes shared.

Moreover, in conjunction with the National Center for Defense Manufacturing and Machining (NCDMM), TBGA also had a significant role in the AMNOW program, which addressed a key technology gap within the digital thread associated with sourcing, producing, and delivering parts.

“We take pride in the success of the AMNOW program, made possible through the collaborative efforts of our team, America Makes, NCDMM, and numerous industry organizations. Together, we facilitated producing several parts, new AMS specifications for industry to use, and two flight-critical rotorcraft parts,” Barnes said.

From a broader industry perspective, TBGA, in collaboration with NCDMM and America Makes, is spearheading the New England Advanced Manufacturing Data Challenge (AMNEW) to enhance engineering workforce development (EWD) efforts. This initiative invites high school and undergraduate students in the New England region to apply their skills in metals and polymers, advancing national manufacturing innovation.

Broadening AM’s ecosystem

Neighborhood 91 has inspired discussions about expanding the concept to other regions where potential “neighborhoods” could serve as innovation hubs to address significant domestic needs across the manufacturing industry and the Department of Defense.

With ongoing efforts to expand AM’s potential, particularly through the creation of innovation hubs like Neighborhood 91, TBGA is laying the groundwork for a more efficient, scalable, and interconnected future of manufacturing.

“We are looking at other Neighborhood 91 opportunities to help support key initiatives, such as submarines. To build parts for submarines you need an ecosystem. Can N91 fit that description? How do we best use additive to build submarines and get our production rate up? We are working with BlueForge Alliance on those types of challenges. That’s a fantastic problem to solve,” Barnes said.

This proactive approach to tackling industry barriers to adoption highlights TBGA’s broader role in advancing AM, both locally and globally. From fostering local economic growth through Neighborhood 91 to shaping the future of the AM industry through strategic partnerships and education and workforce development initiatives, TBGA’s leadership, vision, and commitment have positioned it as a driving force in the transformation of global manufacturing. With ongoing efforts to expand AM’s potential, particularly through the creation of innovation hubs like Neighborhood 91, TBGA is laying the groundwork for a more efficient, scalable, and interconnected future of manufacturing.

The Barnes Global Advisors: Advancing AM Ecosystem Through Neighborhood 91 Initiative