Deployable manufacturing center (DMC) system and process for manufacturing metal parts

A deployable manufacturing center (DMC) system for manufacturing metal parts comprising:

• a foundry module configured to store a feedstock, to remove contaminants from the feedstock, to melt the feedstock to form a molten metal, and to atomize the molten metal into an alloy powder, the foundry module comprising a metallurgical system and a first container configured to contain the metallurgical system, the metallurgical system comprising a plasma torch configured to heat the feedstock into the molten metal, a mixing cold hearth configured to mix the molten metal into a uniform composition and an atomization system configured to atomize the molten metal into the alloy powder;
• an additive manufacturing (AM) module configured to form the alloy powder from the foundry module into rough metal parts, the additive manufacturing (AM) module comprising an additive manufacturing system and a second container configured to contain the additive manufacturing system, the additive manufacturing (AM) system comprising a system selected from the group consisting of 3-D printer systems, direct energy deposition systems, powder bed fusion systems and cold spray systems;
• a machining module configured to machine the rough metal parts formed by the additive manufacturing (AM) module into the metal parts, the machining module comprising a machining system and a third container configured to contain the machining system;
• and
• a quality conformance (QC) module configured to inspect and evaluate the metal parts, the quality conformance module (QC) module comprising an inspection and evaluation system and a fourth container configured to contain the inspection and evaluation system;
• the first container, the second container, the third container and the fourth container configured for deployment to a desired location for manufacturing the metal parts at the desired location.