Could We Really Make Anything, Anywhere, Anytime? A Deep Dive into Distributed Manufacturing
Dr. Charles Johnson-Bey, ERVA Co-Principal Investigator, SVP – Booz Allen Hamilton (retired)
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Distributed manufacturing allows goods to be produced closer to where they’re needed — but enabling that future requires a complete rethink of infrastructure, systems, and workforce development.
In this episode of The TechEd Podcast, Dr. Charles Johnson-Bey joins host Matt Kirchner for a deep dive into Engineering the Future of Distributed Manufacturing — the new national report from the Engineering Research Visioning Alliance (ERVA). Charles, a former professor and recently retired Senior Vice President at Booz Allen Hamilton, brings decades of experience in defense, systems engineering, and academia to this conversation.
Together, they break down ERVA’s five priority areas for enabling distributed manufacturing: modular and reconfigurable infrastructure, digital design tools, edge-to-cloud data systems, workforce education, and new performance metrics. Charles also shares how these priorities came from input across industry, academia, and government — and how they’ll guide research, funding, and education in the years ahead.
Listen to learn:
- What distributed manufacturing actually looks like in practice — and why it matters now
- Why “digital twins + AI” are critical for linking design, production, and data-driven decision-making
- The essential role of public infrastructure in enabling connectivity and access for all communities
- Why proximity to advanced tools like a digital twin or a cyber-physical testbed is essential for scaling distributed manufacturing
3 Big Takeaways from this Episode:
1. Distributed manufacturing is a modular approach to resilient, tech-enabled production. Charles defines distributed manufacturing as a system where production assets can be easily moved, reconfigured, and localized closer to the point of need. He describes how smaller, agile, and digitally connected systems—like reconfigurable machines and regional testbeds—enable manufacturing to respond to disruptions, like the ones exposed during COVID-19.
2. The workforce of the future needs digital fluency—and systems thinking. Students must be prepared not only to operate new technologies, but to understand how those technologies interact within broader systems. Charles highlights the importance of human-machine teaming, digital twins, and cyber-physical testbeds, and calls for education that helps learners “fall in love with the rigor” of complex technical work.
3. America’s manufacturing strategy must include small and mid-sized firms. Charles points out that most manufacturers in the U.S. are small to mid-sized, yet lack access to advanced infrastructure and scalable tools. He argues that national strategies must focus on democratizing technology—making AI, automation, and data systems affordable and available to all levels of the manufacturing sector.
Resources in this Episode:
- Read the ERVA Report: Engineering the Future of Distributed Manufacturing
- Learn more about ERVA
Connect with ERVA on Social Media:
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