skip to Main Content
Flexible Sawing Solution For Additively Manufactured Parts

Flexible Sawing Solution for Additively Manufactured Parts

The growing additive manufacturing industry has demanded new requirements in the sawing process. Article by Behringer.

Additive manufacturing, or 3D printing, has become more and more important in nearly all industries. 3D printing is a ground-breaking and innovative technology that has the potential to bring intermediate changes in manufacturing, society and business. As a crucial medium connecting the virtual and actual world, 3D printing enables the transformation of digital files into tangible objects.

According to market analyst firm Inkwood Research, the global 3D printing market is expected to register a compound annual growth rate (CAGR) of 17 percent from 2019 to 2027 and reach a value of US$ 44.39 billion at the end of the forecast period. While North America is the dominating region, Asia Pacific is the fastest growing market for 3D printing.

One important and growing segment of the 3D printing market is the metal additive manufacturing industry. Metal additive manufacturing is increasingly becoming popular among automobile manufacturers across the world. This is because additive manufacturing helps automakers to build stronger and lighter parts within a short period. The technology is now widely adopted by various Formula 1 teams, including Scuderia Ferrari, Williams Martini Racing, and Mercedes-AMG Petronas to produce lighter components such as rear wings, gearbox assemblies, and bodywork to improve the performance of their cars. Many supercar manufacturers are also adopting metal additive manufacturing to reduce overall cost, lead time, and weight. The rising adoption of metal additive manufacturing in the automobile industry is expected to fuel the growth of the market. According to a report by market analyst Technavio, the metal additive manufacturing industry is expected to grow by $4.42 billion during 2020–2024. 

High Sawing Precision

The additive manufacturing processes make it possible to produce simple as well as complex parts in different materials. 3D printing offers many advantages, such as higher design flexibility, and the individualization of the products (a batch size of one). From a process perspective, the additively manufactured parts are printed on a base plate via a supporting structure. To use and process the 3D printed parts, they have to be detached from the base plate.

To address this trend, and in line with the 100th anniversary of Behringer, the company expanded its product portfolio with the release of its 3D-Series of sawing machines. Available in two models—the two models HBE320-523 3D and LPS-T 3D—the high-performance sawing machines were developed for cutting additively manufactured parts in different sizes and shapes.

To continue reading this article, head on over to our Ebook!

 

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Sandvik Coromant Joins Forces With Microsoft To Shape The Future Of Manufacturing

CHIRON Launches First 3D Metal Printer

New Chucks For Standardised Processes

Boeing Partners With Oerlikon To Increase Adoption Of 3D Printing

DKSH and HP Discuss Industrial Transformation Through 3D Printing

Achieving Consistent Quality

Renishaw Sees Continued Demand for Accuracy and Precision Driving Growth

Auto Sector Faces Biggest Existential Crisis Since 2007-09

Sheet Metal Fabricator Cuts Inspection Time by 60%

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

Heraeus AMLOY, Trumpf Open Door To Industrial 3D Printing Of Amorphous Metals

Heraeus AMLOY, Trumpf Open Door To Industrial 3D Printing Of Amorphous Metals

Heraeus AMLOY and Trumpf have started working together on the 3D printing of amorphous metals, also known as metallic glasses, with the aim of establishing the printing of amorphous parts as a standard production method on the shop floor by improving process and cost efficiencies.

Amorphous metals are twice as strong as steel, yet significantly lighter and more elastic. They exhibit isotropic behaviour, which means their material properties remain identical, regardless of the direction in which the 3D printer builds up the workpiece. In addition to creating highly robust parts, 3D printing also gives engineers more freedom in the design process. A number of areas could benefit from 3D printing of amorphous metals. Key examples include parts that are subject to significant stresses and lightweight design in sectors such as aerospace and mechanical engineering. These materials are also an excellent choice for medical devices due to their biocompatibility.

“3D printing of amorphous components in industry is still in its infancy. This new collaboration will help us speed up printing processes and improve surface quality, ultimately cutting costs for customers. This will make the technology more suitable for a wider range of applications, some of which will be completely new,” said Jürgen Wachter, head of the Heraeus AMLOY business unit.

“Amorphous metals hold potential for numerous industries. For example, they can be used in medical devices – one of the most important industries for additive manufacturing. That’s why we believe this collaboration is such a great opportunity to make even more inroads into this key market with our industrial 3D printing systems,” said Klaus Parey, managing director Trumpf Additive Manufacturing.

READ: Trumpf Enters The World Of Automated Arc Welding

READ: Trumpf Enables Automated Removal, Stacking of Parts

The new TruPrint 2000 3D printer from TRUMPF is the ideal choice for printing amorphous metals from Heraeus AMLOY.

The new TruPrint 2000 3D printer from Trumpf is the ideal choice for printing amorphous metals from Heraeus AMLOY.

Amorphous metals are formed by cooling molten metal extremely quickly. A 3D printer can then build them into larger, more complex parts—something that other methods are unable to do. This opens the door to new industrial applications for amorphous metals. 3D printing also exploits the considerable potential that amorphous metals hold for lightweight design. A 3D printer only builds structures that actually help a part fulfil its function, so material use and weight are kept to a minimum. For their part, amorphous metals are very light by nature, so the combination of 3D printing and amorphous metals can reduce weight in all sorts of applications. 3D printing makes the production of amorphous parts faster and simpler in a wide range of contexts. The technology enables users to build parts in one piece instead of making components one by one and then assembling them into a finished part.

In this cooperation, Heraeus AMLOY combines its expertise in the production and processing of amorphous metals with Trumpf’s experience in additive manufacturing. Heraeus AMLOY has optimized its amorphous alloys for 3D printing and tailored the material for use with Trumpf’s TruPrint systems. The latest-generation TruPrint 2000 machine is a particularly good choice for printing amorphous metals. The machine is designed in such a way that the excess powder can be prepared in an inert gas environment for the subsequent building process. This protects the powder from any adverse influences. This is a key benefit for amorphous metals because they react so quickly with oxygen. Trumpf has also boosted the productivity of the TruPrint 2000. Two 300-watt lasers scan the machine’s entire build chamber in parallel. Using a laser focal diameter of just 55 micrometers, users can carry out both low and high-volume production of amorphous parts with extremely high surface quality. The “Melt Pool Monitoring” function automatically monitors the quality of the melt pool, so any errors in the process are spotted at an early stage.

Customers that already have a Trumpf 3D printer can now use it to process zirconium-based alloys from Heraeus AMLOY. It is also possible to order 3D-printed amorphous parts directly from Heraeus AMLOY. The two partners are also hoping to make copper- and titanium-based alloys available for 3D printing in the future.

 

For more exclusive news and information, visit www.equipment-news.com.

 

Check these articles out:

Punching Machine Adaptability: Room to Grow

BrightLine Weld – A Revolution In Laser Welding

Nissin Electric To Move Production From Thailand And Vietnam To Myanmar

Outlook For Welding And Cutting Equipment Market

PTG Introduces Powerstir Dual Weld-Head Friction Stir Welding For Electric Vehicle OEMs

Coherent Launches Turnkey Solution for Precision Metal Parts Welding

Hypertherm: FlushCut Consumables

Faster Robot Programming With Hypertherm Robotmaster Version 7.2

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

3D Printing Plays Vital Role In New Normal

3D Printing Plays Vital Role in New Normal

COVID-19 has disrupted every aspect of life, accelerating changes in everything from simple daily tasks to traditional key business models; citizens worldwide are preparing for a new normal. In addition to vast social ramifications, the fallout from the COVID-19 pandemic has exposed the fragility and complicated nature of both manufacturing and supply chains as well as their susceptibility to disruption from disease, political unrest, or natural disaster.

Out of necessity, manufacturers in the new normal will build factories much closer to where critical parts are needed, reduce the human workforce, and rely more on software and efficiency technologies like 3D printing. At the epicentre of this sea of change is Sigma Labs Inc., with its revolutionary patented technology that detects and identifies defects and anomalies in real-time during the 3D printing process of metal, paving the way for scalability and economic efficiency.

Amazon.com Inc. has created a blueprint for consumer supply chain evolution, proving the importance of bringing outputs closer to where they are needed. Microsoft Corp. has turned its software prowess toward 3D printing in a consortium that has created a modern manufacturing 3D printing file format, 3MF. For additive manufacturing, this new format replaces older file formats and eliminates many interoperability issues.

Software behemoth Autodesk Inc. makes a broad range of 3D software tools, essential for rapid prototyping and industrial manufacturing, for almost every industry. Engineering simulation software from ANSYS Inc. allows innovation to flow smoothly through design, testing and into 3D printing manufacturing. Software and technology are becoming increasingly important as the world grapples with how to reinvent social interaction and commerce in the post pandemic era.

3D Metal Printing: The Promise and Challenge

Almost daily news reports attest to the speed, agility, and efficiency of 3D printing to create and deliver desperately needed healthcare equipment and devices. Additive manufacturing (AM) is proving in real time that it speeds production, allows flexibility, and brings new ideas to market quicker at lower cost.

Though 3D printing of plastics and polymers has moved easily into the mainstream, and home printers now sell for under $300, 3D metal printing is proving to be a horse of a different colour. Commercial 3D metal printing is gaining vital importance in the entire global manufacturing sector—yet the efficiency it yields is not without challenges. A myriad of variables from machines to materials create production hurdles in metal additive manufacturing. 3D metal part manufacturing continuously welds 10- to 30-micron layers of powdered metal together with a laser to sculpt a final three-dimensional product. Like something from science fiction, a machine is actually creating the metal of a part while simultaneously forming the shape of the part.

As amazing as this process is, metal additive manufacturers lack any assurance that each newly formed part meets precise specifications in every 10-micron layer of a 3D part. As a result, 3D metal printing manufacturers have been forced to rely on costly and time-consuming post-production inspection techniques such as CT scan inspection—which are effective, but also extremely costly.

To meet the supply chain demands of the new normal, achieve high quality volume yields and slash post-production inspection costs, the quality assurance problem in 3D metal manufacturing requires a solution. Third party in-process quality assurance is critical to the adoption and acceleration of metal AM and imperative to adaptation of the new normal of global manufacturing.

Sigma Labs’ Solution

With its patented PrintRite3D software, Sigma Labs presents a solution to the costly quality-control challenges that impede the volume manufacture of precision 3D metal parts. In doing so, Sigma Lab’s software could easily become indispensable in the global efforts to meet the manufacturing challenges of post COVID. The company’s breakthrough software has the potential to bolster and broaden commercial metal additive manufacturing by enabling for the first time cost-effective, non-destructive quality assurance during the production process. PrintRite3D is the leading technology in identifying and classifying defects and anomalies in-process and allows for errors to be corrected in real-time—even remotely.

From its inception by scientists at Los Alamos, Sigma Labs has led the world in developing software that addresses serious quality assurance issues in metal additive manufacturing and has become the leading provider of in-process, quality assurance software to the commercial 3D metal printing industry. Sigma Labs’ breakthrough software looks to be the missing element to fully enable commercial additive metal manufacturing at scale. The company has rocketed from beta development and third-party validation of efficacy to engaging multiple beta customers with some of the biggest names in industry, to use in prestigious universities and R&D institutes, and now to commercialization in an untapped market estimated at over $2 billion dollars.

Sigma Labs has surrounded its IP portfolio with 34 issued and pending patents both domestically and across the globe. These patents encompass the fundamental technologies underlying Sigma Labs’ melt-pool process control, data analytics, anomaly detection, signature identification and future closed-loop-control of 3D metal printing.

Many believe that Sigma Labs’ PrintRite3D is the singular solution the additive manufacturing industry needs. PrintRite3D integrates inspection, feedback, data collection and critical analysis into a unified platform. Unheard of before in the industry, PrintRite3D uniquely leverages thermal signatures to monitor the quality of each product part in the production process, layer by layer and in real time. This allows operators to correct or stop production of a defective part, even remotely, which results in reduced error rates and higher yields and scalability. This incredibly sophisticated and powerful technology may play a key role in the new normal post-pandemic era.

Confluence of Opportunity and Circumstance

3D printing was already posting an astounding CAGR of nearly 30 percent before the world was beset by this virus, and with the impending shifts in supply chain strategy, it’s hard to imagine that 3D printing won’t expand at even greater rates. Industry 4.0 has been underway, and 3D printing remains at the forefront of the $100 trillion-dollar technological transformation, accelerating the confluence of digital, biological, and physical innovations across the planet. The circumstances of this virus will only expedite industry and societal adoption of these transformations.

Sigma Labs enjoys a significant technological lead with formidable barriers of entry, which effectively impedes any potential competition. The company has established strategic partnerships, surrounded the IP with patents and is laser focused on the opportunity ahead. Interestingly, Sigma Lab’s unique business model accelerates both revenue growth and profitability in direct correlation to the explosive industry growth of additive manufacturing. Sigma Labs’ technology is a critical component in a major disruptive industry and has been validated across all major customer segments.

Sigma Lab’s functionality and coverage of 3D printers as well as the depth and breadth of its market footprint are as yet unmatched in the industry by any other third-party solution. The company has identified an addressable market in 2021–2027 of approximately $2 billion and is well on the way to achieving its strategy and mission statement to accelerate the adoption of AM and become the de facto standard for third-party in-process quality assurance of metal 3D printing.

As suppliers continue to seek ways to improve the efficiency of their supply chains while maintaining a strong bottom line, potentially moving production centres closer to distribution outlets, 3D metal printing’s capability and promise have the potential to resonate with industries of all kinds. Sigma Lab’s revolutionary software could prove crucial to reducing time and cost of product development, qualification, and post-processing quality assurance as factories of the future respond to the challenges of the times.

Business in the New Normal

Amazon has already done much to change the shape of supply chains. Its movement of distribution centres closer to the consumer  reflects some of the benefits of 3D printing by producing products closer to where needed. This has allowed Amazon incredible efficiencies, leading to next-day, same-day, and even two-hour delivery of products. Its efficient delivery service has made Amazon a critical resource for many during the COVID-19 crisis.

Software giant Microsoft has extensive experience with supply chain interruption and 3D printing, even before the virus made its presence felt in the United States. Microsoft was hit early on by the effects of the virus in China and the measures needed to control it. Microsoft also invested in the technology several years ago, indicating its confidence in the potential of 3D printing in manufacturing.

Autodesk describes its work as making software for people who make things. The company makes a broad range of 3D software tools for almost every industry, essential for rapid prototyping and industrial manufacturing. Its recent alliance with Aurigo Software provides integrated solutions for the design, manufacture, and production of everything from towering skyscrapers to tiny gadgets. One of six companies creating the Large Additive Subtractive Integrated Modular Machine (LASIMM), one of the world’s largest hybrid manufacturing machines, Autodesk is rapidly bringing 3D printing up to industrial scale across multiple components and sectors.

ANSYS develops multi-physics engineering simulation software for product design, testing and operation. By simulating the performance of products under stress, its software exposes weaknesses in designs, significantly reducing the time and cost involved in bringing production online. Using its products for a complete simulation workflow can help companies move additive metal production from R&D to successful manufacturing operations. Sigma Labs looks to integrate its QA software with ANSYS’s simulation software, to further improve this workflow.

As the world continues to witness the disruption of traditional business models due to the fallout from COVID-19, technological innovations will play an increasingly important role in adjusting to the new normal.

 

For more news and information, visit www.equipment-news.com.

 

Check these articles out:

DKSH and HP Discuss Industrial Transformation Through 3D Printing

Igus Expands 3D Printing Service By Injection Moulding With Printed Tools

HP Inc. And Partners Battles COVID19 With 3D Printing Solutions

Additive Manufacturing and Journey to Industry 4.0

Powering Additive Manufacturing With Data Analytics

HP: Eight Trends In 3D Printing

EOS: Additive Manufacturing For The A350 XWB

Easy And Fast 3D Printing: Igus Tribo-Filaments

With Additive Manufacturing To More Productivity

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Siemens Improves 3D Printing And Scanning Workflows

Siemens Improves 3D Printing And Scanning Workflows

The latest improvements in Siemens Digital Industries Software’s Parasolid can help enable engineers to solve the toughest technical challenges and achieve a clear and growing advantage when implementing 3D printing and scanning based workflows.

Further advances in Convergent Modeling give engineers greater efficiency in workflows that need to mix facet and B-rep geometry, while new functional foundations have been implemented to support lattice structures. Lattices are comprised of repeating networks of nodes and beams and were extremely difficult to manufacture until the advent of 3D printing. Lattices offer increased strength-to-weight ratio compared with solid material, so engineers can design parts with reduced material requirements and mass, while maintaining the required structural integrity.

Additive manufacturing techniques are now bringing the performance benefits of lattice structures into production, driving new requirements for lattice modelling in the design process. Vendors of design and manufacturing software applications that license Parasolid can help deliver the benefits of new lattice modelling functionality to their customers.

[WATCH] Siemens Discusses Initiatives, Outlook Amid COVID-19

The Parasolid geometric modelling kernel is used in Siemens’ own Solid Edge software and NX software and is at the core of the Xcelerator portfolio’s open and flexible ecosystem. Parasolid is also used by over 350 other products including many world-leading CAD/CAM/CAE/AEC software applications.

 

For other exclusive news and information, visit www.equipment-news.com.

 

Check these articles out:

Automotive Manufacturing Developments In Southeast Asia Amid COVID-19

Aircraft Milled Parts Market To Reach US$4.3B In 2025

Top 10 Fast Fab And Metrology Articles For 2019

Mitsui Seiki Remains Operational Amid COVID-19 Guidelines

ABI Research Names Siemens A Leader In Manufacturing Simulation Software

Siemens Connects Healthcare Providers And Medical Designers To Produce Components Through AM

Industrial Automation Sector Amid COVID-19 Pandemic

COVID-19 Forces Companies To Evaluate How They Operate And Embrace Technological Investment

Pandemic Highlights the Need for Smarter, More Adaptable Cities

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

CHIRON Launches First 3D Metal Printer

CHIRON Launches First 3D Metal Printer

CNC vertical milling and turning machining centre specialist CHIRON Group has developed the AM Cube, its first 3D metal printer for manufacturing larger, more complex components. Suitable for coating and repairing components, as well as printing near net shape parts, the new printer extends CHIRON’s core competencies to include additive manufacturing, alongside its existing focuses on metal machining and automation. The AM Cube 3D metal printer was one of the product highlights at CHIRON’s OPEN HOUSE ONLINE held last May 14–19.

“The Additive Manufacturing department is a start-up within our own business group,” explained Axel Boi, head of additive manufacturing at CHIRON. “With this 3D metal printer, made by CHIRON, we are creating a facility for manufacturing larger components with long procurement times and high material prices. This technology can be used effectively in the mechanical engineering, tool manufacturing, energy production and aerospace sectors. These are all important target sectors for the CHIRON Group.”

The new AM Cube is based on a conventional cartesian coordinate system, just like a CNC machining centre. Operation and programming of the AM Cube is intuitive. The system is programmed either using a standardised DIN ISO code or, for complex components, using a CAD/CAM software tool. All aspects of the system can be controlled using tried-and-tested Siemens components, from hardware to the HMI through to programming of the AM Cube.

READ: Global Aerospace 3D Printing Market Poised To Surpass $2,857 Million By 2024

READ: Accelerate Smart Additive Manufacturing with Simulation

Laser metal deposition with wire.

Laser metal deposition with wire.

Unlike other 3D metal printers, the print head of the CHIRON AM Cube can be changed during an active printing/ coating process. This option enables the AM Cube to be used to combine different process requirements: For instance, one print head could be used to achieve a high surface quality, and another could be used to achieve a high deposition rate. The automatic head change function enables these properties to be combined in a single workpiece. This is another area where the professionals at CHIRON have put their comprehensive process expertise and many years of experience in using machining centres into practice. Due to the low quantities manufactured using this process, high flexibility is a crucial factor across all industries. The AM Cube is equipped with a total of three print heads. With the AM Cube, wire and powder as deposition material can be applied within a single manufacturing process in different production phases.

Deposition welding with different raw materials

By designing a printer for the two commonly used deposition materials—wire and powder—the machining centre manufacturer has also patented a completely new technology. Both processes have their applications: While coating with powder is the most commonly used process, wire-based laser metal deposition offers better safety characteristics and an impressive reduction in waste material. Wire also has the benefit that every type of welding wire can be used for manufacturing.

The system is designed as a platform and can be reconfigured from 4-axis machining to 5-axis machining with relatively little effort. The AM Cube is equipped with cutting-edge sensors and meets all relevant safety requirements for operation without monitoring by the operator. If the AM Cube is used to machine particularly reactive materials such as titanium, the entire system can be flooded with protective gas to reduce oxidation, enabling manufacturing to be performed under a protective gas atmosphere for several hours.

 

For more news and information, visit www.equipment-news.com.

 

Check these articles out:

DKSH and HP Discuss Industrial Transformation Through 3D Printing

Igus Expands 3D Printing Service By Injection Moulding With Printed Tools

HP Inc. And Partners Battles COVID19 With 3D Printing Solutions

Additive Manufacturing and Journey to Industry 4.0

Powering Additive Manufacturing With Data Analytics

HP: Eight Trends In 3D Printing

EOS: Additive Manufacturing For The A350 XWB

Easy And Fast 3D Printing: Igus Tribo-Filaments

With Additive Manufacturing To More Productivity

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Formula Student Team Used AM To Produce Oil Cooling System For Electric Racers

Formula Student Team Used AM To Produce Oil Cooling System For Electric Racers

The Formula Student team from Stuttgart solved the thermal stress issues in electric racers by creating an oil cooling system though additive manufacturing (AM). Article by EOS. 

Racers must keep a cool head—and their cars should not overheat either. This applies equally to racing cars with combustion engines and electric motors. The difference: in fuel-fired racers the engine has to be tempered, in electric vehicles this must be considered in particular for the accumulator. The Formula Student team from Stuttgart has solved this task in the truest sense of the word with an additively manufactured oil cooling system and support from EOS.

Challenge

A complex battery system requires powerful heat dissipation—no big deal thanks to additive manufacturing. (Source: GreenTeam Uni Stuttgart)

A battery—as accumulators are called today—for an electric car has diva-like characteristics. It needs to be treated with caution. This applies not only to mechanical stress, but also to thermal stress: It doesn’t like temperatures that are too high or too low. The reason for this is the behaviour of the electron flow: If it is too cold, the electrons do not migrate fast enough for the maximum power output due to the higher internal resistance. If the temperature is too high, for example if the maximum power output is maintained for a longer period or if the climate is simply hot, there is a risk that membranes will be destroyed or that they will age more rapidly, even to the extent of the so-called thermal runaway. 

In order to guarantee an optimum working range, appropriate systems are necessary; liquid-based solutions have the advantage that they can also heat the cells and thus maintain high performance – which is of course of central importance in racing. Oil cooling systems offer very good properties for the battery, but can only be realized with great effort using traditional construction methods: The filled quantity should be kept as low as possible in order to save weight. This also reduces space requirements, which plays a major role not only in tightly cut racing cars.

“In addition, the flow characteristics in the system are important for achieving a high volumetric flow rate,” says Florian Fröhlich from the Stuttgart Formula Student GreenTeam. “Several aspects have to be considered in order to secure an optimum flow velocity, including the expedient design and the lowest possible surface resistance.”

The aim of the racing team was to ensure that a major part of the fluid constantly circulates in the area of the cell flags. Additionally, as oil is quite aggressive, the chosen material must feature a certain level of chemical resistance, while at the same time it must follow the lightweight character of the entire project. High fire resistance is obligatory in racing anyway.

Solution

The young racing team set to work with this sporty technical wish list. Simulations on Computational Fluid Dynamics (CFD) resulted in the expedient design of the cooling system, which is made up of flux direction parts and inlet devices. The geometry was optimized in such a way, that a consistent flow is created through the outlets with their compact design and high surface quality. Due to the planned construction geometry and the incorporated hollow structures as well as, of course, the very small number of units, additive manufacturing was the best choice for the production process: The required flow properties would not have been reproducible with traditional methods.

 

To continue reading this article, head on over to our Ebook!

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

NAP 2020 Drives Malaysia’s Automotive Sector

Infusing Purpose Into Emerging Technologies

Interroll’s New Plant In Thailand Fully Operational

EOS Launches Versatile Online Platform To Fight Further Spread Of The Virus

DKSH and HP Discuss Industrial Transformation Through 3D Printing

Renishaw’s XM-60 Offers Easy Alignment For Stage Builders

KASTO: The Intuitive Way To The Right Storage Space

Hexagon Upgrades VISI CAD/CAM Software

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

High-precision Layer Work

High-precision Layer Work

Find out how MBFZ toolcraft ensures holistic quality control in additive manufacturing. Article by ZEISS

Frederik Mack, Materials Engineer at toolcraft, examines a test specimen under the ZEISS Axio Imager microscope, which he sawed out of a 3D-printed part and ground.

Additive manufacturing is an uncharted territory for many companies, but not for MBFZ toolcraft GmbH. The company in Georgensgmünd, Southern Germany, manufactures high-end precision parts for the aerospace, automotive, medical technology and semiconductor industries, among others, and since 2011 also parts using 3D printing. The young established production technology is a challenge for quality assurance. Toolcraft is mastering this challenge with ZEISS 3D ManuFACT, the only solution on the market for continuous quality assurance in additive manufacturing.

Heat, noise, the smell of oil: They belong to industrial manufacturing like Yin to Yang. Yet this is quite different in the glass hall at toolcraft in Georgensgmünd. Anyone who has access to the area with their employee ID card hears nothing. They smell nothing either. There are few reminders of factory life as we have known it for a hundred years, because parts are not manufactured the way they have been for a hundred years. Instead of peeling the mold out of cast or forged metal blocks by drilling, milling and turning, additive manufacturing comes at the process from the other way.

Through small windows on the twelve 3D printing machines at toolcraft, you can watch glistening laser beams dancing over a wafer-thin layer of metal powder. Where the spot of light hits, the powder melts in a flash and immediately solidifies again, followed by the next layer. Thousands of hair-thin layers are used in 3D laser melting to create „impossible“ components that could never be produced with traditional subtractive manufacturing. Whereas ten years ago only prototypes and design studies were produced by using additive manufacturing, manufacturers of aircraft turbines, racing cars or medical equipment are increasingly incorporating them directly into their series products.

Challenges for Quality Assurance

As always, when a new technology emerges in a market, there are always questions. One of them is quality assurance. Jens Heyder points to a monitor that shows two images taken with the ZEISS Axio Imager light microscope at 50x magnification. On the left you can see a section of a good component. There are no large defects visible, only small pores. The material has an even, homogeneous structure. On the right, there is a cross cut shown, in which blowholes and welding defects are present. The construction process here was not optimal, which is why errors occurred during solidification of the melt.

“Crack formation could occur under high loads,” warned Heyder, who has been working as a material engineer in toolcraft’s materials laboratory for three years. Together with his colleagues, he checks the grain size distribution of the metal powder used. They help to optimize the manufacturing process in such a way that no defects occur in the part during melting and solidification. 

However, the materials laboratory is only one component in the seamless quality assurance at toolcraft. Each process step is followed by a test: when a part comes out of the printer, after heat treatment and finally after milling into the final form, before the part is sent to the customer. Not every part is inspected. Random samples are taken according to customer requirements where typical parts only undergo a final inspection. For more demanding customer requirements, such as the aviation industry, 100% inspection is required. 

But one thing is for sure: when a part is inspected, it is done on a machine with the ZEISS logo. These can be found in several places in measuring rooms and in production at the company: two microscopes (ZEISS Axio Imager and ZEISS Axio Zoom.V16), several coordinate measuring machines (two ZEISS ACCURA, one ZEISS CONTURA and one ZEISS DuraMax) as well as an optical 3D scanner. Although the latter bears the GOM logo, the company also belongs to the ZEISS family since spring 2019.

 

To continue reading this article, head on over to our Ebook!

 

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Intelligent Machine Software For Improved Machining

Hexagon And Ericsson Host Joint Webinar On The Role Of 5G In Industry 4.0

The AMable Project Promotes Flexible AM Solutions To Fight The Coronavirus

Driving the Next Industrial Revolution

NAP 2020 Drives Malaysia’s Automotive Sector

A Look At How 3D Measurement Technology Helps Reduces Total Lead Time

Driving For A Better Tomorrow Hexagon Manufacturing Intelligence

Large-Scale Metrology For Oil Industry Production

ZEISS Acquires GOM To Furthers Its Goal of Technological Leadership in Industrial Metrology and Quality Assurance

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

DOST Metals Industry Research And Development Center Is Mass Producing 5000 Face Shields Daily

DOST Metals Industry Research and Development Center Is Mass Producing 5000 Face Shields Daily

The Department of Science and Technology – Metals Industry Research and Development Center (DOST-MIRDC) is ramping up production of medical face shields to meet the Philippines’ demands for personal protective equipment (PPEs) for the frontline workers battling COVID-19.

Through its Additive Manufacturing Center, DOST-MIRDC was initially producing 50 3D printing face shields a day. To ramp up its production, DOST-MIRDC has fabricated a plastic injection mould at the Die and Mould Solution Center in its Bicutan, Taguig City compound. Using plastic injection technology, it has boosted its production capabilities to 2,500 face shields a day.

READ: The AMable Project Promotes Flexible AM Solutions To Fight The Coronavirus

Furthermore, DOST-MIRDC has partnered with Omnifab, which fabricated another injection mould, and Megasamsotite Plant in San Pedro, Laguna which serves as another site for mass production—totalling production of another 2,500 face shields daily.

“With the mass production of the medical face shields being done simultaneously in Laguna and in Taguig, we can assure the enhanced protection of our frontliners,” said Engr. Fred P. Liza, Chief of the Materials and Process Research Division, and Project Leader of the DOST-MIRDC’s Advanced Manufacturing Center (AMCen).

READ: Automotive Manufacturing Developments In Southeast Asia Amid COVID-19

In addition, the Industrial Technology Development Institute (ITDI), another DOST R&D institute has 3D printed 100 face shields for Philippine Heat Center.

“As we make change happen through research and development, we find ways in helping out our new heroes facing COVID-19. We shall continue to look for better means to support our frontliners through research and development,” said Rowena Guevara, DOST undersecretary for R&D.

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Thailand’s Auto Parts Sector Shrinks Amid COVID19

COVID-19 Forces Companies To Evaluate How They Operate And Embrace Technological Investment

Sandvik Coromant Extends Advanced Insert Grades To Additional Milling Concepts

Sheet Metal Fabricator Cuts Inspection Time by 60%

Leuze Electronic Opens New Logistics Center In Singapore

Philippines Starts Construction of First 3D Printing R&D Centre

Siemens Connects Healthcare Providers And Medical Designers To Produce Components Through AM

Aircraft Milled Parts Market To Reach US$4.3B In 2025

Hexagon WORKPLAN 2021: Enhancing Automation In The Sheet Metal Market

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

EOS Launches Versatile Online Platform To Fight Further Spread Of The Virus

EOS Launches Versatile Online Platform To Fight Further Spread Of The Virus

EOS has launched a versatile online platform and LinkedIn Group to support the battle against COVID-19 on all levels.

In times of crisis individuals, organisations and governments need to stand together. EOS is developing solutions and utilising their network to facilitate inspirational exchange. The team leveraged its global network of suppliers, partners, customers and the broader EOS community.

READ: HP Inc. And Partners Battles COVID19 With 3D Printing Solutions

EOS’s open platform initiative features relevant data, impactful projects, and offers valuable files free to download – ready to print. All of these are designed to support pandemic-fighting and life-saving approaches. The 3DAgainstCorona site will be updated on a regular basis.

“Improving people’s lives with the help of 3D printing has always been our aspiration. The current pandemic now calls for a joint approach, more than ever before. Today, we are asking all supporters to join us in tackling the challenges that lay ahead of us. Let’s do what our technology is enabling us for: Let’s think differently and push the boundaries of what is possible,” said Marie Langer, CEO of EOS.

During a pandemic, scalable and on-demand capabilities become key

The key goal for governments worldwide currently is to maintain adequate patient care. Those fighting COVID-19 on the frontlines are often lacking proper protection equipment due to difficulties in supplying the vast numbers needed e.g. in hospitals worldwide.

READ: Fight Against Corona: TRUMPF Retrofits Mini-Lasers For Ventilators

At the same time, the challenges continue while trying to meet the immense demand for medical devices, protective clothing and masks. Federal governments are approaching both traditional and 3D printing manufacturers to support production scaling of medical equipment needed in a pandemic.

One of the most valuable benefits additive manufacturing can contribute here is that it can help to reduce the sole dependence on traditional supply chains. Based on AM, critical shortages can be more rapidly addressed. Moreover, traditional manufacturing ramp up is accelerated and further supply chain shortages can be eliminated via digital manufacturing.

READ: Impact of COVID-19 On The Automotive Manufacturing Supply Chain

At the same time, the latter also enables a more distributed manufacturing. Data can be shared or sent across the globe and products can be 3D printed where they are most needed. Which becomes even more important during a pandemic when supply chains are disrupted by international shutdowns and transport restrictions.

 

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Renishaw Sees Continued Demand for Accuracy and Precision Driving Growth

Increasing Automation, Connectivity And Energy Efficiency In Metal Cutting

Growth Of Malaysia’s Aerospace Industry

Coronavirus Hits Automotive And Aerospace Supply Chains

Rolling With Additive Manufacturing In The Automotive Sector

Hyundai Motor To Establish A Smart Mobility Innovation Centre In Singapore

EOS To Intensify Collaboration With Siemens For Metal-Based Serial Additive Manufacturing

Renishaw Ramps Up Production Of Ventilator Components

Smart Data in the Metalworking Industry

HP Inc. And Partners Battles COVID19 With 3D Printing Solutions

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Renishaw Sees Continued Demand For Accuracy And Precision Driving Growth

Renishaw Sees Continued Demand for Accuracy and Precision Driving Growth

Steve Bell of Renishaw ASEAN talks about their activities in Thailand and provides his insights on the trend towards electric vehicles.

Steve Bell

Renishaw is one of the leading providers of precision measurement and sensor technologies worldwide. Based in Gloucestershire, United Kingdom, the company has 4,500 employees located in the 36 countries where it has wholly owned subsidiary operations.

At the recent METALEX 2019 trade exhibition in Bangkok, Thailand, Asia Pacific Metalworking Equipment News (APMEN) sat down with Steve Bell, general manager for ASEAN at Renishaw, to talk about their Thailand market, and the industries they are looking at in the region.

READ: Renishaw Ramps Up Production Of Ventilator Components

“We’ve been in Thailand for over 25 years now,” says Bell. “During that time, there have been a lot of changes in Thailand, particularly economically and politically. But generally, through it all Thailand has maintained steady growth. The last couple of years have been something of an exception with the economy being a little flat, but we do now see signs of the market looking up again.”

At METALEX, Renishaw showcased a similar concept they did at the recent Industrial Transformation Asia Pacific (ITAP) 2019 event in Singapore, where they highlighted end-to-end manufacturing of aerospace parts – from initial additive manufacturing, through machining to final assembly – with process and quality control built into every stage. For the Thailand show, the focus is on automotive, rather than aerospace.

READ: Sandvik And Renishaw Collaborate To Qualify New AM Materials

“We are showing automotive parts. Our aim is to show how Renishaw can provide end-to-end solutions—when it comes to Industry 4.0, smart manufacturing, we have the tools to contribute to that drive. Here at Metalex, we are showing the complete story of a component, starting from additive manufacturing, making parts lighter while retaining strength through metal 3D printing parts with a lattice work, largely hollow internal construction. Next up is a calibration station, basically illustrating that before you start the process of manufacturing, you have to ensure that the machines you plan to use are accurate, repeatable and fit for the purpose. Precision machining of critical tight tolerance features follows with on-machine probing and toolsetting being used to set up the part and set the tools to be used. The machine tool is hooked up to an Equator automated flexible gauge which inspects key features of the parts coming off the machine, analyses the trend of results and automatically updates tool offsets in the machine tool control to keep the process within tolerance levels. Lastly, we reach final inspection where we’re showing a CMM with the latest REVO five-axis system,” explains Bell.

Automotive Industry

According to Bell, the automotive manufacturing industry is currently rather flat in Thailand but it remains a key sector for Thailand. “Many of our customers are in Thailand are involved directly in the automotive industry –  that’s why we’ve chosen to feature automotive parts here,” he explains. “We are also beginning to a lot of discussion on additive manufacturing in Thailand. There are a number of projects that we are pursuing in that area. Another big growth area for Renishaw in Thailand is the Equator automated gauging line. We are seeing a lot of manufacturers — particularly Japanese high volume part producers — who have embraced Equator technology and are now using it quite significantly in their manufacturing processes.”

READ: Renishaw Shares Outlook On Vietnam And Philippines

Bell pointed out the maturity of Thailand’s manufacturing industry demonstrated the willingness to adopt and utilize Renishaw’s advanced solutions. “The market is of course driven by our end-user customers. There is a demand for high-quality products, for high-precision parts,” he explains. “And where there is that demand, manufacturers are looking for ways to achieve quality and accuracy … and to become more profitable as they do so. Therefore, products like the Equator gauge are absolutely right for the customers we deal with in Thailand.”

(Editor’s Note: This interview took place in November 2019—months before the COVID-19 outbreak caused a significant impact in the industrial manufacturing landscape.)

 

To continue reading about Thailand’s EV Vehicle development and the outlook for 2020, head on over to our ebook!

For other exclusive articles, visit www.equipment-news.com.

 

Check these articles out:

Manufacturing Sector Maintains Growth Trajectory Amid Challenging Market Conditions

Renishaw Demonstrates Additive Manufacturing Capabilities For Spinal Implants

Renishaw & Infosys To Accelerate Metal Additive Manufacturing Use

Hypertherm Implements Strategies to Enhance Preventive Maintenance Program In Asia

EMO Milano 2021: Meet “the magic world of metalworking”

MVTec Expands Distributor Network in Southeast Asia

Vietnam Could Be The Next Strategic Production Centre For Hyundai

ABB Supports Growing EV Market In Indonesia

Toyota To Invest Two Billion In Indonesia For Electric Vehicles

 

 

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

Back To Top