igus has expanded its 3D printing service for fast production of maintenance-free special parts, and increased design freedom in the automotive industry.
Additive manufacturing is giving designers new freedom and flexibility in the design of special solutions, including the development of efficient vehicle components. If lightweight and durable wear-resistant parts are required, 3D printing is one way of cost-effectively achieving it.
A quick response time and customised design are daily business in the development divisions of the automotive industry. Accordingly, the industry needs partners who deliver special solutions in small quantities, cost-effectively and in the shortest possible time. Because responding quickly to new requirements creates real competitive advantages in the hard fought automotive market.
One company focusing on this aspect is igus, whose 3D printing service is enabling users to order their special part made of tribologically optimised polymers online in just a few seconds, with the option to choose from over 55 lubrication-free iglidur materials.
The expanded 3D printing service from igus is particularly suitable for the short-term production of wear-resistant parts. The motion plastics specialist uses 3D printing to cost-effectively produce prototypes or batches within a very short time. The main advantage of additive manufacturing: the designer has maximum freedom in the design of his component, without having to invest in expensive steel tools with long delivery times.
igus manufactures the solutions from its highly wear-resistant iglidur tribo-polymers. Tests in the igus laboratory show that they are up to 50 times more abrasion-resistant than standard polymers and can keep up with injection-moulded parts in terms of wear resistance. The printed wear-resistant parts made of high-performance polymers are also lightweight and quiet in motion—both an important criteria for vehicle construction. Printed solutions from igus are already being used in turbochargers, as pivot bearings in wheel carriers or for mounting a gas ring in special vehicle construction.
Print2Mould Process Ensures Free Choice of Materials
In the igus 3D printing service, the user can freely choose between different manufacturing processes: they can either manufacture their component using the laser sintering process with the iglidur I3 or iglidur I6 tribo-polymers, or alternatively, using seven different filaments using the FDM process.
For the individual component to be made from the ideal iglidur material for the respective application, igus also offers the Print2Mould process. An injection moulding tool is printed for the special solution and is then used in the injection moulding machine. This allows the user to make free use of the iglidur material range with its 55 tribo-polymers.
Expanded 3D Printing Service
Wear-resistant parts are used wherever there is friction between two surfaces. For this reason, designers in many industrial sectors rely on 55 long-lasting, lubrication-free, high-performance polymers from igus.
To help users quickly get their special solution made of a suitable material, igus has now integrated the Print2Mould process in its online 3D printing service. With a printed tool, the component is manufactured by injection moulding. To do this, the user simply uploads the STEP file of the wear-resistant part into the 3D printing service, selects the material and requests a quotation. Specifications on the material properties as well as the precision, flexural strength and the price help with the choice.
55 iglidur high-performance polymers: if customers are looking for a wear-resistant plain bearing, they can choose from a large selection of igus materials. However, if wear-resistant parts are required—from gears up to special bushings—in any special shape, the user can either machine the component from a suitable iglidur bar stock or use igus’ 3D printing for more complex geometries. For the individual component to be made from the ideal iglidur material for the respective application, igus offers the Print2Mould process. An injection moulding tool is printed for the special solution and is then used in the injection moulding machine. The main advantage: the user can freely use the iglidur material range with its 55 lubrication-free, high-performance polymers. These include iglidur L500 for the automotive sector, and iglidur X for high-temperature applications. igus has now integrated the Print2Mould process online 3D printing service. The production of special parts by this process is characterised above all as a time-saving solution for prototype development and for small batches. This gives the customer the opportunity to obtain identical components in batches at an early stage of development.
Wear-resistant components requested online
The way to a lubrication-free and maintenance-free special solution is very simple: call up the 3D printing service at www.igus.eu/iglidur-designer, upload the STEP file of the component and select the appropriate material.
In addition to the 55 iglidur materials used in the Print2Mould process, the customer also has the opportunity to get their special solution printed cost-effectively in the SLS process with the wear-resistant materials iglidur I3 or iglidur I6 or even in the FDM process with iglidur filaments. The price for production, including the costs for the injection moulding tool as well as information about the material, precision and flexural strength are shown online. After selecting the appropriate high-performance polymer, the user can enter the quantity and directly request a quotation from igus. The additively manufactured special solutions are available after just three to five days. In the case of the Print2Mould process, the injection-moulded solutions are ready for shipping after 10 business days.
Wear-resistant parts are used wherever there is friction between two surfaces. To help users quickly get their special solution made of a suitable material, igus has now integrated the Print2Mould process in its online 3D printing service. With a printed tool, the component is manufactured by injection moulding. To do this, the user simply uploads the STEP file of the wear-resistant part into the 3D printing service, selects the material and requests a quotation. Specifications on the material properties as well as the precision, flexural strength and the price help with the choice.
55 iglidur high-performance polymers
If customers are looking for a wear-resistant plain bearing, they can choose from a large selection of igus materials. However, if wear-resistant parts are required – from gears up to special bushings – in any special shape, the user can either machine the component from a suitable iglidur bar stock or use igus’ 3D printing for more complex geometries.
For the individual component to be made from the ideal iglidur material for the respective application, igus offers the Print2Mould process. An injection moulding tool is printed for the special solution and is then used in the injection moulding machine.
The main advantage: the user can freely use the iglidur material range with its 55 lubrication-free, high-performance polymers. These include, the FDA-compliant materials iglidur A350 and A181 for use in the food industry, iglidur L500 for the automotive sector, and iglidur X for high-temperature applications.
The production of special parts by this process is characterised above all as a time-saving solution for prototype development and for small batches. This gives the customer the opportunity to obtain identical components in batches at an early stage of development.
Due to the co-operation between Ultimaker and igus, the processing of the iglidur tribo-filaments in the Ultimaker 3D printers has become a lot easier. Neither special knowledge nor programming expertise is required to produce lubrication-free, low-wear components. The extensive material tests and the open source software “Cura” make this possible.
The free open source software “Cura” from Ultimaker makes it very easy for users to manufacture their individual components quickly. In just a few minutes, a 3D model is prepared, and after selecting speed and quality, the printing starts.
With pre-configured filament profiles available from the Ultimaker Marketplace, users no longer need to enter specific parameters for their printing material, but still get the best print results at the touch of a button. These profiles are based on extensive tests of the various materials in the Ultimaker printers and include the iglidur tribo-filaments from motion plastics specialist igus, which enable users to print components specifically optimised for friction and wear, such as plain bearings, clamping devices or complex components.
“The collaboration between Ultimaker and igus transforms the processing of iglidur filaments in Ultimaker 3D printers into a ‘plug & play’ solution”, notes Tom Krause, Director of Additive Manufacturing at igus. For this, it is necessary to install the filament profiles in the Cura software, through which the CAD data is transformed into a processable 3D printing file. Experienced users can adapt the provided material profiles to their needs by changing different parameters. The Cura software also allows users to create their own material profiles.
iglidur filaments – friction-optimised polymers for 3D printing
iglidur filaments are suitable for all types of components in motion where wear and friction play a role. Tests in the 3,800 square metre igus test laboratory showed that they have up to 50 times more wear resistance than conventional 3D printing materials. The 3D print with the tribo-filaments from igus is a cost-saving alternative especially in the production of complex moving parts subject to wear in jigs and fixtures, in small batches and special machine construction. For customers who do not have their own 3D printer, igus also offers a 3D printing service for wear-resistant parts, both with iglidur tribo-filaments and with their own laser sintering materials. Customers can upload their data, choose the material, predict the service life, calculate prices and order their individual wear-resistant parts online.
The continuous dirt accumulation poses the biggest challenge for the deep-hole drilling and milling machine. This article looks at how the energy supply for such machines can be maintained reliably under extreme environmental conditions. Article by igus.
The AX-TLF series from Auerbach Maschinenfabrik GmbH combines conventional milling techniques with modern deep-hole drilling systems in one machine.
In machines combining milling and drilling functions, extremely high demands are made on the energy supply system for the main spindle. Dust, dirt and drilling fluid account for maximum loads from the outside. From the inside, heavy hydraulic hoses, in particular, affect the stability. Most of the time, the manufacturer relies on the very thick plastic energy tube for supply so that the performance data of the universal machine remains correct in the long run. This also protects and routes all cables and hoses.
“The continuous dirt accumulation poses the biggest challenge for the deep-hole drilling and milling machine,” says Thomas Gemeinhardt, managing director of the Auerbach Maschinenfabrik GmbH in Ellefeld. “In addition, the performance data of the machine tools increase, but the availability of interior space remains the same. To supply energy to the main spindle reliably, Auerbach uses the new energy tube ‘RX’ in its multi-function ‘AX-TLF’ type, which combines the milling and deep-hole drilling systems in one machine.” According to Gemeinhardt, it is 100 percent tight and ensures safe cable protection even in continuous use.
Milling and Deep-hole Drilling Systems in One
Manufacturing machine tools for over 60 years, Auerbach Maschinenfabrik manufactures not just the traditional milling machines, but also multi-functional machines.
Gemeinhardt comments, “Our customers want multi-functional machines. As a result, our specialty today is the combination of conventional milling techniques with modern deep-hole drilling systems in one machine.”
The ‘AX-TLF’ type series not only saves on purchase costs. The necessary set-up times can be reduced because the complete machining is possible with only one clamping. Depending on the design, the machines work on workpieces with drill diameters from 6mm to 65mm—in special cases up to 100 mm—whereby in one move, drill depths of up to 2.1mm, and in special cases up to 3mm, are possible. “We feel well-equipped for the future,” says Gemeinhardt.
Quality is top priority at the company. “With our high-quality machines, we want to constantly maintain our position as a special supplier in the market,” says Gemeinhardt. “For this, we have our own development department to implement specific customer requirements. We place value on the traditional German engineering quality. This also applies to the selection of suppliers.”
The AX-TLF type series consists of five basic machines, which serve as a platform for numerous variation options. This modularity pays off. In addition to the traditional mold-making and tooling, the combination machines are used in, among other things, the aviation and aerospace industry, general mechanical engineering, solar industry, apparatus engineering, and the oil and gas industry. This wide-ranging spectrum of applications brings more than the most varied machining demands. Even the choice of materials is wide, ranging from soft graphite through aluminum, and standard steels up to high-strength stainless steels and titanium alloys.
Thick, taut hydraulic hoses that are as hard as an iron bar increase the pressure within the energy tube.
Addressing Continuous Dirt Accumulation
“Our machines are versatile,” says Gemeinhardt. In general, they can handle all types of materials. The requirements for a machine vary, such as the components used. And in this instance, dirt accumulation plays a major role. Graphite, for example, is machined dry and is extremely abrasive and lubricating. If it is not exhausted, the entire environment would be black in the shortest time. When it comes to deep-hole drilling, where a lot of drilling oil is used, this creeps in everywhere and is extremely aggressive.
One option is the minimum quantity lubrication. It only works with customers who machine a defined material. Here, lubricated air cooled at high pressure is used for deep-hole drilling. Due to the atomized oil, the particles fly through the work area before they settle everywhere.
While supplying energy to the main spindle, the plastic energy tube lies always in the immediate chip area. This means that hot chips remain partially on the tube, and it is exposed to continuous dirt accumulation and drilling oil. In the process, the machines, depending on orders, work in three shifts for seven days a week. In addition to the extreme environmental conditions, there is a particularly small bending radius of 100mm. And taut hydraulic hoses that are as hard as an iron bar increase the pressure within the energy supply system.
The rounded design of the energy supply system simply makes the chips bounce off. In addition, the pin/hole connection elements and the stop dogs are covered, so that no chips can stick there.
Enter the RX Energy Tube
“Due to increased milling capacity, we sought an even more robust solution for the energy supply for a customer as part of a retrofit with new built-in pressure hoses,” recalls Gemeinhardt. Since that time, only the RX energy tubes in the size 40 are used in the combination machine for milling and drilling.
The RX e-tube enclosed cable carriers from igus offer extreme protection against chips and dirt.
“Our universal machine tool needs to assert itself in a tough competition. Improvements are in the details,” says Gemeinhardt. “Accordingly, we are constantly improving the performance data of our machines. We are currently developing, for example, a water-cooled spindle. Here, the machine is equipped simultaneously with sealing air, which means we must lay two more cables.” Therefore, here, the new large RX size with an inner height of 73mm should be used to ensure energy supply.
Safety plays a key role when humans and robots work hand in hand in the industry. That is why users of cobots and industrial robots are already using igus’ multi-axis round triflex R e-chains for energy and data supply. To easily attach these energy chains and increase work safety in industry, igus has now developed new plastic mounting clamps. With quick installation, these minimise the risk of injury with their rounded edge design. By igus
In the course of Industry 4.0, the interaction between humans and machines is increasingly becoming the focus of automation. Therefore, collaborative robots will play an increasingly role in the future. Currently, cobots are mainly used as assistants in simple or interacting activities and – in contrast to large and fast industrial robots – work hand in hand with humans. For reliable energy supply to cobots and industrial robots, igus offers the optimal energy chain solution with its triflex R range. In addition to metal clamps, customers can now use new cobot designed clamps to attach the energy chain to the robot arm. The design with rounded edges increases workplace safety by reducing the risk of injury when in contact with the robot. The plastic clamps can be quickly attached to the arm of the robot by a screw connection. The triflex R is simply attached to the clamp by a clip and fixed. The new clamps are suitable for cobots from Universal Robots, TMS and Kuka LBR iiwa robot arms.
Triflex Energy Chains For A Safe Energy Supply On The Robot
The triflex R range has been specifically developed for sophisticated 6-axis robots in industrial environments. By combining the flexibility of a hose with the stability of an energy chain, the round triflex R ensures reliable cable guidance in multi-axis movements. A ball/socket principle ensures high tensile strength and easy installation of the e-chain. The interior separation is freely selectable. The circular bend radius stop and the high twistability of the e-chain prevent the over-stressing of cables – this system increases the service life and operational reliability of the application. The triflex e-chains are available as a complete package with cobot designed clamps, cables and connectors immediately ready for connection.
In 2018, we witnessed the rise of Southeast Asia’s manufacturing industry as the Trade War pressured manufacturers into shifting production from China to Southeast Asia. A trend that is expected to continue on in 2019 as Southeast Asia continues to develop its manufacturing capabilities and uncertainties over a US-China truce continue to loom. Through this market outlook series, eight industry leaders share their thoughts on how the regional market will grow and develop in 2019 amidst the changing economic background and the increased presence of disruptive and intelligent technologies.
Vice President, Asia-Pacific Area, MAPAL
2018 was a successful year for MAPAL and the company grew once again although growth in the Chinese market, which had previously been strong, flattened somewhat in the last quarter of 2018 due to factors such as punitive tariffs. For 2019, we have set a goal of generating a turnover of €650 million, and this will be achieved through free trade, the development of country specific expansions, the enhancement of digital capabilities and electric mobility machining capabilities.
Development Of Country Specific Expansions
For the companies under MAPAL Group in Southeast Asia, two new regional branches will be established in Indonesia where we are seeking to build a regional presence. While in the case of Malaysia, the country recently became our Southeast Asia production hub and has been equipped with a dedicated manufacturing facility. Additionally, we are actively investing in Malaysia and expansion is set to continue in Thailand too, where a new facility was established in 2017.
Enhancement Of Digital Capabilities
Digitalisation is a pressing issue globally, and in the face of increasing demands for efficient data management systems, we have identified this trend as a potential growth area. That was why we will be using 2019 to make further refinements to c-Com and to showcase the SaaS solution to interested parties as an open cloud platform for efficient data management.
MAPAL’s new tool management 4.0 is also based on c-Com. The interconnectivity that tool management 4.0 offers means that data can be provided consistently to all those involved – manufacturing, procurement, planning, tool managers and suppliers. That makes the overall process more efficient and digitalises tool management.
We also see great potential in our re-tooling service. Customers use this when they are setting up a new manufacturing facility for a part or re-tooling existing machinery to manufacture a new part, or when optimisations need to be made while production is running.
Electric Mobility Machining Capabilities
Alongside digitalisation, another significant trend at the moment is electric mobility and we have a diverse array of innovative machining solutions available for manufacturing the various parts within the different electric drives. The importance of the automotive industry is growing all the time, as is the number of vehicles being produced with electric drives.
Head of igus Asia Pacific, igus Singapore Pte Ltd
The Asia Pacific region will remain as the growth driver for us in 2019 but we may see regional differences in development. This is due to uncertainties related to tariffs and trade, Brexit discussions and regional tensions may cause some interruption on a global scale. However, in terms of long term sustainability, the opportunities in Asia far outweigh the challenges and we will continue to invest into new markets or expand existing manufacturing facilities.
Combining Digitalisation With Industrial Development
The world is changing faster than ever before, new trends are coming up and past solutions may disappear. Artificial intelligence, complete process automation, remote monitoring of machine performance, intelligent robotics and driverless vehicles are some of the trends in which we see a potential in. The clear objective for us moving forward is to concretely implement automated processes that range from online configuration to digitally supported manufacturing for all product categories. This is a difficult path to take because ready-made solutions usually cannot be bought but have to be developed individually.
Additionally, IoT continues to drive development. And igus as an early adopter, has developed the intelligent cable, energy chain and linear guide which are able to monitor their own condition during use and open up new possibilities of predictive maintenance.
Additive Manufacturing And Low Cost Robotics
Additive manufacturing would be another key trend to mention, with 3D or SLS printing being good examples of the technology. Also, low cost robotics are another trend to watch out for in 2019 and the igus robolink modular robotic system is an example of this.
Asia Pacific Regional Director, Hypertherm
2018 marked Hypertherm’s 50th year and we have grown from a manufacturer of plasma systems to a global provider of cutting solutions. Moving forward, our continued investment in research and development is part of our efforts to bring more breakthrough technologies to the market, such as the recently released X-definition class plasma system.
In 2019, Asia Pacific will continue to be a promising region for the industry due to rapid population and economic growth, industrialization and business-friendly measures introduced by governments. Besides the major markets in Oceania and Japan, the rapidly growing industrial manufacturing sector in India and Southeast Asia are also expected to contribute significantly to the region’s economic growth.
Change In Business Models In The Metal Cutting Industry
The metal cutting industry will shift from a demand driven model to a more competition driven model, where the key driver is automation and customers are increasingly looking to reduce reliance on labour. In fact, automation will continue to be the biggest development in the metal cutting industry as manufacturers in the region continue to balance technology with capacity and competitive demands.
Industry 4.0 Innovations
IIoT will continue to shape the manufacturing industry in 2019. Rising technologies such as machines, robots and other equipment on a production floor will be able to communicate with each other and gather data in the cloud for analysis. And with the data, a manufacturer will have greater insights which allows for predictive analysis to occur. This aligns to the shift in the industry from preventive maintenance to predictive maintenance.
In the future, fluctuating raw material prices will also impact the industry and transformations within the manufacturing sector will also be further propelled by the rapid evolution of technology. To achieve growth targets in the coming year, manufacturers will increasingly see the need to prioritize investments in technology that will enable them to improve their business agility.
Senior Vice President. EOS, Singapore
The additive manufacturing (AM) market is set to grow at a compound annual growth rate (CAGR) of around 27 percent between 2018 (USD 1.73 billion) and 2023 (USD 5.66 billion). In fact, AM in Asia Pacific is expected to have the highest CAGR due to the region having the fastest growth for the automotive and printed electronics sectors. This offers more opportunities for AM adoption in the manufacturing industry.
Decentralised, Distributed And Domestic Manufacturing Models
Rising protectionism and trade conflicts will increasingly push global supply chains towards decentralization and regionalization when it comes to manufacturing. And this, coupled with the digitalization of manufacturing and AM will serve as an enabler for distributed manufacturing. Businesses that adopt smart technologies like AM to 3D print parts and components will also be able to reduce production costs, processes, and time through part redesign and integration. This makes domestic manufacturing more practical than importing from abroad.
Continued Innovation And Adoption Of AM Across Industries
AM is reported to have a global economic impact of USD 250 billion by 2025 and the aerospace and defense industry is expected to continue leading AM adoption. Moreover, the global aerospace AM market is reportedly expected to register a CAGR close to 22.3 percent during the forecast period of 2018 to 2023.
In terms of the healthcare industry, AM adoption is expected to increase and with the aging population expected to rise, this trend is set to continue due to an expected increase in demand for personalized healthcare and treatments, as well as customized 3D-printed medical devices. For the automotive industry, AM’s ability to decrease production lead time, increase efficiency in logistics management, and ensure effective use of components/materials will result in its increased adoption. This trend is set to continue and the global automotive 3D printing market is predicted to be valued at over USD 8 billion by 2024. On the other hand, tooling and robotics are also expected to drive AM’s market share in APAC from 2018 to 2023.
President, Singapore Manufacturing Federation
The manufacturing industry in Asia is polarised into three categories – the “factories of the world”, the factories supplying to “factories of the world”, and the “middleman”, where most manufacturers in Asia are a part of. In Singapore, the industry is undergoing a two-part transformation – digitalisation and servitisation.
Due to Singapore’s relatively high labour cost compared to the region and talent shortage, the industry is also moving up the value chain and exploring the use of AI, IoT, robotics, automation and other digital tools to keep costs low and to increase productivity. Digitalisation itself is expected to quite significantly alter and remake the landscape of the industry.
Digitalisation Of Manufacturing And Supply Chains
To be digitalised is to implement these few technologies – additive manufacturing, AI, advanced manufacturing, blockchain, cloud computing, big data, e-commerce and future technologies (robotics, advanced automation, etc.).
Therefore, as manufacturing becomes increasingly digitalised, supply chain models must also become increasingly digitalised by implementing the above technologies. And this will lead to end-to-end integration. Furthermore, with this evolution of the supply chain model, shorter lead times, increased flexibility through real-time optimisation, increased efficiency and increased transparency and personalisation of services will be observed. A digitalised supply chain model is one in which processes are connected through a sensor network and managed through a central data hub and analytics engine.
Adopting The Right Technologies Amidst Economic Uncertainty
Due to the ongoing trade war, there is a fear that demand and investments will shrink. Protectionist attitude and interest rates are also on the rise. Thus, manufacturers can make use of technologies and innovate their business models to improve their productivity, efficiency and competency in order to overcome the adversities ahead. With the right technologies, the industry may even disrupt and affect other sectors, causing a ripple effect that could accelerate the advancement of businesses embracing Industry 4.0 sooner rather than later.
Automation Charter Chair, The Singapore Industrial Automation Association & Managing Director, Beckhoff
In 2019, at the mass market stage, enterprise digitisation will penetrate deeper into the manufacturing floor. This will cause enterprises to look towards obtaining data from as many machines and sensors as possible, which is a trend that has continued on from past years.
Overcoming The Barriers To Digitalisation
In order to digitalise more effectively, companies have more to gain from standardisation than competition. Currently, Germany is leading the effort to create common industry wide standards and they have done quite well as the VDMA is leading the machine standardisation for Germany. Countries in the ASEAN region may need to follow on their footsteps. Next, governments across the region should also help in funding digitisation initiatives and this is especially important for SMEs.
Finally, re-training and upskilling the workforce is needed. We are facing shortages in data engineers, data scientists, data analysts in the region and re-training and upskilling is especially important as older manufacturing jobs disappear and newer ones are created in their place.
The Importance Of Data Collection, ML And AR Technologies
On top of sending data over standardised communication protocol, companies will increasingly look towards getting standardised information from each machine type. This so called “information modelling” and is relevant to a production line today as there is hardly a “homogenous” production line containing the same machine model from the same manufacturer.
Another focus for the metalworking and CNC world will be the use of AR technologies. While still a cutting edge technology today, this technology holds a lot of promise from speeding up operators to training, to advancing maintenance work. At the bleeding edge, we are seeing an increasing trend of ML implementation directly on a premise or machine. While this is on early stages, we feel that this would be the internal focus of many bleeding edge suppliers moving forward.
Managing Director and Vice President, Southeast Asia, Siemens PLM Software
The outlook in Asia Pacific continues to be favourable in 2019. With a dynamic economy and an extremely fast-growing internet population, Southeast Asian markets are good options for companies looking to diversify and add to their operations in China. Especially as rising labour costs and increasingly volatile market conditions in China cause more firms to relocate their production in order to spread out risk and gain access to new markets.
The Growth Of Mass Customisation Focused Technologies
The shift towards a knowledge-intensive economy in Southeast Asia is a by-product of the global movement towards a more individualized and personalized consumption economy. Therefore, the region is expected to transit from the age of mass-production, to one of mass-customisation which is a trend that has been highlighted at the ASEAN Summit. Due to this, we are expecting manufacturers to adopt and implement technologies such as cloud-based product lifecycle management solutions, as well as Digital Twin technologies, in order to be able to produce meet the level of rigour and scale that is required for mass-customisation.
The Development Of Disruptive And New Technologies
Disruptive technologies such as robotics, computer numerical control (CNC) machines, additive manufacturing, artificial intelligence, scanning technology and smart devices will persist and will be ubiquitous across the product value chain. In the case of additive manufacturing, markets such as Singapore, China and South Korea have already identified it as a growth potential and are actively investing in the technology to create high-end jobs and services.
Additionally, Dyson has also announced plans for its first electric car, to be built in a new automotive manufacturing facility in Singapore that is set for completion in 2020. The selection of Singapore as a site for this facility – which has not seen automotive manufacturing since Ford closed its factory 40 years ago – is a surprise for many. This investment which is part of Dyson’s USD 3.3 billion global investment drive in new technology, is a game changer for the electronics and heavy machinery industries in the region.
Regional Executive Director, UBM
In 2019, the ASEAN region will remain as an attractive area for investment. The ongoing trade war between China and the USA is creating problems and opportunities within the ASEAN region as although foreign investment companies are starting to relocate their manufacturing plants away from China, countries within ASEAN particularly Vietnam and Indonesia, are benefiting from the relocation of manufacturing plants into their countries.
The Rise Of Indonesia And Vietnam
Most of UBM’s trade shows have continued to grow, particularly in Vietnam where there are numerous opportunities in both HCM and Hanoi. Currently, the biggest problem for the organisation of events in Vietnam is the size of the venues in both HCM and Hanoi which restricts UBM’s expansion plans. However, this also reinforces Vietnam’s position as UBM’s strongest market since 2018.
In Indonesia, the economic growth in the short term will be modest due to the Rupiah depreciation as we all as the impact of the upcoming presidential elections in April. This will affect overseas investment as investors take a “wait and see” approach. Thus, investments will be halted for at least the first half of the year. For this reason, Indonesia is expected to rely on domestic consumption and household spending to drive the economy. However in the long term, Indonesia remains a strategic and lucrative market for investors as it continues to offer strong economic fundamentals to spur the growth of the middle class and fuel consumer spending which is a key driver of growth.
Growth Of Smart Factories And Smart Manufacturing In Southeast Asia
Southeast Asia’s main selling point can no longer be its low wages if it is to remain competitive. Implementation of new technologies are needed to help close the productivity gap. This means factories will need to integrate technologies such as robotics to maximise productivity, minimise human failure and prevent work-related accidents. Aside from that, companies could integrate AI and data analytics to make automation processes more intelligent and to improve efficiency.
A report by McKinsey & Company has highlighted that Southeast Asia needs to embrace Industry 4.0 to unlock its potential in manufacturing. Through this report, it is stated that disruptive technologies associated with Industry 4.0 would have an impact on productivity on a scale that is similar to the introduction of the steam engine had during the first Industrial Revolution. Globally, if the digital technologies of Industry 4.0 were to be embraced and integrated efficiently, it is forecasted that it could contribute between USD 1.2 trillion and USD 3.7 trillion in business profits. Meanwhile in ASEAN, the impact of Industry 4.0 could see productivity gains of between USD 216 billion to USD 627 billion.
2018 was one of the most successful years for Bystronic due to numerous product launches in the gold, silver and bronze segments of the market as well as international business expansions.
In 2019, the economy is uncertain because of market turmoil and currency slumps but sheet metal continues to have a wide application in industries that are set for growth such as the automotive, semiconductor and electronic industries. Additionally, governments across Asia are continuously building and developing infrastructure and new industrial areas which create indirect opportunities for the sheet metal fabrication market.
The Growth Of Automation
The industry is currently in the age of automation. This is because automation allows for shorter lead times, greater accuracy, higher quality and competitive pricing. In the field of laser cutting, automation makes it possible to process not only large series but also small batch sizes, while maintaining the flexibility that users require to always respond to changing order situations.
Implementation Of Networked Production
With automation drastically changing the outlook of the sheet metal industry, Bystronic is systematically driving forward the vision of “World Class Manufacturing”. This is based on a comprehensive range of new products and services with which Bystronic is gearing its users’ process landscape towards networked production. It features innovative solutions that go far beyond the conventional idea of a machine tool. It’s about fusing the individual processes relating to laser cutting and bending into a network of intelligent components.
Igus has developed the lokchain energy chain with extending and retracting pins for brand-new machine style ideas. The goal of the new lokchain energy offer system is to mechanically increase the operational responsibility. They make sure that the energy chain operates safely and quietly, even with tiny bending radii and over long travel distances. This has the potential to reinvent power, information and media offer in several dynamic applications. Mechanically extending pins hold the e-chain firmly within the guide, permitting utterly new solutions in vertical, hanging or circular movement applications.
Due to the special construction of the lokchain there’s hardly any abrasion and wear, therefore the service lifetime of the e-chain is accumulated another advantage of the new e-chain system is that the quality of the chain links; The pliability of this e-chain offers the user the chance to develop utterly new machine style ideas this method also can be employed in vertical circular applications.
Digital catalogue data now provided for chainflex cables
Selection, procurement, ordering, invoicing – complex merchandise management with products in the B2B area needs one thing above all: simple and standardised processes from the manufacturer to the recipient, and uniform worldwide. Under the name BMEcat, the Federal Association for Supply Chain Management, Procurement and Logistics (Bundesverband Materialwirtschaft und Einkauf (BME)) has developed a standard system for the electronic exchange of catalogue data that can easily be integrated into existing merchandise management systems. igus, the motion plastics specialist, is now using the exchange format for catalogue data for its chainflex cables used in moving applications.
Customers are demanding increased accuracy and precision from their production equipment across a wide range of applications. By Dan Thompson, product manager for energy chain cable carrier systems, igus Incorporated.
Increasingly complex automation has created the additional challenge of vibration of dynamic machine components significantly increasing vibration of the complete system. In a number of industries—including semiconductor manufacturing, machine tools and printer design—cable carrier systems can be a possible source of vibration.
Cable carrier systems supply energy, data and other media, and as technology increases, so too does the number of cables and hoses that require guidance. As cable carriers guide and protect cables and hoses throughout the motion of the printer, machine tool, etc., vibration of the supporting structure of the cable carrier can occur, as well as at the moving end or tow arm of the machine.
This vibration can negatively influence the performance of a machine once it reaches a certain level. For manufacturers, as well as their customers, factors that limit the capabilities of precision systems must be tackled using cable carrier systems that minimise vibrations and maximise smooth and precise operation.
In milling, printing, or other precise tasks, dynamic loads are the typical source of vibration, which can cause chatter on tools and workpieces alike. These chatter vibrations not only decrease the quality of the print, product, etc., but can also cause increased wear on the components of the machine itself, leading to product defects, system malfunctions and downtime. Because of this, the dependence on low vibration materials and machine components is on the rise in an effort to limit self-generated machine vibrations.
Designing Vibration-Reducing Components
Most cable carrier systems utilise a pin-and-bore connection between the individual links of the carrier in order to guarantee a secure connection under high dynamic loads. This type of connection also gives the carrier system protection against external influences, resistance to high torsional forces, high tensile strength, and high mechanical durability. However, a disadvantage of the pin-and-bore design is the resulting relative motion between the links, which over time can cause wear on moving parts.
In addition, the rolling motion of a cable carrier system exhibits the so-called “polygon effect,” where the chain does not form a smooth rolling motion, resulting in an angular, or polygonal, transition between links. In addition to increased wear, this also results in a “stepping” motion, which can create system vibrations. This can—in a worst-case scenario—result in material failure due to catastrophic resonance. Even in less extreme cases, the vibration caused by the polygon effect results in material wear and decreased accuracy on the workpiece.
To improve upon the design of cable carriers to reduce vibration, most manufacturers rely on a short link pitch to offer smooth, quiet motion. Igus’ low-vibration energy chain cable carriers combine a short pitch length with an advanced plastic spring element to replace the traditional pin-and-bore design. Replacing the conventional pin-and-bore design, the E3, E6, and E6-1 series of energy chains feature a flexible connection element that reduces the polygon effect due to their alternative geometry. This upgraded design offers extremely smooth and nearly vibration-free operation, even under high acceleration forces.
Material Selection And Its Impact On Vibration
No matter how specialised the design of a cable carrier system, without materials that are properly able to dampen vibrations, damage and eventual failure can still occur. Compared to their metal counterparts, plastic materials are much better at damping vibration forces, due to plastics’ viscoelastic behaviours.
The plastic material igumid G, which makes up igus energy chains, is a proprietary blend, made up of a reinforced polyamide 6 (PA6) base. Polymer blends like these are also able to dampen vibrations by using the interface between the material’s components (ie: fibres and other structures blended throughout the base polymer) as a mechanism for reducing vibratory forces.
The new E6-1 series of cable carriers has shown to have the lowest levels of noise and vibration in cable carrier applications due to its material makeup and design. This new generation offers a weight reduction of approximately 30 percent when compared to the E6 series, and exhibits even lower noise and vibration levels. A shortened pitch and “brake” in the stop dog system reduce the sound pressure levels by an additional 2 dB(A). Optimised geometry makes operation of the E6-1 system very smooth, eliminating the polygon effect almost entirely, even at higher speeds and accelerations.
Another option for reducing vibration on machine tools can be provided via special cable carrier design. An example of this would be creating a nested arrangement of cable carriers, which can dramatically increase milling accuracy in certain cases. These nested systems can change the system properties of the machine, and can be combined with additional systems to help minimise or eliminate damaging vibrations. These systems apply external forces to minimise or completely eliminate damaging vibrations via damping or cancelling solutions, differentiated into passive and active systems.
Passive systems attain their vibration damping effect by converting the vibration energy to another form. In this circumstance, an additional mass transforms the kinematic energy from the vibration into thermal energy or a relative motion between two other bodies. Active systems employ an external energy supply to create a phase-canceling vibration.
Both passive and active systems can effectively compensate for vibrations, but also have a cost impact, as these types of systems are typically only available as a customised one-off solution and cannot be transferred to other machinery. The economic use of these types of adaptive solutions is not always viable for the price-sensitive machine tool market; therefore, the primary effort in research and development for vibration-reducing systems going forward should focus on identifying and reducing the component sources of vibration.
Improving Operational Efficiency
As the demands for process accuracy for a range of applications increases, the need for technical advances to reduce vibrations also grows. An important element of a successful strategy is to improve the operational smoothness of energy supply systems in dynamic applications. New solutions, such as the polymer spring link connection for igus energy chain, can significantly contribute towards realising the objective of attaining a low-vibration machine tool. While other solutions are available, the lowest cost option to create a low-vibration system is to integrate low-vibration machine components.
For applications in metalworking where energy tubes come into contact with hot chips, motion plastics specialist igus has now brought a high-temperature version of its proven R4.1L to the market. Due to the igumid HT material, even extreme temperatures up to 850 deg C can be withstood briefly, with no chips penetrating or even adhering to the plastic.
The R4.1 L series has been specifically developed for the machine tool industry in order to be able to offer torsionally stable, enclosed and light energy tubes. The modular design makes adapting to the particular application simple and installation quick. With openable lids, filling with cables and hoses is easy and fast.