Advanced Manufacturing Now

Pratt & Whitney's Kimberley Hagerty, whose "year of living digitally" was featured in the May issue of Smart Manufacturing magazine, quickly reviews lessons she and her team learned, outlines three main challenges they faced and how she solved them, and describes some of the organizational changes she sees Industry 4.0 demanding of manufacturers.

Rego-Fix Corp., a manufacturer of precision tooling, has been on a deliberate, long-term growth and expansion program. Starting a few years ago in the company's home base of Switzerland, this year the program came to fruition in the US Vice President Sales and Marketing Bill Obras sat down with Manufacturing Engineering's James D. Sawyer at Eastec to discuss the program and provide details on the company's new 20,000 ft2 facility near Indianapolis.

Manufacturing Engineering's James D. Sawyer interviews Chris Pollack, East Coast regional business manager for motion control , Siemens Industry, about the growing skills gap in US manufacturing and the challenges and opportunities inherent in training new users to operate the controls of machine tools.

As the technology has matured, the manufacturing world has seen an explosion in the number of metal parts, components and products manufactured additively. Yet despite this improvement the cost of metal 3D printing has not really become more affordable. In this sponsored podcast, Markforged Applications Engineer Peter Kootstra explains to SME's Jim Sawyer how his company has developed a process that can cut the cost of metal 3D printing by as much as 80% compared to standard methods. Not only does this make metal 3D printing more affordable, but it opens the additive manufacturing door to more applications—and more manufacturers.

As water jet technology has improved so, too, has the precision of these abrasive cutting machines. Along the way the applications for water jet cutting has expanded as well. At Eastec, Michael Ruppenthal, Omax vice president for North American sales, sat down with Manufacturing Engineering's James D. Sawyer to detail how the MicroMax, an ultra-precise fully enclosed water jet, has carved out a place for itself in the electronics industry, where it is used to make molds, circuit boards and other components.

Hermle Machine Co., a manufacturer of high-end machine tools, annually employs 100 to 120 apprentices in its German operations. The apprentices make up about 13% of that workforce. Manuel Merkt, executive vice president of operations at Hermle's US operations (Franklin, WI), is working with the German American Chamber of Commerce to establish a similar program in Wisconsin which would provide graduates with the same skills and certifications that the program in Germany offers. Merkt, himself a product of the apprenticeship program, explains to Manufacturing Engineering's James D. Sawyer how the effort is proceeding.

Charlie Slagle, president and CEO of Hoffmann Group USA, talks with Editor in Chief Alan Rooks about the history of The Hoffmann Group as a tooling manufacturer and distributor in Europe, and its 2016 entry into the US market. The company markets its Garant and Holex brand portfolios and distributes a wide variety of products from other tooling manufacturers.

In an interview with Jim Sawyer of Manufacturing Engineering, Jan Andersson, global director of Greenleaf Corp.'s Tech Team and marketing explores the four pillars of metalcutting are and why it is crucial to pay attention to each of them to achieve the best results.

Additive manufacturing has come a long way from being a prototyping technology. In many instances, it is now a viable method of production. Not every manufacturer, however, has the expertise and resources to put 3D manufacturing into practice. In this sponsored podcast, Manufacturing Engineering's Jim Sawyer interviews Shane Fox, founder and CEO of Link3D, to learn how the company's proprietary technology provides engineers with a secure, fully automated request-for-quote process to identify vetted additive manufacturing partners from around the world.

A manufacturing concern can get the greatest return on its investment by optimizing its overall equipment effectiveness, or OEE. In this sponsored podcast, Memex CEO David McPhail details the relationship between OEE and the Industrial Internet of Things. Data, he explains, is what drives this relationship. Data-driven manufacturing consists of keeping track of everything that happens on the shop floor, and software, including Memex's Merlin Tempus solution, helps monitor and manage that data.

Ken Baeszler, a market segment manager and product manager at GF Machining Solutions, sat down at SME's Eastec show with Manufacturing Engineering's Jim Sawyer to discuss GFMS's new offerings of machine tools. Baeszler begins by describing the new Mill P 900, a high-precision machine tool for the mold and die industry.

SME this year gave the Dick Aubin Distinguished Paper Award to the authors of "Liquid Metal 3D Printing: A Magnetohydrodynamic Approach." One of the authors, Swati Chandran Thirumangalath, explains what the paper says about the work she did as a design and simulation engineer at Vader Systems in Buffalo, NY.

SME's Additive Manufacturing Community this year gave Dieter Schwarze, PhD, of SLM Solutions GmbH the 2017 Industry Achievement Award. The award recognizes of his significant and continued impact on additive manufacturing through development of processes and technology applied in industry. In 1989, Schwarze began his R&D work on additive manufacturing and its commercialization. He is one of the primary inventors of selective laser melting. Schwarze holds several patents and previously studied physics at the University of Paderborn. He sat down with Smart Manufacturing magazine Editor in Chief Brett Brune at RAPID + TCT to review the technology's progress and give his opinion about what is to come. "Today we are only in markets that use metal. But that does not mean it should stay like this in the future."

Brian Bittner, national sales manager of Beamer Laser Systems, talks to Senior Editor Bill Koenig at the Eastec Show, held in May in West Springfield, MA. Bittner describes the company's operations.

Jill Young of Exsys (San Antonio, FL) describes the company's products and markets in an interview with Bill Koenig, senior editor at Advanced Manufacturing Media. They spoke at SME's Eastec Show in May.

Rod Leek of Vektek LLC talks about his company's line of clamps and workholding products with Senior Editor Bill Koenig. They talked at the Eastec show in West Springfield, MA, held in May.

Dyan Finkhousen, director of open innovation & advanced manufacturing at GE Global Operations, discusses Fuse LLC, an 8-month-old service offering of GeniusLink that involves small batch mfg. Key takeaways: The benefits GE businesses, customers and sponsors find by using Fuse to solve tough technology challenges; the types of problems that are a good fit for Fuse; and how to learn about and participate in a product or technology innovation contest sponsored by Fuse. (GeniusLink is GE Global Operations' crowd-sourcing division.)

Matt Sand, president of 3DEO, and Matt Petros, the company's CEO, discuss 3DEO's additive manufacturing technology and the markets it serves. 3DEO produces low-cost metal parts for customers. 3DEO says its process is "fundamentally different than anything else in additive manufacturing." "We started the company with the idea there has to be a better way to make metal parts with additive manufacturing," Matt Sand says. To learn more about 3DEO listen to the podcast or check out the company's website at http://www.3deo.co/

Gene Granata, Vericut product manager at CGTech, describes Vericut's new additive module. Set to be available publicly at the end of September, it can be used in a hybrid simulation along with subtractive technologies. With this and other technology, CGTech works with customers and tech partners to solve AM challenges, such as accurate laser cladding and material deposition, detecting collisions between the machine and additive part, and finding errors, voids and misplaced material. Mr. Granata explains how people who already own Vericut can acquire the additive capability. "This is a turning point" for additive, where "a lot of people are coming into the fold," he says.

At RAPID + TCT in Pittsburgh, Roger Kelesoglu, director of sales enablement at Stratasys, previews the company's new Continuous-Build 3D Demonstrator. (It's not yet clear when it will be commercially available.) It allows for continuous production of plastic parts--with a cloud-enabled software management control system that enables automation on the front end all the way through the manufacturing process. Last year, the company's big announcement at the show was about size: the Infinite-Build 3D Demonstrator. The Continuous-Build 3D Demonstrator eases tooling and setup costs and lead times, allowing for lower-volume production of parts. This makes mass customization possible. TheContinuous-Build 3D Demonstrator also enables automation on the hardware side. He also discusses the ways the firm's Robotic Composite 3D Printer breaks some boundaries.

Duann Scott, head of business development and strategy for digital manufacturing at Autodesk, details the solutions his firm offers. He also weighs in on which manufacturing industry segments he believes will use AM the most heavily. Mr. Scott outlines the most compelling recent advances in the technology, and he addresses the barriers to more widespread industrial adoption.

Benjamin Fisk, general manager of 3D additive manufacturing for Methods Machine Tools Inc., discusses his company's 3D printing strategy. Fisk talks about the speed in which 3D printing is being adapted among manufacturers as well as his company's partnership with 3D Systems. He was interviewed by Senior Editor Bill Koenig during the RAPID + TCT show in Pittsburgh in May.

Tom O'Reilly, VP, Global Business Development at Rockwell Automation, details how his company's five-year plan to restructure its facility and supplier networks has led to a four- to five-percent annual improvement in productivity: "If you look at how we did/do it, here are some examples: inventory days dropped from 120 to 82. We reduced our CAPEX ... by 30 percent per year. Our delivery within our supply chain went from 80 percent to 96 percent. Our lead times were actually reduced by 50 percent. And then, for customer service, our delivery-to-customer want date went from 82 percent to 98 percent. And with regard to quality, we reduced our PPM by 50 percent."

SLM Solutions Software out of Austria is set to this year begin selling a new package to improve workflow in AM, SLM Solutions' Richard Grylls said At RAPID + TCT in Pittsburgh. "It will help to streamline the entire workflow--from the initial idea from the designer to geting it into the machine in one piece." He also talks about how OEMs can help a customer quality and certify metal parts. Grylls also discusses how selective laser melting is helping to speed up metal AM. And he gives an overview of process monitoring capabilities SLM Solutions is showing at the AM tech show, as well as emerging applications for SLM's machines (serial production of components in aircraft, space and automotive applications, for example). Lastly, he explains why SLM has a monthly user group meeting. Managing things as "a lone wolf" is a bad idea, he warns.

John Graham, senior product marketing manager for Ansys Spaceclaim, Ansys Inc., talks with Manufacturing Engineering Senior Editor Patrick Waurzyniak about how 3D modeling software can help manufacturers streamline designs and boost manufacturing productivity. With today's 3D modeling software, manufacturers are able to efficiently repair incomplete models, reverse engineer files, and incorporate powerful computer-aided engineering (CAE) software into manufacturers' toolbox to more efficiently create manufacturing processes.

Jeannine Kunz, vice president of Tooling U-SME, details how awareness of AM's capabilities is clearly on the rise: Some big manufacturers are focusing on what AM means to their human capital, and AM is often being incorporated into existing roles. Kunz also discusses how Tooling U-SME can help customers increase their use of additive technologies while the world waits for standards. Her division at SME leverages the knowledge of SME members to help companies work through challenges, including "make or buy decisions," she notes. And--the pièce de résistance--she previews the "first-and-only additive certification," at a fundamentals level: SME is set to announce it next month at RAPID +TCT (www.rapid3devent.com) in Pittsburgh.

Randolph Bradley, Technical Fellow in Supply Chain Management at Boeing, explains the Center for Excellence in Logistics and Distribution's reason for being, and Boeing's involvement with the industry-academia partnership. Among what is covered: energy use in the supply chain; demand forecasting using Bayes' Rule (also used to crack Germany's Enigma code during WWII), and insights gained from MHI's US Roadmap for Material Handling and Logistics.

Joe Lampinen, Senior Director, Global Practice Consultant for Engineering, Business, & Professional Services at Kelly Services, explores how manufacturers today must meet the challenge of engaging younger workers just entering the profession. These workers have the expectation that they will change employers ten times or more during their careers. Employers must be able to upskill and engage all of their workers and choose the right option from the many available for bringing in outside workers, including temporary workers, independent contractors, outsourcing, and consulting firms.

What's up with AM machines this year? At the Aerodef conference, SLM Solutions' Winthrop Sheldon takes on this and several other market-trend questions. "You're seeing more multi-laser systems. You're seeing generally more open systems (in terms of parameter control and material use). And you're also seeing larger format systems. So there are quite a few new trends that I feel SLM was instrumental in bringing to market. Now the question is can we maintain our position with these technologies—now that more of our competitors have, let's say, multi-laser systems."

Dimitrije Milovich, president and CEO of Radius Engineering Inc. (Salt Lake City), discusses the role small manufacturers play in aerospace. His company has fewer than 40 employees but has established a niche in aerospace. Milovich was at SME's AeroDef Manufacturing Show in Fort Worth, TX, where he received the 2017 J.H. "Jud" Hall Composites Manufacturing Award. He spoke with Senior Editor Bill Koenig about how small companies play an important role in aerospace manufacturing. Milovich also discusses advances in composites and what they mean for aerospace.

EnvisionTEC CEO Al Siblani explains why the SLCOM 1, a machine that does selective lamination composite object manufacturing and is in beta testing, is an important development in 3D printing: "There's absolutely no limitation in terms of geometry in terms of what kinds of composite parts you can build—unless it's a closed volume. Besides any closed volume, the SLCOM 1 allows you to additively manufacture parts that are 24 inches wide, 30 inches long and 24 inches deep. So what really makes the SLCOM an interesting product is its ability to print very large parts that could be used in some luxury automobiles as finished goods. It could also be used in a production capacity in aerospace companies." In part because of automation, SLCOM 1 promises to reduce to two or three days a manual manufacturing process that now takes about 13 days: making one GE90 engine blade in composites.

Zane Michael, director of thermal business development for Yaskawa America/Motoman Robotics Division, explains why the biggest challenge for welding manufacturers today is the shortage of welders. He notes that fabricators can apply robotic welding technology with a high degree of success by first using simple systems, and explains why human welders still play a major role in robotic welding by analyzing and managing the performance of robotic welding units.

At the Aerodef conference in Texas, Conrad Leiva, VP for product strategy and alliance at iBASEt and chair of the smart manufacturing working group at MESA, says companies should first evaluate their business model today to get ready for a smart manufacturing future. Next, they should look at their IT infrastructure. And don't forget to address digital handoffs between systems. "We're coming from a culture of silos and moving to a culture of collaboration--across our departments internally and into the supply chain."

For starters, NASA's HUNCH program brings projects, mentors, expertise and schools. SME's PRIME initiative brings mentors, equipment and a scholarship component. "It's kind of a big deal that those things mesh so well," says Blake Ratcliff, program manager of NASA HUNCH.

Sandra Rios, ‎Head of Product Management & Marketing, AXOOM GmbH, explores the development of the platform market for the Internet of Things, the company's vision for the IoT platform market, and its plans in North America.

At the Aerodef show in Texas, Mike Judge, executive vice president of Cincinnati-based 5ME, delivers the lowdown on cryogenic machining. He notes that 5ME can add cryogenic machining to machines in the field. (Installation takes 1-3 days.)

Bob Yancey, vice president of additive manufacturing at Altair Engineering, also discusses the importance of an upfront design process and advances in manufacturing simulation

The co-author of "The Smartest Places on Earth: Why Rustbelts Are the Emerging Hotspots of Global Innovation" discusses not only all he discovered in writing the book but also what he has learned since it was published. Example of the latter: "The movement from a focus on cheap to a focus on smart is ... a real competitive advantage, but it's not permanent. I discovered that China now very well understands that this is an issue. China is now the biggest buyer of robots in the world."

Steve Immel, head of Americas Business Development for Materialise, explains why a traditional manufacturing company may want to get into additive manufacturing, the main considerations for manufacturers looking to add capabilities in additive manufacturing, and explores the "triangle of materials, hardware and software."

Dr. Jeffery Ahrstrom, President and COO of BLM Group USA, explores how a tube laser system can help manufacturers replace the physical processes of punching, sawing and milling with lasing in order to reduce work-in-progress, improve upon existing manufacturing processes, and create new ones.

John Thompson, National Technical Sales Manager for PFERD Inc., offers his predictions on the future of metal finishing, examines new solutions that can help improve productivity and reduce risk in hand-held applications, and discusses how systems are changing to adapt to the growing use of composite materials.

Diego Tamburini, Senior Design and Manufacturing Industry Strategist for Autodesk, explores the main forces shaping the future of the fabricating industry; key strategies manufacturers can use to remain competitive; promising technologies Autodesk is currently developing; and the opportunity of the IoT for manufacturers.

Bonnie Martens, Marketing Communications Manager for Dimplex Thermal Solutions, examines key trends in process cooling; how chillers can be designed for energy efficiency; solutions that increase system uptime; and how the Internet of Things is changing how chillers operate.

John Galich, marketing manager for Mate Precision Tooling, discusses trends in the CNC punch press tooling and press brake tooling market; challenges facing the industry; and the evolving mission of Mate Precision Tooling.

John Heuring, Regional Sales Manager for Dallas Industries, explores the challenges fabricators face when their feed line operators process advanced, high-strength steels. He also outlines the special considerations that stampers should consider for feed lines being paired with servo presses.

Frank Arteaga, Head of Product Marketing for Bystronic, explains why Industry 4.0 isn't just for big companies and why small to medium-sized job shops should learn about and adopt it. He also explains how job shops can implement Industry 4.0 without making major changes to equipment and software.

Mark Scherler, General Manager of Materials Joining for FANUC America, explores how the Internet of Things is changing robotic manufacturing, laser processes that are being used with robotics, and how changes in the manufacturing labor force are affecting the need for robotics.

Craig Tomita, Area Sales Manager for Universal Robots, and David Jackson, President of CleanLogix (an OEM partner of Universal Robots) discuss the use of collaborative robot (cobots) in manufacturing. Cobots can be used without safety guarding on production and assembly lines, and CleanLogix has incorporated a UR cobot in one of its CO2 cleaning applications.

Will Healy, Strategic Marketing Manager, and Dave Bird, Key Account Manager, Metal Forming and Robotic Welding for Balluff Inc., discuss how press shops can dramatically improve uptime, tackle the biggest problems with sensors and networking in robotic welding, and surmount the challenges to implementing Industrial Internet of Things. They also explain how machine builders can increase the value they deliver to manufacturers.

Sandra L. Bouckley, FSME, 2017 President for SME, discusses the current state of the manufacturing workforce, what this means for the future, how companies can help bridge the skills gap and the role of new technology in resolving workforce challenges.