Browse Topic: Manufacturing equipment and machinery

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Recommendations and Background Material for Battery Package TestingAIR6840 (Current)11/26/2025
AS 6413 and slash sheets /1 & /2 hold the main information for testing of battery packaging. This document holds further information and expansion of philosophy, clarification etc. surrounding the testing and industry needs.
G-27 Lithium Battery Packaging Performance
Shortwave Infrared Cameras for High-Temperature Manufacturing and R&D ProcessesTBMG-361463/1/2020
With the range of infrared cameras on the market today, it may be difficult for end-users to know which camera is best suited to their application. There are longwave, midwave, and shortwave camera systems—each with its own advantages for specific industries and uses.
Marubeni Citizen-Cincom Opens New Technical CenterTBMG-362733/1/2020
Marubeni Citizen-Cincom Inc. (MCC) has opened a new technical center in Agawam, MA. The company is holding a ribbon cutting and grand opening celebration March 9. An open house will follow to introduce the company’s new L12 Type X and the new 12 mm laser cutting and welding machine. A variety of Cincom sliding headstock and Miyano fixed headstock lathes will be on display as well. The event will also include technical seminars presented by Sandvik, Esprit, and Gen Swiss.
Smart Manufacturing ControlTBMG-359972/1/2020
The manufacturing process of today involves many challenges, from mass production down to a lot size of one. The CNC controls in factories have to master this market trend without an adequate amount of skilled labor in the US manufacturing world. In essence, manufacturing is facing a renaissance in the CNC control technology shift.
Q&A20TOFHP02_142/1/2020
Off-highway industrial machines require multi-function implement operation with dynamic duty cycles. In many cases, machine implements demand short bursts of full engine power and brake dynamic loads requiring 50% or more of energy consumed. Many next-generation machines reduce energy loss and improve productivity by incorporating hybrid-electric approaches with energy storage. An efficient implement solution enabling the hybrid-electric approach is essential to achieve maximum improvement potential. At the upcoming IFPE 2020 show in Las Vegas (www.ifpe.com), education sessions offered to attendees will address this challenge and other issues facing the fluid power and motion control industries. A session titled “Fundamentals of Hydraulic Systems” will include speakers from Ultra Clean Technologies Corp., Atos North America, Parker Hannifin, and Hallite Seals Americas. Show organizer AEM (Association of Equipment Manufacturers) spoke with presenter Dale Vanderlaan, R&D engineering manager at Parker Hannifin, to discuss electro-hydrostatic actuation (EHA), its benefits, and how electrification will impact next-generation hydraulic systems.
Going Beyond the Basics: Innovative Step Motor Designs Give Machine Designers More Options for Motion ControlTBMG-360022/1/2020
Machine and system designers now have greater options in choosing a motor to meet motion control requirements. While basic step motors with open-loop control schemes abound in the marketplace, different motor and drive designs offer interesting solutions for smarter, faster, quieter operations with more torque. Some incorporate smart drives for higher-level streaming commands or onboard motion control, while others add encoders for greater torque and accuracy. These options can offer better solutions as applications become more sophisticated and demanding, while companies address initiatives for greener operations. This article outlines different step motor options available on the market and considerations for their use.
Collaborative Automation: It's More Than Just the CobotTBMG-3560812/1/2019
Collaborative robots, often called “cobots,” offer opportunities for companies of almost any size to cost-effectively automate processes that were previously out of reach. Cobots are available in a wide range of sizes, payloads, and capabilities but they all share attributes that define the term “collaborative.” The aspect that most people think of first is safety — the ability for cobots to work alongside human workers without bulky, expensive guarding. Cobots include a number of built-in safety mechanisms including rounded edges and softer materials as well as power-and force-limiting technologies that avoid injury and minimize discomfort in case of contact, and sensors that automatically slow or stop the robot arm if a human enters its workspace.
How Augmented Reality Can Modernize Aerospace And Defense ManufacturingTBMG-3568512/1/2019
You've probably heard about augmented reality (AR) in the context of consumer entertainment: video gaming, virtual tours, or interactive displays. But AR for enterprise business is here. It's no longer an emerging technology, or a novelty; businesses are using AR to overhaul processes, drive efficiencies, reduce manufacturing errors, and improve their bottom line.
2019 'Create the Future' Manufacturing/Robotics/Automation Category Winner: The HPCI® Joining GunTBMG-3544011/1/2019
Plate Handler Adds Automation in Medical LaboratoriesTBMG-3550411/1/2019
Peak Analysis and Automation (PAA), Farnborough, UK, has designed a budget-friendly plate handler that works in a tight laboratory footprint, developing an innovative product that could be a game-changing development in the medical community.
Filter and Filter Element for Hydraulic System(s) Used on Manufacturing and Assembly EquipmentJ2066_201910 (Current)10/2/2019
This SAE Standard establishes a common specification and ordering code for hydraulic filter assemblies and hydraulic filter elements, and establishes minimum performance criteria and test methods. This document establishes two filter diameter sizes, five basic micron ratings, and two basic collapse ratings. These classifications will satisfy most hydraulic filter applications, and thereby can minimize inventory requirements for hydraulic filter elements.
Motor Vehicle Council
Tiny “Walking” Motor Moves in Discrete Mechanical StepsTBMG-3526110/1/2019
A set of five tiny fundamental parts can be assembled into a wide variety of functional devices including a tiny “walking” motor that can move back and forth across a surface or turn the gears of a machine. The work offers an alternative to current approaches to constructing robots, which largely fall into one of two types: custom machines that work well but are relatively expensive and inflexible, and reconfigurable ones that sacrifice performance for versatility.
NIST Research Sparks New Insights on Laser WeldingTBMG-3537310/1/2019
On its surface, the work is deceptively simple: Shoot a high-power laser beam onto a piece of metal for a fraction of a second and see what happens. But researchers say the physics of laser welding is surprisingly complex. A better understanding of the interaction between laser and metal could give industry more control over laser welding, a technology that is becoming increasingly popular in manufacturing.
Deep-Space Food Science Research Improves 3D PrintingTBMG-3528210/1/2019
Spinoff is NASA’s annual publication featuring successfully commercialized NASA technology. This commercialization has contributed to the development of products and services in the fields of health and medicine, consumer goods, transportation, public safety, computer technology, and environmental resources.
Design Guidelines for Fiberboard MaterialsJ1774_201909 (Current)9/25/2019
This document provides information on the various fiberboard products, which are available for automotive application. It is intended to give engineers and designers a better understanding of product usage, characteristics, properties and industry terminology. The following sections cover these topics: 2 General Product Information 3 Design Characteristics 4 Physical/Mechanical Properties 5 Fiberboard Definitions In sections 2, 3 and 4 the fiberboard products are categorized. These sections give an overview of product types, with general information about characteristics and properties. In cases where product categories encompass more than one material or material grade, ranges were established to cover all of the products in that category. The individual companies that supply fiberboard products should be consulted for specific information about a particular product or application.
Textile and Flexible Plastics Committee
Cross-Training Made Possible by Common Control PlatformTBMG-345796/1/2019
EMAG L.L.C. is the U.S. subsidiary of a major German machine tool builder that specializes in machine tools for the production of automotive, off-highway, agricultural, and oil field components. The company’s equipment ranges from basic round part turning centers to large-workpiece, five-axis machining centers; gear hobbing machines; and alternative equipment such as laser welding and electrochemical machining centers. This wide variety of machine tools requires an assortment of control technologies to power and manage the motion. For one customer requirement where a major agricultural equipment builder needed grinding, turning, and turn-grind machines, EMAG looked to Siemens for a standardized CNC solution.
Industrial Blue LasersTBMG-344155/1/2019
Industrial lasers are integrated into manufacturing and fabrication facilities around the world. Every moment, there is an industrial laser somewhere that is cutting, etching, or welding. But the energy from traditional industrial lasers is not absorbed well by copper, so using them for copper processing has been slow and produced inferior quality.
Dynamic Modeling of CNC Drive Systems: Comparison of Two Models2019-01-08034/2/2019
Accurate positioning and precision of CNC machines are directly affected by performance of their mechanical drive system and control unit (CNC feeddrive system). This is more important in contouring operations where axes motion is synchronized by interpolators and errors are accumulative. This research work is focused on study of dynamics of the feeddrive unit. In this regard, a detailed dynamic model is developed in state-space format that is used to study its response properties. A parametric study of the system is carried out by studying shifts in eigenvalue loci when a parameter is changed. The results are used in further simplifying this model to a reduced order system which is simpler in structure and more appropriate for control applications. A comparison is made between these models and the merits of each individual model are presented.
Mehrabi, Mostafa
A Process for Delivering Extreme AFP Head Reliability2019-01-13493/19/2019
Every now and then a good idea happens. The Modular head was a great idea and enabled the use of multiple types of AFP heads, ATL, ply cutting, part probing, etc. with the use of a single machine and machining cell. At the time the modular head was developed by Electroimpact circa 2004, the industry assumed (and accepted) that AFP was an unreliable process. It still isn’t as reliable as we’d like. One way of coping with this lack of reliability is to stage more than one head in the AFP cell so that a spare head of the exact same type is ready to jump into action if the head out on the floor has an issue. If the reliability of the AFP process were to increase 10x or 50x, would there still be a business case for the multiple AFP head system? The modular head may still win the day, but the metrics change. For instance, if there was only 20 minutes of down time for every head load, it may no longer be advantageous to have 2 heads of the exact same type in the cell. It is our goal to eliminate AFP process unreliability to the point where this discussion has real meaning. To address the #1 cause of reliability issues experienced in 777x we invented the Modular-Servo-Creel head. We built a full working prototype of this machine and demonstrated it to Boeing and others over the past year. What we learned was indeed we did fix the #1 cause of reliability issues that we see in production of the 777x spar (the loss of tension during large speed changes during the zero degree ply). In the process of using this head other causes for unreliability also came into view. They actually had nothing to do with the theory of operation of the head as we previously experienced with the old creel system, but more to do with preparation. These items are: Head Cleanliness Blade Sharpness A valve that is failing or leaking A seal that is worn or leaking A spring plate that failed Each of these items caused an error on a part that we were trying to make and diagnosis took longer than acceptable causing even more issues on the part until the correct diagnosis and remedy was made. Because we identified these items as potential causes of mistakes on the part, we created a system described in detail in this paper. This section describes a process and method for cleaning the AFP head using a dishwasher, a method for checking blade sharpness and finally a method for checking the module functionality. We demonstrate this this system running our prototype AFP head building 16 plys of the 50’ spar, some stringer charges and then a hexagonal test part placing 100,000 individual tow strips without a process error, not even a slipped tow.
Rudberg, Todd, Cemenska, Joshua, Sherrard, Ethan
Manufacturing: Tooling Up for SuccessTBMG-337362/1/2019
In the medical industry, metal parts play an integral role in a vast array of diagnostic, testing, medical instruments, and equipment. Although certain complex metal parts can only be machined, thinner gauge parts and enclosures are typically stamped using hard tooling or fabricated using lasers, turret presses, or press brakes. These parts include carts, cabinets, enclosures, and user workstations that safeguard sensitive controls, electronics, or hardware. While not as high tech as the diagnostic equipment itself, these structural components are still critical to the product's function and longevity.
Custom Optomechanics in Industrial UV LasersTBMG-3328311/1/2018
Reliability and longevity directly impact the cost of using Q-switched, diode pumped, solid state, ultraviolet lasers in industrial applications. Damage to the intracavity harmonic crystal is often the major limiting factor in the lifetime of these lasers.
Improving Manufacturing Efficiencies through Industry 4.0 Technologies in Aerospace2018-01-192910/30/2018
1 In the age of 4th industrial revolution, operational and information technologies are increasingly getting converged to help organizations improve their topline through new innovative products and services, and improve bottom line by improving efficiencies. This transformation is driven by convergence of many advanced technologies such as advanced sensor and communication technologies, big data, advanced analytics, Artificial Intelligence (AI), robotics, additive manufacturing, virtual and augmented reality (VR/AR). Enterprises digitization journey continues to adopt advanced technologies through multi-pronged approach to achieve their near-term and long-term goals. This paper summarizes Industry 4.0 journey, its relevance and applications to aerospace. It also summarizes how Industry 4.0 concepts can be applied to a composite manufacturing shop floor of aerospace components, how effective convergence of IoT, analytics, machine learning, AI and AR/VR help in improving the overall efficiency, reliability, availability and quality of the manufacturing shop floor by monitoring real time data to evaluate the overall performance of manufacturing plant “As Designed” Vs “As Operated” quantifying the business value.
Veluri, Sastry, Kumar, Ravi, Vasudevan, Ramji, Gorur, Ravi Prakash, Nampuraja, Enose, Shankaraiah, Mahesh, Tanjore, Simha, Rao, Shama
Collaborative Robots Fill Automation Gaps For Medical Device ManufacturersTBMG-3308310/1/2018
When small and mid-sized medical device manufacturers envision a robot, many think of either huge industrial robots working in fenced-off areas in large factories or futuristic cyberbots mimicking human behavior. But between these two scenarios lies a new emerging reality: A class of robots dubbed collaborative robots — or simply cobots — are bridging the gap between fully manual assembly and fully automated manufacturing lines. This new technology is filling automation gaps for larger manufacturers that have processes that couldn't be cost-effectively automated in the past and is bringing the advantages of automation within reach for even small, specialty manufacturers.
How Second Stage Speed Influences the Molding ProcessTBMG-3308710/1/2018
Hold speed or hold velocity? How many machines today have it, and what does it do to the process?
Motion Control in Factories: Choosing the Right SolutionTBMG-3307610/1/2018
The need for Ethernet-based communication within the factory has grown over the past 10 years. Detailed information about the tasks and performance of machines at every stage is critical to productivity. As capabilities have expanded from performance reporting to predictive maintenance warnings and beyond, the need to connect multiple controllers within the same machine and elsewhere in the factory has also grown.
IMTS2018 PreviewTBMG-324698/1/2018
Presented by the Association for Manufacturing Technology (AMT), the International Manufacturing Technology Show (IMTS) has been the premier manufacturing technology show in the Northern Hemisphere. IMTS is held every even year and attracts attendees from more than 117 countries. The 2018 edition will be the 32nd show.
Guiding the Way in Automotive PlantsTBMG-290016/1/2018
Vision-guided robotics commonly used in today's automotive plants enables robots to “see” the object they are working on so they can perform the required activity accurately on/to an object that is not in a repeatable location.
Diagnostics Manufacturing: Strategies for OutsourcingTBMG-286794/1/2018
When new assays or diagnostic tests are ready for commercialization, there can be tremendous hurdles to overcome, including significant investment in the infrastructure for automated manufacturing and test equipment and hiring and retaining highly trained personnel, as well as implementing high-end quality management systems. In addition, FDA, ISO, GMP, and other approvals or certifications may be required. This article examines the requirements for manufacturing these complex diagnostics as well as the critical factors to consider when selecting a manufacturer.
Choosing the Right Brake for Robotic ApplicationsTBMG-288124/1/2018
Industrial robots play an essential role in manufacturing, from assembly, to pick-and-place, to packaging. One of the major risks of robotics — and what OEMs seek to mitigate — is uncontrolled or non-commanded motion by a robot. Most electric robots today incorporate servomotors for direct-drive operation. This approach largely eliminates the need for clutches, but robots still need brakes, both to apply holding torque once the motor moving the joint has stopped, and to provide dynamic stopping in the event of emergency.
Additive Manufacturing Facility for Utilization Primarily in Microgravity EnvironmentsTBMG-281521/1/2018
The purpose of this innovation is to create the ability to manufacture off Earth, primarily in a microgravity environment. This additive manufacturing facility (AMF) will have the capability to build tools, parts, experimental hardware, and upgrade hardware while primarily being utilized in microgravity environments.
Robot System Safety in Medical ManufacturingTBMG-2774110/1/2017
Industrial manufacturing of medical products presents distinct challenges. This is particularly true for manufacturing of injectable drug products, which requires minimizing contamination to ensure the safety of patients and personnel as well as the quality of the product. In order to meet these challenges, pharmaceutical companies are increasingly implementing Advanced Aseptic Processing (AAP) systems. These systems utilize advanced automation, restricted access barrier systems (RABS), isolator-barrier systems, and robotics, with the goal of restricting operator access to the product and to critical areas of manufacturing machinery.
High Volume Automated Spar Assembly Line (SAL)2017-01-20739/19/2017
The decision to replace a successful automated production system at the heart of a high volume aircraft factory does not come easily. A point is reached when upgrades and retrofits are insufficient to meet increasing capacity demands and additional floor space is simply unavailable. The goals of this project were to increase production volume, reduce floor space usage, improve the build process, and smooth factory flow without disrupting today’s manufacturing. Two decades of lessons learned were leveraged along with advancements in the aircraft assembly industry, modern machine control technologies, and maturing safety standards to justify the risk and expense of a ground-up redesign. This paper will describe how an automated wing spar fastening system that has performed well for 20 years is analyzed and ultimately replaced without disturbing the high manufacturing rate of a single aisle commercial aircraft program.
Calawa, Rick, Smith, Gavin
Ruggedization of Imaging LensesTBMG-272277/1/2017
Imaging lenses used in many industrial machine vision applications have special requirements beyond those of standard imaging lenses. The lenses used in factory automation, robotics, and industrial inspection have to work in specific and demanding environments, which could involve vibrations, shocks, temperature changes, and contaminants. Because of these environmental requirements, new classes of ruggedized lenses are being designed specifically to work in a multitude of different scenarios, therefore creating different types of ruggedization. There are three distinct types of ruggedization available: industrial ruggedization, ingress protection ruggedization, and stability ruggedization.
Composites and Metal Bonding GlossaryAIR4844C (Historical)6/20/2017
The following terminology has been generated by the ATA/IATA/SAE Commercial Aircraft Composite Repair Committee (CACRC) and provides terminology for design, fabrication, and repair of composite and bonded metal structures.
AMS CACRC Commercial Aircraft Composite Repair Committee
Automotive Vehicle Assembly Processes and Operations ManagementR-4561/30/2017
Proven technologies and processes are explored in this examination of modern automotive manufacturing. Fundamentals and applications, as well as new advances are discussed as the author bridges the gap between academic research and industrial practice. Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author presents a concise understanding that reflects both technical and managerial perspectives with the aim of providing improvement through practical methods. Each chapter includes review questions and research topics, and, in addition, analysis problems are often included that comprehensively address: • Automotive Industry and Competition • Manufacturing Operations • Joining and Paint Processes • Production Operations and Quality Management • Performance Improvement Directly extracted and summarized from automotive manufacturing practices, this book serves as a fundamental manual. The subject is complemented by the author’s second book, Manufacturing System and Process Development for Vehicle Assembly, which provides even greater depth to the subject of modern automotive manufacturing.
Tang, He
Emerging Technologies: Challenge or Opportunity for the Medical Device Industry?TBMG-2554710/13/2016
Visiongain predicts the global medical devices market will reach $398 billion in 2017.1 To win share in this growing market, device companies need to stay out in front of manufacturing advancements so they can quickly integrate information technology (IT) functionality, accelerate time to market, and control costs.
Vibration Assisted Drilling on Automated Drilling Units: Challenges, Dynamic Modelization and Prospective Developments2016-01-20979/27/2016
The Vibration Assisted Drilling (VAD) process has been implemented in Automated Drilling Equipment (ADE) on an industrial scale since 2011. Today more than 11000 ADEs are currently used on aircraft assembly lines. As well as drawing up a short report on the use of this new process, the authors make an assessment on new challenges that VAD has to face up. Indeed production rates are increasing and ADE manufacturers improve their technologies, one of the most recent and major development concerning the electrical motorization of the machines. These evolutions are as many opportunities for the VAD provided you have a clever understanding as well as an expert knowledge of the process. Thus the authors propose a new dynamic model of the whole VAD system which integrates the behavior of the part, cutting tool/material pair and the machine. The confrontation of model results and experimental validation tests demonstrates the relevance of the works. On this basis the authors detail some perspective of ADE process of tomorrow in terms of implementation technologies, parameters settings or even cutting tool optimization. They also show the interest of a smart connection between this new model and the Mitis database which is fed for ten years by monitored VAD tests.
Laporte, Sylvain, De Castelbajac, Cosme, Ladonne, Mathieu
An Attempt for an Industry 4.0 Inspired Cloud-Supported Approach for Predictive Maintenance on the Example of Refill Friction Stir Spot Welding (RFSSW)2016-01-21259/27/2016
This paper presents an approach to how existing production systems can benefit from Industry 4.0 driven concepts. This attempt is based on a communication gateway and a cloud-based system, that hosts all algorithms and models to calculate a prediction of the tool wear. As an example we will show the Refill Friction Stir Spot Welding (RFSSW), a solid state joining technique, which is examined at the Institute of Production Engineering (LaFT) of the Helmut-Schmidt-University, University of the Federal Armed Forces Hamburg, for years. RFSSW is a sub-section of friction welding, where a rotating tool that consists out of three parts is used to heat up material to a dough-like state. Since Refill Friction Stir Spot Welding produces a selective dot-shaped connection of overlapping materials, the production requirements are similar to riveting or resistance spot welding. In contrast to other bonding techniques, Refill Friction Stir Spot Welding can be integrated within the production process without major interferences or changes. At the LaFT we build a prototype from which we collected a big amount of data which we are now trying to analyze with methods that are known from the Industrie 4.0. For the Industry 4.0 idea, the production environment respectively the welding equipment acts like an Internet of things device, that publishes its data to the cloud and retrieves a calculated result.
Hameister, Henry
End-Effector for Automatic Shimming of Composites2016-01-21119/27/2016
Gaps in composite structures are a risky factor in aeronautical assemblies. For mechanically joined composite components, the geometrical conformance of the part can be problematic due to undesired or unknown re-distribution of loads within a composite component, with these unknowns being potentially destructive. To prevent unnecessary preloading of a metallic structure, and the possibility of cracking and delamination in a composite structure, it is important to measure all gaps and then shim any gaps greater than 127 microns. A strategy to overcome the high relative tolerances for assemblies lies in the automated manufacturing of shims for the gaps previously predicted through the evaluation of their volumes via a simulation tool. This paper deals with the development of a special end-effector prototype to enable the shimming of gaps in composites structures using a pre-processed geometry. The aim of this end-effector is to provide movement to a temperature controlled hot-end in order to generate a solid shim of ABS on the target composite surface. This process is defined according to the trajectories and velocities marked by the 3D printing process using standard G-code. The geometry and material volume to be printed are indicated by the simulated gap volume which is based on previous metrological measurements. The final objective will be to attach this end-effector to an anthropomorphic robot to enable autonomous manufacturing. This work is part of the EU FP7 funded LOCOMACHS project, under grant agreement n°314003.
Antolin-Urbaneja, Juan Carlos, Livinalli, Juan, Puerto, Mildred, Liceaga, Mikel, Rubio, Antonio, San-Roman, Angel, Goenaga, Igor
Powder Reuse and Its Effects on Laser Based Powder Fusion Additive Manufactured Alloy 7182016-01-20719/20/2016
Laser Based Powder Bed Fusion, a specific application of additive manufacturing, has shown promise to replace traditionally fabricated components, including castings and wrought products (and multiple-piece assemblies thereof). In this process, powder is applied, layer by layer, to a build plate, and each layer is fused by a laser to the layers below. Depending on the component, it appears that only 3-5% of the powder charged into the powder bed fusion machine is fused. Honeywell’s initial part qualification efforts have prohibited the reuse of powder. Any unfused powder that exits the dispenser (i.e., surrounds the build or is captured in the overflow) is considered used. In order for the process to be broadly applicable in an economical manner, a methodology should be developed to render the balance of the powder (up to 97% of the initial charge weight) as re-usable. Though multiple manufacturers may be re-using powder, there is no industry standard methodology or practice for powder re-use. The present study (with 10 uses of the same powder lot) shows no appreciable impact on nickel-base superalloy 718 chemistry, powder size / distribution, or mechanical properties, with exception of gradual increase in oxygen content of the powder.
Hann, Brian A.
Simplified Machine Design Approach for Optimal Servomotor ControlTBMG-248936/1/2016
An often asked question from industrial machine builders or integrators is how they can effectively design or implement the conversion of a machine with servo technology to meet performance expectations. This is a specialized task filled with layers of complexity that can prove difficult to execute, even when the scope of work is fully understood.
Barriers to Entry in Automotive Production and Opportunities with Emerging Additive Manufacturing Techniques2016-01-03294/5/2016
Conventional car manufacturing is extremely capital and energy-intensive. Due to these limitations, major auto manufacturers produce very similar, if not virtually identical, vehicles at very large volumes. This limits potential customization for different users and acts as a barrier to entry for new companies or production techniques. Better understanding of the barriers for low volume production and possible solutions with innovative production techniques is crucial for making low volume vehicles viable and accelerating the adoption of new production techniques and lightweight materials into the competitive marketplace. Additive manufacturing can enable innovative design with minimal capital investment in tooling and hence should be ideal for low and perhaps high volume parts. For this reason, it was desired to evaluate potential opportunities in manufacturing automotive parts with additive techniques. Analysis of traditional processes was first performed to identify and quantify capital expenditure (CAPEX) barriers for low volume production of B-pillars, K-frames, HVAC assemblies, door inner trims and clutch housings. Review of emerging production techniques has shown promising potential in reducing CAPEX barriers by direct printing of K-frames and door trims as well as dies for metal and plastic parts. Key insights from the study include views on current performance of additive techniques compared to traditional processes and identified avenues for R&D advancements to improve their viability. This analysis is based on cost models developed under ARPA-E funding which use a consistent set of assumptions and repeatable framework to calculate the cost of fabrication and assembly of components.
Bubna, Piyush, Humbert, Michael P., Wiseman, Marc, Manes, Enrico
Finding the Right Lens: The Factors to Focus OnTBMG-2355712/1/2015
A sharp image requires more than just a good camera; it also takes the right lens. Several aspects must be considered to make sure that the camera and lens work perfectly together and fit a specific application.
Industry Roundtable: 3D PrintingTBMG-220435/1/2015
It seems that every day, designers and engineers are finding exciting new applications for 3D printing, from creating custom prostheses to making tools used for repairs on the International Space Station. 3D printing is considered a revolutionary technology that can transform our lives. But what are the real benefits — and the real consequences — of such a drastic change in manufacturing?
Hubble Spinoffs: Space Age Technology for the MassesTBMG-217083/1/2015
Over the plast 25 years, some of the sophisticated technology developed for the HST has been successfully spun off and commercialized to improve life on Earth.
A Recipe for Electroforming Success: Making Ultra-Precise, Ultra-Small 3D StructuresTBMG-216843/1/2015
Precision electroforming is an additive process in which two and three-dimensional (3D) microstructures are formed by electrochemically depositing metal into a precisely formed photoresist mold. Electroforming is ideal for fabricating micron-scale, metallic components, as well as for making injection molds used for forming non-metallic microstructures with nano-scale features.
Hybrid Lean-Agile Manufacturing System Strategic Facet in Automotive Sector2014-01-91041/1/2015
The lean production system has been successful in the cost-based winning order criterion markets. However, the automotive market has been volatile and the new criterion of winning orders has been availability, which has called for an agile system. The present paper argues that because of fierce competition the current automotive market winning order criterion is now a blend of cost and availability. It shows how a hybrid lean-agile system can strategically meet such a challenging criterion. The study presents the drivers, attributes and providers in lean manufacturing, agile manufacturing, and hybrid lean-agile manufacturing systems. It investigates how the strategic facet of the proposed hybrid lean-agile manufacturing system addresses the six manufacturing competitive dimensions. It presents as well the hybrid lean-agile manufacturing key performance indicators. The strategic facet of the proposed hybrid lean-agile manufacturing system has been validated through industrial case studies in automotive sector. A cost-benefit ratio qualitative analysis has been conducted on the proposed system and the benefits outweigh corresponding costs resulting in positive present value.
Elmoselhy, Salah A.
As 3D Printing Grows, Compounders Become Production PartnersTBMG-1748810/1/2013
Additive manufacturing, also known as 3D printing, grew from startup roots in the mid- 1980s to a $2.2 billion business by 2012, according to industry consultants Wohlers Associates, Fort Collins, CO. While it took 20 years to reach the $1 billion plateau, the industry reached its second billion in just five years and is expected to double again to $4 billion by 2015. The explosion of 3D printing has yielded a compound annual growth rate of 25 percent over the last 25 years, according to Wohlers Report 2013.
Medical Device Market Pushes the Limits of TubingTBMG-172169/1/2013
Medical device manufacturers are being challenged by strong market demand for tubing that delivers increased functionality, lower profiles, and lower costs—pushing the limits of material behavior and manufacturing science. Next-generation balloon catheters are expected to deliver significantly higher burst pressures and better puncture resistance. They are also being designed to transport target-specific drug-polymer payloads or flexible microelectronic packages to various parts of the human body. These enhanced miniaturization and functionality requirements of medical devices are also creating substantial design and manufacturability challenges. For example, how can an R&D team combine a 35-atm balloon with a robust weld and corresponding shaft tube, within a folded balloon profile that is compatible with a 0.065 inch sheath?
Increasing Competitiveness and Sustainability in Structural Assembly by Using Friction Spot Welding2013-01-08354/8/2013
To join sheet metal made out of aluminium, riveting is common practice. This process contains several disadvantages. On the one hand, large, specially designed and cost-intensive machines are used within automation engineering. Normally, those tools are not reconfigurable and cannot be used for general purposes. On the other hand, adding the rivet to the structure also increases weight of the whole craft. The proposed method of friction welding addresses those limitations of riveting. At the Institute of Production Engineering, Helmut-Schmidt-University, research is conducted to provide a control assuring process reliability to perform friction welding fully automated as well as manually. Friction spot welding is a sub-section of friction welding, where a rotating tool that consists out of three parts is used to heat up material to a dough-like state. Since friction spot welding produces selective dot-shaped connections of overlapping materials, the production requirements are similar to riveting or resistance spot welding. In contrast to other bonding techniques, friction spot welding can be integrated within the production process without major interferences or changes. Another advantage of friction spot welding is the simple process operation. Friction spot welding only requires one operation. Processing time and expenses are therefore reduced.
Hameister, Henry
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