AMT JUN/JUL 2017

Australian Manufacturing Technology

Your Industry. Your Magazine.

JUN JUL

Austech Review

Shipping & Logistics State Spotlight: Western Australia Cutting Tools Additive Manufacturing Advanced Materials & Composites Motors & Drives Forming & Fabrication Material Removal

Supporting Australian Manufacturing

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Contents

Volume 17 Number 03 JUNE/JULY 2017 ISSN 1832-6080

FEATURES Austech review Australian manufacturing puts on a show

44

CUTTING TOOLS Awards crown centenary year for Sutton Tools Sandvik Coromant unveils a revolution in turning Iscar – A welcome power cut Ten simple steps to peak performance & productivity

66 68 70 72

STATE SPOTLIGHT: WA High-tech manufacturing advances WA economy 3D printing in the deep blue sea

76 78

ADDITIVE MANUFACTURING Composite 3D printing: A-strength solution Making the most of additive manufacturing RAM3D – beyond the hype Moving to a regional hub bolsters business

80 82 83 84

SHIPPING & LOGISTICS Skilling up for a ship building boom DMD gets driveshafts up to speed on container ships

86 87

COMPOSITES & ADVANCED MATERIALS Graphene – Finding a commercial sweet spot Making light work of it: enhanced dynamics with CFRP High-end machine enables graphene purification

88 90 92

MOTORS & DRIVES Technology inspired by ecology

94

FORMING & FABRICATION CNC synchronised bending has never been easier

99

MATERIAL REMOVAL Some like it cold

44 Australian manufacturing puts on a show Australia’s advanced manufacturing industry flocked to the Melbourne Convention & Exhibition Centre from 9 to 12 May for Austech 2017 – the most successful Austech in years.

62 David Chuter - CEO of the IMCRC David Chuter is the CEO of the Innovative Manufacturing Co-operative Research Centre (IMCRC).

102

REGULARS From the Editor From the CEO From the Minister From the Industry From the Union

10 12 14 16 18

INDUSTRY NEWS Current news from the industry

22

VOICEBOX Opinions from across the manufacturing industry

34

PRODUCT NEWS Our selection of new and interesting products

38

ONE ON ONE David Chuter - CEO of the IMCRC

62

COMPANY FOCUS Avtech Engineering – Thriving despite the downturn

74

66 Awards crown centenary year for Sutton Tools As one of Australia’s longest-established manufacturing businesses, Sutton Tools is no stranger to being recognised for its achievements.

74

AMTIL FORUM Forum Law Forum Export Forum OHS Forum IP

104 105 106 107

MANUFACTURERS’ PAVILION

108

AMTIL INSIDE The latest news from AMTIL

112

Avtech Engineering – Thriving despite the downturn

MANUFACTURING HISTORY – A LOOK BACK IN TIME 118

Perth-based Avtech Engineeringis still finding strategies to succeed, despite the downturn in WA’s mining & resources sector.

AMT Jun/Jul 2017

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010

From the Editor William Poole

Finding the manufacturers of the future There were a lot of positives to be taken away from Austech 2017 – the mood was certainly the most upbeat I’ve seen in the five years I’ve been attending. But there was still room for caution, and in one area in particular – bringing young people into the industry.

I had several conversations during the show about the difficulties facing Australian manufacturing in terms of skills, recruitment, and building the workforce of the future.

Concerns ranged from inadequate training and weaknesses in the apprenticeship system, to a general perception among the public that manufacturing cannot offer stimulating, long-term employment. One person even observed that young people contemplating a manufacturing career were often warned to reconsider by their parents, on the basis it’s an industry “in decline”.

These are valid concerns that our industry must tackle to ensure it continues to attract talented workers. But there are broader issues at play within the wider economy, which will affect our industry as much as any other. And funnily enough, just as Austech was going on, these issues were being explored in the same building.

In one of the plenary rooms of the Melbourne Convention and Exhibition Centre, global education expert and futurist Charles Fadel gave a talk entitled ‘The New Success’, which addressed such questions as: what skills do our children need to thrive in the 21st century? And how does education need to change?

Fadel made some fascinating points, citing research that found today’s young people are likely to have 17 jobs across five different careers over the course of their working lives.

We can see this happening today, with the disappearance of the old-fashioned job for life, and the emergence of the ‘gig economy’, characterised by casual contracts with the likes of Uber and Airtasker. Fadel said the ability to learn, unlearn, relearn is in itself the key skill that people will require in this rapidly changing labour market.

Such concerns are reflected in a new report from recruitment agency Hays, which found that as we approach the Fourth Industrial Revolution, the digital and technological divide between jobseekers’ skills and employers’ requirements has never been greater.

According to Hays, the jobs and skills that are increasingly in demand generally place the emphasis on having the knowledge and capabilities to utilise new technologies – such as robotics, 3D printing to data analytics. And again, the ability to continually develop new skills was seen as critical.

However, Nick Deligiannis, Hays’ Managing Director in Australia & New Zealand, stressed the need to prioritise skills that are relevant to your industry: “Our advice is to narrow your focus to those that are or could be adopted in your field. No one can be an expert in every new development, so upskill in only those relevant to your job or the job you aspire to.”

The report noted that many people are aware of the need to upskill, which is why development opportunities are vital to jobseekers. In a recent survey, 60% said they were looking for a new job due to a lack of career development in their existing or former role – second only to a desire for more challenging, exciting work (61%).

What’s interesting is that, on both of these counts and on many more, manufacturing is well placed to compete in the battle for talent. This is an industry where the technology, and the challenges, are constantly changing, and that’s got to be the basis for an exciting career – better than being an Uber driver, surely. It’s just a case of changing the way our industry is perceived.

Your Industry. Your Magazine.

Australian Manufacturing Technology

Editor William Poole wpoole@amtil.com.au Contributors Carole Goldsmith Brent Balinski Sales Manager Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia using FSC® mix of paper from responsible sources FSC® C007821 Contact Details AMT Magazine AMTIL Suite 1, 673 Boronia Rd Wantirna VIC 3152 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright © Australian Manufacturing Technology (AMT).

All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher.

Contained specifications and claims are those supplied by the manufacturer (contributor)

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes.

AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published monthly.

Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $165 (inc GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

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AMT Jun/Jul 2017

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012

From the CEO Shane Infanti – Chief Executive Officer AMTIL

Another Austech success

In the wash-up of our Austech exhibition there are many people to thank. First and foremost - the 163 exhibitors who put on a fantastic showcase and the 11,501 attendees who came to visit Austech and our co-located partner show National Manufacturing Week.

Thank you to Michael Begg and his team at Harry the Hirer. The 4-6 months of daily pre-show email communication to ensure every “T” is crossed and every “I” dotted with our team ensured the smoothest move in to a show we have had in almost 20 years. Beggy’s unique “Sector” plan, which involved four sectors of carpet lay and stand build over three days, was well received by other contractors and certainly gave us a few laughs along the way. Also thanks to Travis Wall and his team of electricians and riggers. Safety is paramount during our move-in and move-out process and the challenge of having carpet laid, rigging done and crane movements all at the same time (along with everything else) was made easy by the professionalism of the HTH staff. An interesting fact is, that in order to provide power to all the stands and equipment, over 13kms of electrical cable needed to be laid in the carpark prior to the show.

Our logistics contractor Agility Fairs & Events, ably led by the “Freightman” Michael Stubbs, again did a great job of controlling the logistics of freight, loading dock chaos, fork lifts and crane movements. Special thanks to Michael Barker and his team for an outstanding effort. To be on-site from 6.00am until 10.00pm most days and be organised and flexible at the same time takes a great deal of management and patience. An interesting fact about Michael Barker is he is actually in the national roller hockey team and I thought a picture of him in the national colours would be a great way to embarrass him!

Photo by Jay Hughes

I would also like to thank our contractors who largely go unnoticed in the overall scheme of putting on such a large event but are an integral part of making it happen.

So at the risk of embarrassing some companies and individuals, I write this article to thank them and give our readers some insight into the mechanics of running our show.

Thanks to Bruce Emmett at Houghton Australia for supplying and removing over 5,000 litres of cutting fluid and meeting all the exhibitor requirements.

Thanks to Nigel and Tony at Oztag for testing and tagging all the electrical leads.

Thanks to Jamie and Rajesh at Ikon Cleaning for being so accessible each and every day. Cleaning is often a thankless task, so good on your team for having our show looking so good at opening time.

Thanks to Kevin and Richard and their team at Australian Security Services.

Interesting fact: 716 man hours of security were provided during the show.

Thanks to Rick Kober and the Info Salons group for their patience and understanding of our registration process. We had quite a number of extra activities at the show this year that required varying registration changes and, once again, easily accommodated by the Info Salons team.

F Wood and Son is our plumbing contractor and well done to Paul Wood and his team on another smooth show. Paul has such confidence in his team that he arranged to get married on the Sunday of move-in and take off on a honeymoon! Thanks to Bryan and Mandy for getting the job done in his absence.

Thanks to Chris Petropoulos and the guys at Sims Metal, with some late changes to our schedule being easily accommodated.

Another interesting fact is that we recycled nearly seven tonnes of swarf and scrap metal generated by exhibitors at the show.

Thanks to our gas suppliers, Coregas and BOC, again accommodating some rushed changes to our schedules and late orders being placed. Interesting fact: On the Friday prior to the show opening, 54 tonnes of gas packs were delivered to the venue and each morning of the show a number of stands had to have gas pack changeovers.

Thanks to the MCEC venue staff and their Operations Manager Jamal Gittens for his appreciation of our efforts. Quite understandingly the MCEC has very strict guidelines and safety considerations and liaising with Jamal to provide a safe working environment provided an excellent outcome. Thanks to Kaylor Clark, our event coordinator at the MCEC, working behind the scenes to help make everything happen.

Thanks to our partners, Reed Exhibitions, who we co-locate with. NMW is a good show and one we are pleased to run Austech alongside. Thanks to the operations team led by Christiane Beck for all their efforts and assistance on-site.

Finally, thanks to my team led by our Events Manager Kim Banks on another outstanding show. Our critical path has 131 line items and each one of them has been managed and ticked off on time on budget.

Great effort team.

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AMT & AMTIL Digital Media Kit 2016 Call Anne Samuelsson at AMTIL on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

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Thank you for your support.

WINNER Manufacturer Of The Year - Large Business 2017 Victorian Manufacturing Hall of Fame www.suttontools.com

014

From the ministry The Hon Arthur Sinodinos MP – Minister for Industry, Innovation and Science

A Budget for Manufacturing

Here are some facts and figures about Australia’s manufacturing industry that may surprise you.

In 2016, manufacturing in this country produced $98.2bn in output and employed more than 900,000 Australians. Hundreds of thousands more are also employed indirectly in roles ranging from packaging to industrial design to truck driving. Manufacturing employment is increasing, with more than 10,000 additional manufacturing jobs created in the last 12 months. And the sector is expanding, with the Ai Group’s Australian Performance of Manufacturing Index for May sitting at 59.2 points — representing the seventh month in a row of growth.

Regardless of how you crunch these numbers, it’s obvious that manufacturing is big business in Australia and a crucial element of our economy. It’s also abundantly clear that there’s momentum in the sector – so let’s keep it going.

The $100m Advanced Manufacturing Fund we announced in the Budget is going to help the sector create jobs, grow their businesses, improve productivity and perform on the global stage.

The fund is more than just a short-term ‘kick-along’ for the sector; it’s a systematic approach designed to provide the platform for Australian manufacturing to thrive in the long-term.

Innovation is the key to our plan. If Australian manufacturers can embrace smarter, more efficient means of production, and develop innovative support services on top of this, we are going to be able to stand out from our competitors. Differentiating ourselves is vital if we’re going to stay ahead of the pack globally and, importantly, take full advantage of the opportunities being presented by the rise of Asian markets.

The wind-down of car manufacturing in Victoria and South Australia has been well-documented of late. But we don’t see the cessation of passenger vehicle production as the end of the story. Instead, it’s the chance to begin a new chapter.

The centrepiece of our package is funding designed to help manufacturing transition to new processes and equipment to ensure they are world-leaders in competitive global markets. The new Advanced Manufacturing Growth Fund, worth nearly $47.5m over two years, will help industry adjust to the changing landscape of manufacturing in Victoria and South Australia. This significant injection of funds builds on the successful $155m Growth Fund to assist with the transition from passenger motor vehicle production. Other measures in the Advanced Manufacturing Fund will further research; invest in emerging engineers and scientists; provide facilities to test new products; and develop business capability.

The additional $4m for the Advanced Manufacturing Growth Centre will support small-scale and pilot research

AMT Jun/Jul 2017

“It’s obvious that manufacturing is big business in Australia and a crucial element of our economy.

It’s also abundantly clear that there’s momentum in the sector – so let’s keep it going.” projects in advanced manufacturing, allowing small firms and early stage researchers to quickly move to larger scale research or commercialisation. A further $20m has been allocated for larger scale advanced manufacturing research projects of up to $3m in funding over three years. And a further $10m will be used to establish Innovation Labs in South Australia and Victoria to test and showcase new products and improve business capability.

Highly skilled workers are a crucial part of our plan, too. The Government will invest $5m in student research at universities, technology institutions and in industry to maintain the flow of highly trained automotive engineers to the automotive design and engineering sector. And we’re removing tariffs on imported vehicle prototypes and components used by Australian motor vehicle design and engineering services that operate in a global network.

This all builds on what the Government is already doing through the National Innovation and Science Agenda and initiatives like the Industry Growth Centres, the Cooperative Research Centres Programme, and the Entrepreneurs’ Programme—measures that are helping Australian businesses and researchers to collaborate, innovate and succeed.

Along with the tax cut for around 3.2 million small and medium-sized Australian businesses, these initiatives will help our manufacturing businesses to modernise their operations, create new opportunities and new jobs, and sell their smart, new products to the world. The Federal Government is working hard to safeguard a positive future for globally competitive Australian manufacturing.

All the current signs point to a sector that is riding the bumps and well-placed to remain a pivotal cog in the nation’s economy. But we’re not resting on our laurels. That’s why we’re injecting $100m into this new fund. Australia must keep up as manufacturing around the globe undergoes major transformation.

The Advanced Manufacturing Fund, which puts innovation front and centre, will help Australian manufacturers thrive by enabling them to contribute distinctive products, components and services to global supply chains. That’s where the future of manufacturing in Australia is headed and we’re committed to helping it on its journey.

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016

From the industry Innes Willox – Chief Executive Australian Industry Group

Industry drags its heels on digital technology

The imperative to “disrupt or be disrupted” keeps a lot of CEOs up at night. Accelerating change, advancing technology and new business models are sources both of opportunity and threat for established businesses, with a disruptive new competitor never more than one start-up away.

In this environment, one thing is certain: if Australia’s businesses – and manufacturers in particular – are going to thrive and deliver employment and prosperity to the community, they need to make the most of emerging technologies. But a new Ai Group report, Business Beyond Broadband, has found that, while Australian businesses are investing in new technologies to enhance profit and performance, industry as a whole is lagging in adoption of key innovations.

Based on a wide survey of Australian businesses, the report confirms a close association between investment in digital technologies and higher business performance. Businesses are investing to improve customer service, lift productivity and boost competitiveness – and businesses that did not use any of the digital technologies surveyed had about 14% lower gross profit margins.

Cloud computing is now widely used to cut costs, improve service and ease business growth. Of the businesses we surveyed, 42% use cloud computing, and they experienced an average of 5% growth in profit margins over the year of the survey, compared to an average 2% reduction in profit margins for other businesses.

Business also makes extensive use of mobile apps (58% of Australian businesses), enabled by our vibrant and mature mobile telephony market.

“Getting the most out of technology requires businesses to build digital into their strategies. Many are doing so, for instance by growing digital skills through staff training and recruitment. However, some 17% of businesses plan to do nothing to improve staff digital skills.”

The Internet of Things is widely discussed, and ever more devices are becoming connected, but most businesses are not yet investing in or using the building blocks of this technology. It remains elusive, as businesses are yet to fully integrate its technological foundations.

For manufacturers, the relatively low use of networked technologies (as proxies to the Internet of Things) suggests that they are still at the early stages of embracing the technological foundation for the new manufacturing vision often referred to as “Industry 4.0”.

With the impact of the WannaCry ransomware attack still reverberating, it is of particular concern that the report shows that businesses have been slow to adopt cyber security technology.

Cyber security is a critical risk management issue for the boardroom, and is growing more so as more activities go online, more devices become connected, and threats evolve. Despite this, 78% of businesses surveyed did not report using cyber security technology beyond common defaults.

In addition, few of those surveyed saw cyber security issues as a barrier to new digital investments – only 13% reported this as an inhibiting factor. This confirms the findings of other observers, and is deeply concerning given the demonstrated ability of cyber breaches to damage reputations, disrupt business operations and bring down critical infrastructure. We need to get on top of cyber security as digital technologies and the Internet of Things continue to grow in Australia.

‘Big data’ appears to be another area of largely untapped potential at this point. Businesses in our survey that made use of big data experienced an average 16% growth in gross profit margin over the year – yet only 7% of Australian businesses make significant use of it.

The National Broadband Network (NBN) continues to play an important role in supporting growth. While rollout is accelerating, most regions are yet to be served – only 8% of businesses reported having an NBN connection, with 82% accessing the internet via ADSL. Among our survey respondents, 20% experienced frequent

AMT Jun/Jul 2017

internet service interruptions, and 59% of businesses indicated that they would be willing to pay for faster internet services. These results suggest that much demand remains to be met, and 2017 should see the NBN strive to meet more businesses’ needs than ever before.

Getting the most out of technology requires businesses to build digital into their strategies. Many are doing so, for instance by growing digital skills through staff training and recruitment. This will be vital to ensure businesses have a future-ready workforce.

However, some 17% of businesses plan to do nothing to improve staff digital skills. This and other disconnects leave too many businesses at risk of falling behind local and global competition.

There is much that industry can do to improve performance and collaborate with governments and other bodies to help Australia embrace the Fourth Industrial Revolution. Our Business Beyond Broadband report highlights the progress we’ve made – and the imperative that Australia not become one of the unlucky countries that falls behind.

Ai Group’s Business Beyond Broadband report is available online at: www.aigroup.com.au/policy-and-research/ mediacentre/reports

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From The Union Paul Bastian – National Secretary Australian Manufacturing Workers Union

The 2017 Budget: Blue collar workers forgotten again The 2017 budget has failed blue collar workers and the manufacturing industry.

It is clear that the Government has no vision for the future of the manufacturing industry and this program is just more lip service, when real action is needed. Out of a budget of that announced $15bn of new spending, only $87m has been allocated to the manufacturing industry.

For a Government that has overseen record numbers of manufacturing jobs losses, this really is a slap in the face to manufacturing workers and their families. There is no plan for investment in emerging sectors of the manufacturing economy. There is not a single cent of new spending to renewable energy jobs.

We have been advocating for a Manufacturing Finance Corporation to boost investment in our industry and create local jobs. This is critical given that the capital investment in manufacturing is at record lows. The budget has failed to allocate any funding to this issue. If you’re a blue-collar worker that is worried about the future, this budget is very little comfort.

Money for training and skills development On the bright side, we were pleased to see that the Federal Government has finally decided to take the decline in apprentice numbers seriously. They’ve set up a $1.5bn training fund, financed by a new levy on work visas. This should act as a disincentive for employers to use visas where there is a local worker available and to ensure that our kids have the opportunity to learn a trade.

This is a positive step, but it will only work if there are actual apprenticeships for young workers to go into. In NSW alone, apprenticeship take-ups have halved in the last five years. Youth unemployment is up at 13.5%. The fund is a good initiative, but it can only work if the jobs exist to support it. Also, it’s worth pointing out that the Federal and State governments have gutted TAFE over the last few years and this budget includes another $600m cut in TAFE spending. So we have lots of money for new apprentices but fewer opportunities to employ and train them.

Infrastructure spending The Government has announced a big spend on new rail infrastructure. This is potentially the shot in the arm that our industry needs. In particular, there is big

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potential for steel and rolling stock. That said, we will only see the benefit of this if the Government mandates local builds for these infrastructure projects.

Too often, we have seen government contracts on steel and rail delivered to overseas companies. Unless the Government mandates that contracts are delivered to local companies, we risk missing out on thousands of local jobs.

Tax cuts for the rich There are a few new taxes in this budget and very few tax cuts. What is most astounding is that the tax cuts that do exist are targeted to the most well-off. There is a $16,000 tax cut for people earning a million dollars. On top of this, the budget has made insultingly small changes to the generous tax concessions for property investors. It means that an entire generation of young people risk being locked out of the housing market.

This is a tax system still skewed towards the millionaires. Meanwhile workers in our industries are struggling with record low wage growth.

Where is the money coming from?

The Government has announced that it will be achieve a budget surplus by 2021. To achieve this they’re whacking the banks for $6.2bn – which sounds great at first, but then you realise that they’re only doing it to fund a $65.4bn tax cut for corporations.

Once the banks receive the business tax cuts proposed by the Government, they will end up billions better off.

As mentioned above, workers across the economy have suffered from record low wage growth. But the Government appears to be very optimistic about what is going to happen to wages in the next few years. The budget projects that wages will rise 2.5% next year, rising to 3.75% by 2020.

Without wage growth at these levels, it is unlikely that the budget will return to surplus as forecast. So the AMWU will be making sure that all employers in the industry are doing their patriotic duty by offering pay rises at least in line with these projections.

After all, we wouldn’t want to make a liar of the treasurer, would we?

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Government unveils Naval Shipbuilding Plan Prime Minister Malcolm Turnbull on 16 May unveiled Australia’s first Naval Shipbuilding Plan, outlining the nation’s largest ever programme of naval shipbuilding and sustainment.

The plan includes a $1.3bn injection of funds to modernise construction shipyards in South Australia and Western Australia in order to build the Navy’s next generation of naval vessels.

The Federal Government is investing around $90bn in the rolling acquisition of new submarines and the continuous build of major ships such as future frigates, as well as minor naval vessels. The Plan will ensure delivery of these modern defence capabilities set out in the 2016 Defence White Paper, creating thousands of jobs and securing the naval shipbuilding and sustainment industry for future generations of Australians.

Work will commence this year on the development of infrastructure at the Osborne Naval Shipyard in South Australia. The Henderson Maritime Precinct in WA will also be upgraded. This will encompass construction of new cranes and heavy lift transportation capability, welding stations and upgrades to workshops and storage facilities including new steel framed sheds.

The naval shipbuilding workforce is expected to grow to around 5,200 workers by the mid to late 2020s, with more than double this number of workers in sustainment activities and throughout supply chains across Australia.

The Ai Group welcomed the announcement, saying it would end the boom-bust cycle of recent decades in naval shipbuilding, which has seen hundreds of job losses and local shipyards become increasingly redundant.

“A key to the success of the continuous shipbuilding program will be establishment by prime contractors of strong supply chains of Australian SMEs,” said Innes Willox, Ai Group Chief Executive.

“This is especially critical for the new submarine program. Lead contractor DCNS needs to engage fully with local industry to ensure that it can meet the Federal Government’s caste-iron commitment to construction of 12 new submarines at Osborne.”

However, the Australian Manufacturing Workers Union (AMWU) warned that urgent action was required to secure existing expertise and prevent the loss of 500 skilled jobs in South Australia before construction starts next year.

“The Government talks often about working to maximize Australian industry and content,” said AMWU Assistant National Secretary Glenn Thompson. “We need mandated Australian industry participation and content written into all build contracts. Around 500 existing jobs are at risk before major building operations commence next year. If we lose this expertise we really will be starting these projects from a long way behind, in terms of using the projects to enhance domestic shipbuilding capability and expertise.”

Australian manufacturing’s $75bn opportunity

Australia’s manufacturing sector stands to generate an additional $75bn worth of exports by 2030 – according to a new report released by ANZ. The report titled Australian Made highlights the shift in China’s economy from the manufacturing sector to the services sector as a potential catalyst for the resurgence of Australia’s manufacturing sector. ANZ General Manager Regional Business Banking, Christine Linden, said: “To realise this growth opportunity, Australian manufacturing must build efficiency through technology and scale, integrate itself in the regional Asia supply chain and use Australia’s intellectual property as a competitive advantage.”

According to the report, manufacturing is Australia’s fifth largest sector, contributing 6.1% of gross domestic product, and employing more than 900,000 people. By 2030, manufactured exports to China will increase across the full range of goods, including by: $1.7bn (a 55% increase) in processed primary goods, such as food, fibres and minerals; $2.6bn (88% increase) in ‘simply transformed manufactures’, including clay bricks, paper, pig iron and plaster; and $1bn (a 53% increase) for Australian exports of ‘elaborately transformed goods’, such as clothing, machinery and paint.

Notwithstanding the opportunity, the report found that the sector is responding to a range of challenges including global competitiveness, labour costs and skills shortages, various high input costs (including energy) and overall productivity challenges, and is determining ways to stimulate further investment in research & development.

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“Market access and speed to market are just a couple of the real competitive advantages Australian manufacturing possesses,” Linden added. “Like our agriculture and education sectors, Australian manufacturing has a strong brand reputation overseas steeped in quality and innovation.”

The report found subsectors emerging as top performers as Australian manufacturing evolves and moves towards R&Dintensive products and consumables. A leading subsector that continues to go from strength to strength is food & beverage manufacturing. Capitalising on Australia’s ability to produce quality food on a large scale, the subsector is now Australia’s largest, reaching $25bn in value alone in 2016. Linden pointed out that a large portion of the growth in food &beverage manufacturing – and manufacturing in Australia generally – has been driven by demand from China.

“Export destinations of Australian manufactured goods haven’t changed dramatically since 1990 - Asia’s still our top market,” she added. “What we have seen, however, is the sharp rise in manufactured goods heading to China driven by the demand from the emerging middle class for high-quality goods. This has seen our manufactured exports to China rise in value from $1.4bn in 2000 to more than $8bn in 2015.”

industry news

Consumers want Aussie Made

If it’s Australian-made, say it. That’s the latest call from the Australian Made Campaign, which is encouraging companies that make Australian goods to display their Aussie credentials and leverage consumer preference for Australian-made products.

Roy Morgan research recently revealed that more than two thirds of Australians (69.9%) would give preference to buying genuine Australian-made products. In fact, the Australian-made attribute is particularly important to consumers across a number of product categories, including food, complementary health, pet care, furniture and bedding, as well as building and renovation.

“It comes as no surprise that consumers are increasingly demanding authentic, premium-quality products that originate from our clean, green environment and are made to demanding Australian standards,” said Australian Made Campaign Chief Executive, Ian Harrison.

What is clear from the research is that businesses that make products in Australia and market this key point to consumers have an advantage in the marketplace.

“It makes absolute sense for businesses that produce products locally, to leverage consumer preference for Aussie products,” said Harrison. “And the best way for business to tell consumers that their products are genuinely Aussie is by branding them with the Australian Made logo.

“The famous green and gold kangaroo logo has long been the quickest and easiest way for consumers to identify genuine Australian products. It’s instantly recognised, it’s trusted and it works. So, if it’s Australian-made, say it”

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While Australian-made products remain highly popular among Australian consumers, “Made in Germany” is the most highly regarded quality label for goods and services around the world, according to Statista’s Made-In-Country Index (MICI). Statista, in cooperation with Dalia Research, surveyed over 43,000 consumers from 52 countries, in one of the world’s largest, most comprehensive studies on international trade.

The “Made in Germany” label’s first-place position was mainly based on positive ratings in the “quality” and “security standards” categories, along with overall popularity in many countries: Germany held the number one position in 13 countries. Switzerland was in second place with very high ratings in the “status symbol” and “authenticity” categories. Italy excelled with regard to design, while Japan received the best “advanced technology” ratings of all countries, and China outshone others regarding “price/performance ratio”.

Australia secured a highly creditable 14th place in the Statista rankings.

Businesses can register to use the Australian Made logo by contacting the Australian Made Campaign on 1800 350 520 or visiting www.australianmade.com.au. Consumers looking to find genuine Australian-made or grown products should visit www.australianmade.com.au.

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CSIRO kick-start for Tomcar

Victorian vehicle manufacturing start-up Tomcar Australia has been given a kickstart thanks to a new funding initiative that helps companies to access CSIRO research expertise and capabilities.

CSIRO Kick-Start is a new initiative that offers dollar-matched funding of up to $50,000 to enable research projects for start-ups and small businesses that are on their way to becoming Australian success stories.

Tomcar, which aims to be Australia’s first production electric vehicle, is just one of the first six businesses to receive the funding. The company will use it to conduct feasibility research into electrification of their modified off-grid, off-road vehicles with CSIRO’s Manufacturing team. The work will provide an integrated systems solution tailored to Tomcar’s vehicles, and builds on CSIRO’s electric motors expertise.

Following the feasibility testing, Tomcar plans to continue its collaboration with CSIRO in the development of prototypes and full production of Australia’s first electric vehicle, forecasted for a 2018 launch.

“We pride ourselves on being a disruptive vehicle manufacturer, and being able to partner with Australia’s research institutes to access engineering capabilities and expertise that we wouldn’t normally have access to is what’s helping us achieve that,” said Tomcar Australia co-founder and CEO David Brim. “CSIRO’s Kick-Start program has taken away the financial burdens that would have prohibited us from taking this next step.”

Keith McLean, Director, Manufacturing at CSIRO said Australian start-ups and SMEs were critical in driving Australia’s innovation output.

“CSIRO is committed to supporting them by providing access to our research expertise, capabilities and facilities,” said Dr McLean.

“CSIRO Kick-Start is just the beginning of what we hope to be longstanding collaborations and strategic partnerships.”

The new CSIRO Kick-Start initiative boosts the national science organisation’s existing support for SMEs and small businesses, now offering funding and linkage solutions to all Australian businesses with a turnover up to $100m to undertake research projects that will help their businesses develop and grow.

For more information on CSIRO Kick-Start and CSIRO’s suite of SME solutions visit SME Connect at: www.csiro.au/en/Do-business/Solutions-for-SMEs

HEC Group joins Rail CRC, UTS battery project

The Rail Manufacturing Co-operative Research Centre (CRC) has announced the HEC Group will join the Centre as a new participant on an innovative lithium battery project.

Working in partnership with the University of Technology Sydney (UTS) and HEC, the project overseen by the Rail Manufacturing CRC will focus on the development of new materials for lithium ion batteries to be used for rail vehicle propulsion, regenerative braking, signalling systems and auxiliary applications.

The Rail Manufacturing CRC is responsible for connecting industry organisations with Australian research institutions to deliver leading rail R&D projects, with Dr Stuart Thomson, the CRC’s CEO, recognising a strong connection between HEC’s capabilities and the Rail Manufacturing CRC’s purpose.

“The Rail Manufacturing CRC is pleased to have the HEC Group join the Centre as a new participant, and is excited to work together to develop new lithium battery technologies to service the rail industry’s need for new energy regeneration and storage solutions,” Dr Thomson said.

Targeting high-tech batteries as a major growth engine, HEC has invested heavily in the energy storage sector. Dr Shuwei Wan, CEO of the HEC Group’s Australian division, is looking forward to his organisation working on a project that could have far reaching benefits to the rail industry.

“HEC has extensive experience in the development of electronic components and energy storage materials,” said Dr Wan. “These have the potential to contribute to new battery technologies that could reduce the need for overhead electrical infrastructure and also aid in the future development of hybrid-powered trains.”

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UTS is the lead university on the lithium ion batteries project.

The Director of the UTS Centre for Clean Energy Technology, Distinguished Professor Guoxiu Wang will be responsible for driving the delivery of the research project.

“This is an important collaborative project between the Rail Manufacturing CRC, the HEC Group and UTS, which has the potential to bring about innovative new battery technologies that not only benefit the Australian industry, but the global rail market as a whole,” Professor Wang said.

The lithium ion batteries project is co-funded by the Rail Manufacturing CRC, and is expected to be completed by December 2019.

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Boeing, CSIRO launch new $35m research program

CSIRO signs a new $35m research agreement with Boeing. The organisations will work together on a broad range of areas of mutual interest including space sciences, advanced materials and manufacturing.

The move is the latest step in a 28-year partnership between CSIRO and Boeing, which saw Boeing name CSIRO as a 2016 Supplier of the Year in early April. Over the years the organisations have invested more than $170m on 190 joint research projects into everything from innovative new manufacturing processes, to fire retardants, biofuels and software. CSIRO’s Paintbond technology, for instance, has been applied to more than 1,000 Boeing aeroplanes, saving millions of dollars in maintenance costs.

Announcing the new funding agreement, CSIRO Chief Executive Larry Marshall said: “With almost three decades of ground-breaking research that has created jobs and growth for Australia and the US, it’s hard to overstate the impact that our relationship with Boeing has had. Adopting a global outlook for national benefit is a key pillar of CSIRO’s Strategy 2020, and it’s an approach that has yielded enormous benefits through our relationship with Boeing.”

The strong relationship with CSIRO was a key factor in Boeing choosing Australia as the location for its largest research and development operation outside the US. “Boeing celebrates 90 years in Australia this year, and for nearly a third of that time, we’ve partnered with CSIRO on advanced technologies that have made a real difference to the aerospace industry,” said Maureen Dougherty, President of Boeing Australia, New Zealand and South Pacific. “We’re excited to see that relationship move forward as a result of this new multi-year agreement.”

Meanwhile, Boeing Defence Australia has signed a partnership agreement with the South Australian Government to open a new office in Adelaide’s CBD, expanding its defence presence in SA. The new office will encompass research, development and innovation programs spanning intelligence, surveillance, reconnaissance and advanced experimentation and prototyping.

“Boeing Defence Australia is committed to building local capability in SA,” said Boeing Defence Australia Vice-President and Managing Director Darren Edwards. “One way we are doing this is by investing $500,000 over five years in the Techstars Adelaide global accelerator program to support SA’s entrepreneurial start-ups. We greatly appreciate the partnership with South Australia that made this office opening a reality.”

Premier Jay Weatherill said companies such as Boeing Defence Australia are an exciting part of the state’s future. “South Australia will become a strategic hub for Boeing Defence Australia, creating around 250 new highly skilled technical and advanced research positions. These skilled roles will offer significant sustainable employment opportunities to young SA graduates, with the added benefit of creating jobs with defence contractors and significant numbers of indirect jobs.”

Boeing Defence Australia is a leading Australian aerospace enterprise, with more than 2,000 employees at 14 locations throughout Australia and three international sites.

Australian businesses not prepared for disruption A new report by RMIT Activator reveals the majority of Australian businesses are vulnerable when it comes to responding to disruption in their industry.

The results from the RMIT Activator survey Disruption - Ignore or Embrace? show 73% of businesses recognise they are operating in a disruptive environment, but one-third of those are choosing to ignore the trend, and only 30% are just starting to explore options of how to adapt. Smaller enterprises consider themselves less susceptible to disruption and are, therefore, the least prepared for change if it occurs.

“One key to being a successful entrepreneur is to recognise where a market can be disrupted and build a sustainable business around such an opportunity,” RMIT Director Renzo Scacco said.

“Knowing how to embrace disruption and navigate the range of opportunities is what we seek to teach our community at the Activator as each individual builds their entrepreneurial mindset.”

Papercloud co-founder and RMIT advisory board member Simon Holland was surprised at how many businesses were choosing to ignore disruptive change in their industries.

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“If they are not being affected today, they will notice it tomorrow,” he said. “Businesses need to adopt, embrace and nurture disruption and see how they can be a part of it. It’s about supporting change and getting excited about it rather than being scared.”

Disruption - Ignore or Embrace? is the first survey in the RMIT Activator Enterprise Insights series, which examines key topics related to enterprise and entrepreneurship as seen by the broader business community. A cross-section of Australian businesses from the primary production, manufacturing, sales and service, and knowledge-based industries were asked about the level of disruption they were seeing in their sector and the economy as a whole. The survey revealed that many businesses recognised the need to actively address the challenge of new technology, innovation and new entrants, but lacked the motivation to invest time and money into it.

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Industry News

WTIA, DMTC collaborate to support Australian welders

The Welding Technology Institute of Australia (WTIA) and the Defence Materials Technology Centre (DMTC) have signed a collaboration agreement designed to support Australian welders, as well as small-to-medium enterprises.

Under the agreement, the two organisations will work together to develop a broader understanding of existing technology footprints and build a program of benchmarking, capacity building, training and certification activities. In particular, the WTIA and DMTC will help build industry capacity in areas of Defence priority, such as the welding of high-strength steels.

According to WTIA CEO, Geoff Crittenden: “Together with DMTC, the WTIA will help Australian welders, suppliers and contractors embrace new technology, upskill the workforce, and gain a deeper understanding of the requirements of Defence industry primes.

“Governments at all levels are becoming increasingly aware of the potential shortfall in qualified welders that will be required to deliver the Commonwealth’s ambitious $100bn Defence equipment programs. The WTIA is committed to ensuring that all new Defence equipment is built by Australian welders and that Defence contractors have no reason or excuse for importing skilled labour to deliver these projects.”

Crittenden and his counterpart at the DMTC Dr Mark Hodge signed the agreement at National Manufacturing Week in mid-May. Under the agreement, both organisations will also work closely with the Centre for Defence Industry Capability (CDIC), the establishment of which was one of the key announcements in the 2016 Defence Industry Policy Statement.

Supashock lands partnership to develop military truck suspensions Adelaide-based Supashock has entered a partnership with Rheinmetall MAN Military Vehicles (RMMV) for the development and manufacture of innovative suspension technology for RMMV’s range of military trucks.

Supashock specialises in high-performance engineered solutions for the automotive, racing and defence sectors with particular expertise in motion control and suspension technology. RMMV has funded Supashock to develop the system for the Australian and global markets. The system integrates Supashock’s novel active suspension technology with an integrated, intelligent load handling system and will substantially increase the capability and safety of RMMV’s military trucks in demanding on and off-road environments.

Through comparative testing, Supashock’s suspension technology has been shown to substantially improve the mobility of RMMV’s trucks, while at the same time enhancing on-road safety and reducing the shock and vibration experienced by the load the truck is carrying. Rheinmetall sees broad application of the load handling system and Supashock’s suspension technology on both Australian and international programs.

Rheinmetall’s investment in Supashock is on the back of a Federal Government grant that was announced by the Minister for Defence Industry, Christopher Pyne.

“We are convinced that our partnership with Rheinmetall will underpin our growth and create high technology, enduring jobs in the automotive sector that will deliver performance improvements to our customers and real benefits to the Australian economy,” said Oscar Fiorinotto, Managing Director of Supashock.

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CEO Geoff Crittenden, CEO of the Welding Technology Institute of Australia (WTIA) (left), and Dr Mark Hodge, CEO of the Defence Materials Technology Centre (DMTC).

Quickstep names new CEO Quickstep Holdings has appointed Mark Burgess as Managing Director and Chief Executive Officer following David Marino’s decision to step down.

Burgess was previously Vice-President at Honeywell Aerospace Asia Pacific, responsible for driving sustained profitable growth during his four years in that role across a defence, space and commercial helicopter portfolio. Previously Burgess had a successful career with BAE Systems in the UK, Middle East and South East Asia in sales, contracts, project and general management roles.

Tony Quick, Chairman of Quickstep, welcomed Burgess to the company: “We are very pleased to attract someone of Mark’s calibre and international experience to take on the leadership of the company at this exciting stage in the company’s development.”

The Quickstep board paid tribute to Marino for his work in establishing the company as a supplier on the Joint Strike Fighter (JSF) and Lockheed Martin C-130J programs and completing the investment that will enable Quickstep to cope with the JSF growth and other opportunities in aerospace manufacturing. Marino was instrumental in proving Quickstep’s innovative advanced carbon fibre composites technology.

“I pay tribute to the instrumental role David has played in building the foundations for the future success of the business,” said Burgess. “Quickstep has a highly capable executive team, supported by an internationally regarded board, and I am delighted to take over the leadership of Quickstep at this exciting point in its growth.”

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Government news

Sutton Tools honoured as Victoria’s manufacturing champions take centre stage Long-time AMTIL member Sutton Tools was one of the big prizewinners when Victoria’s best and brightest manufacturers were recognised at the 2017 Manufacturing Hall of Fame Awards on 9 May. With a theme of Growing Advanced Manufacturing, the Manufacturing Hall of Fame Awards celebrated creators and innovators from across the state. Among the evening’s winners: • Sutton Tools in Thomastown – named Large Manufacturer of the Year.

• Major Furnace Australia in Clayton South – named Medium Manufacturer of the Year.

• Paarhammer in Ballan – named Small Manufacturer of the Year.

Philip Leslie from pharmaceutical company GlaxoSmithKline (GSK) was announced this year’s Honouree. With 26 years’ experience with the company in various leadership roles, Mr Leslie has used new technology to drive innovation and pioneer new techniques at GSK’s Boronia manufacturing plant. The Young Manufacturer of the Year award was presented to Anne Koopmann from Bombardier Transportation. Ms Koopmann was recognised as a valued part of the company’s leadership team and commended for her strong engagement and management skills.

A number of companies were also recognised with awards for excellence in some of Victoria’s key growth sectors, including: • Impresa House – Defence, Transport and Construction Technologies.

• Setec – New Energy Technologies.

• IDT Australia Limited – Medical Technologies and Pharmaceuticals.

• Procal Dairies – Food and Fibre.

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Victoria is the nation’s manufacturing state. The industry contributes around $26bn to the Victorian economy each year and employs more than 270,000 people. In 2016, employment in manufacturing grew by around 40,000 jobs.

“Manufacturing in Victoria is alive and well, and we are proud to recognise the industry’s best and brightest,” said State Minister for Industry and Employment Wade Noonan. “These award winners are the benchmark of innovation in advanced manufacturing – and Victoria has cemented its place as the country’s leader in this field.” www.business.vic.gov.au/support-for-your-business/ awards/victorian-manufacturing-hall-of-fame

Government news Manufacturer of the Year: Small Business

Honour Roll

Paarhammer

Philip Leslie

Ballan based Paarhammer, a family business founded in 1990, manufactures award winning energy efficient double and tripled glazed timber windows and doors.

Paarhammer continues to grow and now employs 20 staff. Staff education and community is very important to the company with 35 apprentices trained in house, and two key staff supported to go to Europe to learn to make aluminium clad windows, which Paarhammer now manufacture as an import replacement. The company were the first in Australia to have developed and patented bushfire-resistant windows and doors.

Technical Lead, GlaxoSmithKline

Manufacturer of the Year: Medium Business

Major Furnace Australia Family owned Major Furnace engineers and manufactures medium to large scale furnaces, incinerators and cremators, process ovens and coolers, thermal oxidizers, dust filters and related capital equipment and services. With a significant export record, Major Furnace continues to adapt to the economic conditions of the day and provides their customers with a ‘one-stop-shop’ offering services ranging from concept design through to routine maintenance, component sales and after sales support.

Manufacturer of the Year: Large Business

Sutton Tools Sutton Tools is celebrating one hundred years of manufacturing in Australia in 2017 (see page 66) and remains family owned and operated. Renowned for their high quality engineering of cutting and power tool accessories and manufacturing over 15,000 individual items ranging over 50 product groups and employing around 380 staff, Sutton Tools maintains a commitment to investment, ensuring its staff, products and manufacturing techniques remain world class.

Philip Leslie has been with GlaxoSmithKline (GSK) for 26 years in various leadership roles in one of Australia’s largest pharmaceutical manufacturing facilities.

During that time, Philip has been instrumental in pioneering new techniques and evolving the plant into a modern technology led facility. As Technical Lead at GSK, Philip supports the Boronia based teams with product and process improvements. His team progresses innovation using “Blow-Fill-Seal” technology, with the aim of reducing costs and increasing production of affordable medicines. A passionate advocate of continuous development for both students and colleagues, Philip was instrumental in forming a partnership with Monash University, which helped over 85 students gain industry experience. This partnership formed the basis for the launch, in late 2016, of the Medicines Manufacturing Innovation Centre which supports the wider Victorian pharmaceuticals industry.

Young Manufacturer of the Year

Anne Koopmann Head of Quality and LEAN Australia, Bombardier Transportation Anne Koopmann started with Bombardier Transportation in Berlin, Germany as a Global Graduate Trainee and moved to Australia in 2012 as a Methods Engineer. Her understanding and insights into lean manufacturing processes, strong people management skills, track record in cost reduction, business acumen, problem solving and implementation of quality excellence, led her to her current role. Anne is proving to be an integral part of the Bombardier leadership team. Her achievements at Dandenong include savings of over $2.4 million, production hour savings of 6000 hours on a key light rail project and successfully reduced throughput time by 20% on rolling stock vehicles.

Company Inductions • Sutton Tools • Warren & Brown Technologies

Growth Sector Awards Defence, Transport & Construction Technologies – Impresa House New Energy Technologies – Setec Food & Fibre – Procal Dairies Medical Technologies & Pharmaceuticals – IDT Australia

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Government news

Victorian auto supply chain gears up for future Victorian automotive supply chain businesses are responding to the changing industry landscape by reshaping their operations, transitioning to other markets and developing new products. That was the message at the Automotive Supply Chain Transition Outcomes Forum, held in Melbourne on 28 March.

The event was the first of its type hosted by the Victorian Government, which brought together almost 60 automotive local supply chain businesses. Presenters at the event included Brian Hughes from CME Engineering, Bernard Brussow from Backwell IXL, and Dean Haritos from MH Group of Companies, providing insight about how they have successfully transitioned to other markets and found new growth opportunities. The forum was also attended by State Minister for Industry and Employment Wade Noonan.

The Victorian Government’s Automotive Supply Chain Transition Program (ASCTP) has, to date, helped 44 companies to undertake 62 projects to help them develop and implement a plan for transition. The ASCTP is part of the Automotive Transition Plan to help Victorian automotive businesses transition into new markets, retrain and find sustainable new work for workers, and attract investment into the communities most affected by the closure of automotive manufacturing.

With the pending closure of Toyota and Holden later this year, the State Government has extended applications beyond 30 June.

For more information about ASCTP and to apply, visit: www. business.vic.gov.au/asctp.

Tasmanian industry to benefit Made in Queensland record defence spend grants for manufacturers from The Minister for Defence Industry, Christopher Pyne, Made in Queensland is a State Government initiative created to help Queensland’s manufacturing sector to become more internationally competitive and adopt innovative processes and technologies.

The $20m grants program is aimed at increasing jobs in Queensland manufacturing businesses and growing the state’s economy. The ‘Made in Queensland’ Grants Program aligns with the ‘Advance Queensland Advanced Manufacturing 10-Year Roadmap and Action Plan’ that is supporting Businesses to transition from traditional to Advanced Manufacturing.

The program aims to: • Increase Queensland-based manufacturing businesses’ productivity and competitiveness • Encourage these businesses to adopt innovative processes and technologies • Encourage more of these businesses to become advanced manufacturers, and • Protect traditional manufacturing jobs and create the new high-skill manufacturing jobs of the future.

Grants will range between $50,000 to $2.5m on a dollar-for-dollar basis. A grant can reimburse a business up to 50% of the cost of implementing recommendations in the Benchmarking Report (or equivalent) and associated Action Plan.

Owners of small-to-medium Queensland manufacturers are invited to register their interest in the Made in Queensland program. Eligible registrants will receive support from the Department to undertake a benchmarking program that will address areas where their businesses can become more competitive and create high-value jobs for Queenslanders. www.statedevelopment.qld.gov.au/industry-development/ made-in-queensland

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addressed the Launceston Future Frigates Roadshow on 3 May and outlined the enormous potential of Australia’s continuous naval shipbuilding plan and the opportunities it presents to local Tasmanian industry.

The Minister also visited the Australian Maritime College in Launceston to discuss how the new recently announced Naval Shipbuilding College will work in partnership with Australia’s leading maritime training institution.

Minister Pyne said that the Tasmanian economy could receive a significant boost from the Turnbull Government’s record $195bn spend on defence industry over a decade. He restated the Government’s commitment to working with local businesses to ensure they have every opportunity to take part in these important projects.

“The Government’s commitment to create and sustain a continuous naval shipbuilding and sustainment capability in Australia and to maximise Australian industry involvement, will provide many opportunities for Tasmania and the nation as a whole,” Minister Pyne said. “Launceston has a proud maritime history and is a renowned maritime hub and I look forward to seeing local industry participate in the Future Frigate project.

“Defence has a strong association with the Australian Maritime College in Launceston; the new Naval Shipbuilding College will complement, rather than compete with, existing institutions like the AMC. The Naval Shipbuilding College will work closely with defence industry, in particular the ship and submarine builders to ensure availability of skilled workers that meet the shipbuilders’ requirements.

Minister Pyne met with Tasmanian Premier Will Hodgman to discuss Tasmania’s potential to maximise defence industry opportunities. He also visited the Elphinstone Group to discuss the defence industry opportunities that are available to regional Australia.

Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

It’s all about you.

Innovation Connections

The Entrepreneurs’ Programme (EP) is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. AMTIL is a partner organisation working with the Department of Industry in the delivery of the EP. The Programme forms a part of the Australian Government’s Economic Action Strategy and will deploy over 100 experienced Advisers and Facilitators, offering support to businesses through three key elements: 1. Business Management 2. Innovation Connections 3. Accelerating Commercialisation Innovation Connections is a facilitation service to encourage and assist small and medium businesses to access knowledge, engage with researchers and foster innovation. Access to the latest technologies and cuttingedge research and knowledge is critical to help Australian businesses innovate and remain competitive. However, finding the unbiased advice, research and knowledge specific to your business can be challenging.

Innovation Connections offers: • Support from experienced Innovation Facilitators to help you assess your technical, research or knowledge requirements. These Innovation Facilitators will provide you with unbiased recommendations to help you develop new ideas with commercial potential.

• Introductions to researchers, technology or knowledge providers to work with you on collaborative projects.

• Matched grants of up to $50,000 to engage a research organisation to undertake research projects in collaboration with your business.

• Introductions to researchers, technology or knowledge providers to work with you on collaborative projects.

Every business has different needs.

www.amtil.com.au

1302AMTILEP03

To find out what the Entrepreneurs’ Programme can do for you, call 13 28 46 or visit www.business.gov.au or contact Greg Chalker 03 9800 3666 or email gchalker@amtil.com.au

034

voice box Opinions from across the manufacturing industry

Budget 2017: a glimmer of support for innovation and advanced manufacturing Prime Minister Malcolm Turnbull’s 2015 National Innovation and Science Agenda was a call to arms for Australia’s research and industry sectors to collaborate and drive our economy. One and a half years on, you’d be excused for thinking a few pages of notes were missing from Budget 2017. By Drew Evans.

Specifically no comment was made about the vision of where our great “ideas boom” was taking us – setting the scene to unite industry and researchers alike. For manufacturing there was a glimmer of hope in the announcement of $100m to boost innovation, skills and employment in advanced manufacturing. It addresses people, know-how, process and partnerships. If connected into a strategic plan there could be benefits for businesses as the manufacturing sector redeploys into new activity.

However, it does appear narrowly focused on the here and now for closed and closing automotive manufacturers. In the absence of linkage with the National Innovation and Science Agenda, the pending 2030 Roadmap from Innovation and Science Australia, and comment on the Research & Development Tax Incentive review, the $100m may be an expensive Band-Aid. The announcement refers to $47.5m for an Advanced Manufacturing Growth Fund to support South Australian and Victorian manufacturers for capital upgrades to “make their businesses more competitive through innovative processes and equipment”.

My experience of project work with manufacturing companies is that capital cost of equipment (capital expenditure, or “CapEx”) has never been a roadblock to growth and success. When the business case stacks up, CapEx is easily justified. The business case is built upon having the right people and know-how in the business.

In isolation the drive to purchase new equipment presents no value to business, and may even lead to stranded assets. But coupled with people and know-how, opportunities may come.

It’s important to recognise that right now existing manufacturers are looking at how to utilise and/or redeploy their existing assets.

In particular the automotive parts manufacturers are seeking new opportunities that match with existing equipment. An example is a company I’m working with: Precision Components in SA. They are redeploying their large metal presses, previously used in car component manufacturing, to create components for capturing solar energy at HeliostatSA. It’s a project that has contributed to export capability for HeliostatSA. Redeployment is the focus for many businesses today, not new equipment.

The funding announcement refers to $4m to support small-scale and pilot research projects in advanced manufacturing, administered through the Advanced Manufacturing Growth Centre. This seems like a good move. Boosting innovation requires broadening the base of businesses looking to grow, and collaboration with university research programs is one way to achieve this. Small grants build confidence in collaborative partnerships, and help to clarify what the innovation is and its future return on investment.

For example, the Government’s Innovation Connections scheme has had success in seeding innovation and collaboration. A recent recipient of an Innovation Connections grant, Sentek Pty Ltd, is utilising this scheme to fund new product development, and to underpin justification for future and larger investment. I am collaborating with Sentek on this project.

The funding announcement refers to $20m under the Cooperative Research Centre (CRC) – Projects initiative for larger scale advanced

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manufacturing research projects. This funding should be warmly received. The CRC program links researchers and industry, with the aim of delivering economic value to the industry partner and the sector more broadly. This scheme funds the real costs of research, develops skills in people, and incentivises transitioning knowledge out of the university.

The newly formed CRC Projects scheme is in its infancy, with industry firmly in the driving seat for administering the projects.

From the first two rounds of funding under the CRC Projects, a total of 28 projects have been funded. Each project has seen a co-investment from industry, universities, other research institutes, and the federal government. Crunching the numbers for the funded projects shows, on average, the government invested $2.04m per project. This indicates that the new $20m of funding could support around an additional 10 projects. This will stimulate activity and add value to our advanced manufacturing sector.

The funding announcement refers to $10m to establish Innovation Labs in SA and Victoria to serve industry. It’s difficult to know what this means in reality. Perhaps the purpose is to provide facilities for early-stage innovation to be tested at minimal expense, and reduce the risk of the business making significant investment in infrastructure. Perhaps it will allow researchers or companies to shore up concepts before seeking investment and raising capital.

Maybe existing facilities will seek financial support to expand their remit across a diverse advanced manufacturing sector.

A topical example relates to additive manufacturing. Businesses producing 3D-printed products need a testing ground to conduct certification and accreditation of products prior to sale. The Innovation Labs could fill this void, and complete the link between laboratory research and commercial product.

The funding announcement refers to $5m investment in engineering student research at universities, technology institutions and in industry to maintain the flow of highly trained engineers to the automotive design and engineering sector.

At the heart of innovation are people. Engineers represent one discipline that contributes to the pipeline of innovation. An investment to see the continual training of excellent engineers may address the loss of traditional career pathways. Perhaps the funds will aid in restructuring of engineering education towards emerging opportunities in the health and medical, agriculture, renewable energy and other sectors.

As more details come to light in the coming weeks and months, the Turnbull government’s vision for Australia’s manufacturing future may become clearer. But the sense from the manufacturers themselves is that they will just get on and do it anyway.

Drew Evans is an Associate Professor of Energy & Advanced Manufacturing, Australian Research Council Future Fellow, University of South Australia. This article was originally published by The Conversation. www.unisa.edu.au www.theconversation.com/au

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voice box Opinions from across the manufacturing industry

How we came up with a new product Coming up with a new product takes more than just a light-bulb moment. It takes a rare synchronicity of factors – from capabilities and strengths, to professional networks, to finances, to consumer demand – and then that ‘sweet spot’ for any successful product where design intersects with humanity. By Paul Hughes.

For us at Integra Systems, synchronicity was achieved when we hit on the concept of new range of sit-stand office desks, which developed into the WorkSmart Collection of BioSmart and AeroSmart workstation solutions. Fourteen prototypes and a lot of mental and physical muscle later, we’ve got a story to tell about how our company transitioned from creating innovative products for other businesses, to devising our own intellectual property under the subsidiary company Integra TransForm.

We were familiar with the sit-stand workplace trend sweeping the globe – we’d been asked to produce an industrial sit-stand solution for a client’s assembly line, using Linak actuators, which we consider to be the best available. From a technical point of view, we already understood how the actuators worked, giving us a legup to create a new kind of desk in our own unique vision. But that wasn’t the tipping point.

I personally had been suffering from a prolapsed disc in my back and, being a highly active person, was mindful of how I went about my daily business and whether I would be putting additional pressure on my already-weakened spine. This led me to consider others working at Integra, and how they dealt (or failed to deal) with their own health and mobility challenges.

We knew what we could create with the sit-stand Linak technology, and we knew other sit-stand products available were inferior in structure and longevity. Anything robust was quite ‘clunky’, requiring a mechanical assist that forced the user to move their body – sometimes even leaning right over the desk – to raise the unit. We felt that was counter-intuitive to the desk’s purpose. We may not have invented the sit-stand desk, but we knew we could really improve on it, which became our primary objective.

It was important for us to make excellence our defining factor. Other sit-stand solutions had compromised quality to meet a certain price-point. We recognised our product would not be the cheapest, but it would be the best.

One way we tackled the cost issue was to create two solutions: BioSmart and AeroSmart. As the desk converter, BioSmart is the range’s flagship product, adapting existing office furniture rather than replacing it. As a whole-desk solution, AeroSmart figures at a higher price, and is more suited to those establishing a new office or replacing furniture and starting again. We were increasing our workload by perfecting two new products instead of one, but it also allowed us to service two very different markets without sacrificing quality for cost.

We have a breakout table in our office – which happens to be a sit-stand table – so we gathered around it as a group for some intensive brainstorming. The WorkSmart Collection started as just a few sketches; it took significant time and consideration before it leapt from page to prototype.

We recognised one definite challenge: with a freestanding unit like the BioSmart, you’re relying on one central point, the actuator.

How do you create a secure, stable platform that looks great but is essentially just a pole? The actuator is only one part. The

design genius comes through the engineering combined with the industrial design to create a unit that is ergonomic, attractive and mechanically functional with the strength to last the distance.

Our industrial designer looked at our sketches and worked out how to make our concepts manufacturable and beneficial to the consumer. From there, we continued to narrow it down until we settled on the winning design.

In commencing our sit-stand journey, we were mindful the market rapidly changes. Despite the time required to perfect and launch a product, we would need to respond to market demands quickly – whatever they may be. Without the aid of a crystal ball, we anticipated wanting to tool certain parts – such as the universal joints where computer screens are mounted – as well as making other advancements down the track.

With this in mind, we constructed our sit-stand units in a flexible manner to allow the product to evolve with the consumer. You could call it ‘scalable manufacturing’. Sometimes, if you go to tooling too early, it locks down creativity so you cannot improve your product later. We like to keep manufacturing methods flexible in the early stages so we can adapt to user demands. We’re constantly getting market research information, so if we were to lock in our processes, we would be unable to respond to that information. It is important to remain flexible, keep your design pencil sharp, and leave room for refinement.

You may have a burning desire to create a certain product – but is anyone buying it? That’s the question you need to ask yourself.

We chose to develop and fund our WorkSmart Collection ourselves without the support of government funding or angel investment.

This meant we had to keep processes Lean and complete as much development as possible in-house to manage our costs.

We chose to conceive an idea and then head down a path of design before we completed the market research, but our initiation into sitstand desks and our ability to produce something entirely ourselves meant we were confident in taking this developmental journey.

Considering the groups we wanted to target, we got into the minds of medical practitioners, patients, ergonomists and even interior decorators. One medical practitioner – Dr Carolyn Royce –proved integral to our research. Within three days of supplying sit-stand units to her clinic free of charge, she asked us to send her an invoice because her staff loved them so much she felt it unconscionable not to pay for them.

We created a prototype for an RMIT ergonomist, as well as the senior ergonomist for the Coles Myer Group. He’s a perfectionist, putting us through all manner of hoops and hurdles before agreeing to sign-off on the units. We’ve been through four reviews with him, which, while a little frustrating, has been incredibly beneficial to us.

We now know we’ve produced a product that is ergonomically sound.

Paul Hughes is the CEO of Integra Systems. In the next issue of AMT, Paul will explain how Integra brought its new product to market. www.integrasystems.com.au

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Tech News

Germany: Cold plasma treatment detects cavities/recesses

Australia: 103 year-old racing car saved by 3D printer

Fraunhofer researchers have produced cold plasmas and used them for the surface treatment of temperature-sensitive materials such as plastics or wood. Now, recesses or undercuts are no longer a problem, thanks to the “Disc Jet”. Previously, only flat surfaces could be treated; the plasma simply slid over recesses, cavities or undercuts. Researchers have combined two plasma processes – the plasma jet and the glide discharge – in order to process three-dimensional components effectively. The temperature of this process can be kept low at 30 to 60 deg.C – ideal for the treatment of heat-sensitive materials.

CRISO’s Lab22 was approached by an Australian car enthusiast who was painstakingly restoring a 1914 Delage Type S (a French race car) and the only one left in the world. After 103 years, the engine block cracked and the team was asked to help make a new one.

But how does one clone a 1914 engine block with its complicated 16-valve engine with no detailed plans or traditional manufacturing methods? 3D printing company, WYSIWYG scanned and made a digital copy of the existing engine. Then, using the Voxeljet VX1000 – Australia’s only 3D sand printer - a 3D printed sand mould was created, which later had cast iron poured into it by Keech Australia to make a casting. The result … a brand new 1914 engine block.

After the engine was installed, there was enormous relief when the Delage turned over successfully.

Fraunhofer

CSIRO and ABC.

USA: 3D printing -Electricity for stronger objects The startup company – Essentium – recently demonstrated its FuseBox technology which addresses the issue of structural integrity that is one of a number of roadblocks slowing 3D printing’s growth as a legitimate option in manufacturing. The FuseBox utilises heat and electricity to increase the temperature of plastic material before and after each level is deposited. This strengthens the body of the printed product where it’s traditionally weakest during the FDM (fused deposition modeling) printing. The result, according to the company, creates a part that’s around 95% as strong as one created with injection moulding.

Tech Crunch

USA: Light to remotely control plastics’ curvature Researchers have developed a technique that uses light to get twodimensional (2D) plastic sheets to curve into three-dimensional (3D) structures, such as spheres, tubes or bowls. The advance builds on earlier work and the key advance is that rather than having the plastic fold along sharp lines, the plastics bend and curve.

North Carolina State University

USA: Seeing through concrete detects early corrosion Researchers have developed is a noninvasive “spectral fingerprint” that reveals the corrosion of concrete-encased steel. It was shown that terahertz radiation (frequencies 10 to 100 times higher than microwaves) can detect corrosion in the early stages of formation.

Current imaging methods use microwaves. Unfortunately, by the time such changes are detectable, the corrosive process is already well on its way. Additionally, most of the microwave imaging methods rely on comparisons with baseline measurements of the steel taken at the time of construction, a practice that only goes back about 25 years which is a real problem since the average age of the 400,000 steel-reinforced concrete bridges in the US is 50 years.

NIST

Completely restored to its former glory – the sole surviving 1914 GP Delage

Germany: Continuous fitness check for robots An early warning system for industrial assembly, handling and packaging processes has been developed. Intelligent sensors continuously collect a wide array of measurement data from inside plant machinery and compare the signal patterns against those for normal operating conditions. If the system detects a difference in the patterns that indicates a potential fault, it immediately notifies the operator about what remedial measures should be taken. Sensors are fitted inside the machines and these sensors are able to interact with each other and with existing process sensors. This enables the registration of even the smallest of changes which are very subtle and undetectable to normal senses. The customised sensors can either be integrated into the machinery when it is being made or can be retrofitted.

University Saarland

Australia: Electronic inks “rewrite” our energy future Australia’s position as a global leader in printed solar has surged, following the unveiling of its first printed solar demonstration site at the University of Newcastle. Unlike traditional PV panels, the technology maintains a more constant power flow in low-light and cloud cover. The material is made by printing an advanced electronic ink onto paper-thin, clear laminated sheets using conventional printing presses. The team pioneered both the electronic ink which uses non-toxic carbon-based materials and the printing process.

The material could be rapidly manufactured (10 printers operating around the clock could print enough to deliver power to 1000 homes per day) and a production cost of less than $10 per sqm. By reinventing the delivery model, the need for initial lump sum outlays is removed.

University of Newcastle

AMT Jun/Jul 2017

Tech Heading News

USA: Waterlike polymer to create high-temperature ceramics Using five ingredients — silicon, boron, carbon, nitrogen and hydrogen, a liquid polymer has been created that can transform into a ceramic with valuable thermal, optical and electronic properties.

The waterlike polymer, which becomes a ceramic when heated, can be mass-produced. The liquid remains a liquid at room temperature and has a longer shelf life than other SiBNC polymers. But when heated, the polymer undergoes a liquid to solid transition. This transparent liquid polymer can transform into a very black, glasslike ceramic.

Kansas State University

Norway: World’s first ship tunnel Norway has announced plans to build the world’s first full-scale ship tunnel in the Stadhavet Sea, a hazardous region of coastline that is difficult to navigate. The 1700m long Stad Ship Tunnel will take approximately three-to-four years to build and will require the removal of 3 million cubic metres of rock. Construction is expected to begin in 2019. The tunnel will have a height of 49m, and a width of 36m. The tunnel will prioritise commercial shipping, although leisure vessels will be allowed to pass through. The combination of sea currents and subsea topography creates complex and unpredictable navigational conditions in this area.

The Engineer

Germany: 3D-printing of glass 3D-printing techniques so far have been used on polymers or metals, but never on glass – until now. Scientists mixed nanoparticles of high-purity quartz glass and a small quantity of liquid polymer and allowed this mixture to be cured by light at specific points – the material is washed out in a solvent bath, leaving only the desired cured structure. The polymer still mixed in this glass structure was removed by heating. The resulting glass structures range from a few micrometers to a few centimeters in size. As a consequence of the properties of glass, such as transparency, thermal stability and resistance to acids, the use of this material in 3D-printing opens up new applications.

Karlsruhe Institute of Technology.

Japan: New umbrella design after 1000 years?

USA: New strategy produces stronger polymers At the molecular level, polymer networks contain structural flaws that weaken them.These defects are called “loops,” which are caused when a chain in the polymer network binds to itself instead of another chain. Now, researchers have found a simple way to reduce the number of loops and thus strengthen materials made from polymers. To achieve this, the researchers added one of the components of the polymer network very slowly to a large quantity of the second component. They were thereby able to cut the number of loops in half, in a variety of different polymer network structures.

They were able to strengthen materials just by changing how fast one component is added to the other. Depending on how many loops were in the original material, this “slow then fast” strategy can improve the material’s strength by as much as 600% Massachusetts Institute of Technology

The umbrella has not changed its design in 1000 years, but that could soon change. Scientists at the University of Tokyo have studied how the wings of a Ladybird beetle – fold origami-like under the spotted hard outer shell (the elytron) which covers the delicate wings when not flying. It was found that the wings (which take just 0.1 seconds to open) have curved ‘crease line’ shapes in their veins to help support them, make them bendable and to use stored (“elastic”) energy to extend them when they take flight. The insects use the edges and lower surfaces of the elytra to guide the folding of the wing. A UV-cured resin was used to construct and transplant a clear replacement for the strong but flexible elytron so that the wings underneath could be observed. These wing secrets could impact the development of robotics, satellite antennas and microscopic medical instruments. And umbrellas!

Gizmodo and mixed

“At a time when buildings are still being made in the same way the Pyramids were erected, Australia has the power to be a disrupter” Andrew Harris, Director of the Engineering Excellence Group at Laing O’Rourke, describing the FreeFAB Wax system which was invented and developed in NSW by this group. This is a construction scale 3D printing technology that allows complex concrete building components and prototypes to be designed & developed more cost-effectively and with shorter lead times. The machine is one of the largest 3D printers in the world and can fabricate wax moulds for offsite facilities. The panels produced can be shipped anywhere in the world.

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product news

Vuable: Connecting industry through video QMI Solutions has a great history of offering new ideas and technologies to solve industry challenges. This has included Australia’s first 3D printing solution, water-jet cutting and selective laser sintering.

Each year QMI asks small-to-medium-sized businesses what their top two challenges are. The results of its most recent survey have shown that customer and market access, and visibility, is what businesses are consistently struggling with.

As technology rapidly changes, how we consume information is also changing. By 2018, 80% of global internet consumption will be video content. While there is no replacement for face-to-face communications, a considerable about for business activity is now done online.

To address small business challenges and to continue to deliver innovative products to industry, QMI has now introduced Vuable, Australia’s first online video social network. Vuable joins QMI’s existing brand portfolio, including the Industry Capability Network (Qld), Online Procurement Services and the Australian Institute for Commercialisation.

Vuable is an innovative, cost-effective solution that connects suppliers, innovators, inventors, project owners and industry leaders. It enables businesses to promote their product or service to gain work and access new opportunities. For start-ups, it’s a connection with a wide industry network, allowing them to share their ideas to gain the support needed to grow.

With access to video on your smartphone, filming and uploading a short video is easy to do. Share a project update, film the

creation of a product, or take viewers on a tour of your facility.

The options for what you can say with videos are endless, and so are the number of video uploads permitted from your account.

There are no unwanted ads on user accounts or restriction to the length of videos.

To celebrate the launch of Vuable in June, QMI is offering a free trial to the Vuable platform. www.qmisolutions.com.au www.vuable.video

Epson launches Low-TCO SCARA robots

Epson is expanding its line-up of industrial SCARA (selective compliance assembly robot arm) robots with the launch of its new T series of robots that will offer a low total cost of ownership (TCO).

The T3 is designed primarily for simple material-handling applications, such as test machine loading/ unloading. It provides companies with the opportunity to free operators from repetitive and non-creative tasks such as transporting components, which to date had not been performed by robots due to financial concerns.

Manufacturers who automate tasks by combining multiple low-cost single-axis robots will find that they can replace these with T3 robots.

Doing so will enable them to reduce or eliminate troublesome single-axis robot maintenance work and save money over the long run. Deploying T3 robots will enable factory owners to free up space that was taken up by a large number of robots and use their floor space more efficiently and productively.

Epson’s existing line-up of 3kg-payload industrial SCARA robots includes the G3 series, RS3 series, and LS3 series. G3 series robots have an established reputation for speed, precision, and low vibration. RS3 series robots are mounted overhead and thus use the work envelope with maximum efficiency. LS3 series robots offer high performance at a low cost. The addition of the T3 series, which offers simple set-up and outstanding usability, gives Epson an even stronger line-up that meets a wider range of needs.

The T3’s built-in controller saves space and simplifies robot setup and redeployment. Epson was able to integrate all the controller

AMT Jun/Jul 2017

components into the robot arm meaning that customers do not need a controller box. Meanwhile a battery-less motor unit reduces maintenance and factory downtime. Factory owners do not need to exchange batteries because the T3 is able to record the back-up status of its motors by using a simple mechanical system with the latest motor technologies.

Epson has provided an I/O communications port closer to the end-effector. This port makes it easier to connect cables to the endeffector and supply power to it. There is no longer any need to route a long cable to the controller. The cable conduit, which contains pneumatic hoses as well as electrical cables, is shorter than in previous models. The shorter design gives it stability while the robot is moving, making it easier to route cables outside the conduit.

The T3 runs on a low supply voltage (AC100V), using 30% less power than comparable Epson robot systems, therefore helping factory owners reduce long-term running costs. The T3 also runs on a single-phase alternating current at input voltages ranging from 100V to 240V, meaning it can also be used in facilities where a large power supply is not available.

In Australia, Epson’s robot sales, service and support is managed

by Motion Solutions Australia. www.motion-solutions.com.au

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product news

Dormer Pramet – Widening the options Dormer Pramet has launched a new range of chip breakers for turning and bar peeling.

The negative NRM turning chip breaker is for roughing and semi-roughing of stainless steel and low alloy steel. Launched under the company’s Pramet brand, NRM is available for both double-sided and large single-sided inserts.

It has been designed for continuous and mass levels of production, offering consistent performance and high feeds.

However, the NRM has excellent chipbreaking properties and can also be used for roughing of stainless steel even at lower feeds, without the risk of work hardening.

Its positive geometry with a wide T-land offers a broad depth of cut and promotes good chip evacuation in a wide number of applications. The chip breaker is available in grades T7325, T7335 and T9315.

The NRM enhances Pramet’s existing range of turning chip breakers for stainless steel, including the NMR for medium to roughing operations, NM for medium turning and NF for finishing to medium turning. In a recent test, machining M group material DIN 1.4301, the NRM on the CNMG insert with T7335 grade, achieved a 60% longer tool life than a competitor equivalent.

Meanwhile, Dormer Pramet has developed a new chip breaker for bar peeling of stainless steel, steel and super alloys. Suitable for roughing to finishing operations, the MM chip breaker has been designed with a wide, strong T-land to offer increased stability of the cutting edge. This gives the Pramet chip breaker good chip control with an even spread of the cutting forces, making it suitable for high feeds in heavy conditions.

There are three cutting edge options: S01 is for hard materials, S02 for medium hardness and S03 has a stabilised facet on the main cutting edge for soft materials.

The MM chip breaker is available for use with the LNGF inserts, for roughing to finishing, RNGH inserts for roughing and WNGF inserts for roughing to finishing. It is suitable for use with the grades T7325, T9315 and T6310. www.dormerpramet.com

Balluff: Non-contact safety sensors

Balluff has replaced its safety portfolio with magnetic, transponder and inductive safety sensors, connected directly to the safe Balluff IO-Link I/O module or to any safety controller using standard M12 connectors.

The magnetically coded safety switch is unaffected by mechanical play – for example, when doors settle or are imprecisely guided – thanks to its non-contact operating principle. This makes it simple to install. With separate processing electronics, the safety switch can be used for applications up to PLe/ SIL 3.

The proven magnetic technology with intelligent arrangement of the reed contacts in the switch housing offers high tampering security and reduces the risk of bypassing the safety function.

With the optional available spacer you can even install the safety switch in a ferromagnetic environment.

The transponder-coded safety sensor is also ideal for monitoring guard doors and flaps. Since the passive RFID transponder is uniquely identified by the sensor, high coding levels and accordingly high bypass protection can be implemented.

The generous detection range of the sensor also makes it insensitive to

AMT Jun/Jul 2017

vibration and mechanical play on the protection device, and the detection range simplifies installation. The compact size offers you greater flexibility in integrating the device into your application. It’s easy to use the devices in applications up to PLe and SIL 3 thanks to the integrated safety logic and the OSSD output stage.

New in the Balluff line of safety products is also an inductive safety sensor, which detects the approach of metallic targets.

Unlike traditional safety switches, it requires

no special mating part. This means for example it can generate safe signals for position and end-of-travel or directly sense metallic workpiece carriers.

The sensor is also suitable as a pulse transmitter for counting tasks and speed sensing. Moreover, the inductive safety sensor can be connected to any desired safety processor, including safety relays, programmable logic modules or safety controllers. Wiring is simple using standardised M12 plug connections. www.balluff.com

Heading

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product news

SMC – Electric actuators for wide range of applications

With numerous dynamic industrial processes requiring sophistication and precision, processes such as the assembly of circuit boards, positioning of workpieces, and sorting of goods all depend on a high level of automation to make them possible.

SMC combines the advantages of pneumatics with the world of electronics in its comprehensive assortment of electrical actuators, motors and controllers. The standard product assortment alone provides solutions for countless applications and a wide range of solutions from miniature and carriage actuators to compact slides, grippers, cylinders and controllers.

SMC organises its range of electrical actuators and controllers into three tiers that represent typical user requirements, from easy operation to absolute effectiveness and flexibility. Tiers and levels of flexibility are all based around customer’s unique needs: For customers whose operating conditions rarely change and who prefer quick start-up times to high flexibility, SMC’s standard assortment actuators with pre-set actuator parameters are especially easy-to-use. For more complex applications that demand a higher level of functionality, SMC’s progressive programmable drivers offer interface options ranging from latest network protocols such as EtherCAT right through to High Speed Pulse or parallel IO wiring with functional capabilities extending from basic positioning, torque and motion control. Finally, AC servomotor amplifiers (series LECS) provide the highest level of precision in terms of position, speed and force control.

The AC servomotor power amplifier LECY was developed for machines and systems with quick and high-precision axis motion. It is equipped with an STO function (Safe Torque-Off), which prevents the drive from starting up unexpectedly. Such safety functions are becoming increasingly more important for machine manufacturers with regard to EN ISO13849 machine safety guidelines.

SMC’s LE series is available in a large number of different components. Each of the series (over a dozen in total) contains numerous products with various sizes and specifications as well as additional equipment options. These include, for instance, an integrated motor brake and cleanroom-suitable versions. SMC has designed the range over time to meet a wide range of customer requirements and today, the great product variety covers the needs of most industrial applications. www.smcworld.com

evok3d unveils HP’s cutting-edge 3D printing solution evok3d has been announced as a key partner of HP’s new production-ready 3D printing system, set to disrupt the additive manufacturing industry.

HP’s Jet Fusion 3D Printing Solution is designed to deliver superior-quality physical parts up to 10 times faster, and at half the cost of other 3D printing technologies currently available on the market. evok3d’s nomination as sole distributor for the cutting edge printing technology, is a significant win for the Melbourne-based business. The fastgrowing company, now in its fourth year of operation, provides the market with broadest range of 3D printing technologies across the Oceania region.

HP believes its Jet Fusion 3D Printing Solution will revolutionise design, prototyping and local manufacturing once it is available in Australia. The new system is the result of decades of research and expertise in precision mechanics and material sciences.

Developed in conjunction with industry partners including Nike, BMW and Siemens, the HP printer has the ability to address more than 340 million voxels per second, versus one point at a time, enabling radically faster build speeds, functional parts and breakthrough cost savings. It offers customers an unprecedented

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ability to transform part properties and deliver mass customisation.

Joe Carmody, Managing Director evok3d, says the new HP Jet Fusion 3D Printing Solution will ensure a combination of speed, quality and production savings never seen in the industry.

“Businesses and manufacturers can completely rethink how they design and deliver solutions to their customers,” adds Carmody.

The advantages of HP’s cost-effective printing solution, and the ability for it to create customised parts en masse, has the potential to transform a range of industries including orthotics, prosthetics, auto parts and motorsport, biomedical, movie and stage props, defence and aerospace industries. Global brands BMW and Nike have expressed early interest in the new printing technology and the opportunities the HP Jet Fusion 3D Printing Solution will provide to disrupt the market through cost effective serial part production and personal customisation. www.evok3d.com.au

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Austech 2017 review

Australian

manufacturing puts on a

show Australia’s advanced manufacturing industry flocked to the Melbourne Convention & Exhibition Centre from 9 to 12 May for Austech 2017 – the biggest Austech in years.

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Austech 2017Heading review

Co-located with National Manufacturing Week (NMW), Austech is Australia’s premier advanced manufacturing and machine tool exhibition. This was only the second Austech since the decision to change from an annual event to one held every second year, and with the exhibition space fully booked well in advance , and high levels of preregistrations from prospective visitors, expectations had clearly been running high ahead of the event.

Those expectations were not misplaced, as Austech 2017 was the most successful in years, with a total of 163 exhibitors showcasing their products and services.

Together Austech and NMW attracted 11,501 visitors, the highest turnout since 2009. This included a strong interstate contingent – with almost one-fifth of those in attendance travelling from outside Victoria – and even a striking number of international visitors, from as far afield as China, Taiwan and India.

Most importantly, a high proportion of visitors were key decision-makers in terms of purchasing decisions – 23.03% were business owners, directors, CEOs, managing directors or general managers, with engineering and technical managers accounting for a further 13.82%.

The buoyant mood was evident on the trade-show floor, with the aisles of the exhibition crowded throughout, and the stands buzzing with activity. One company exhibiting at Austech for the first time was Integra Systems, and according to Managing Director & CEO Paul Hughes, it was a very successful week.

“Austech was a first for our company,” said Hughes. “We did not know what to expect, but we’re pleased to say we came away with some solid takeaways and a palpable sense of accomplishment. Exhibiting at Austech has been an extremely valuable exercise and we would highly recommend it.”

One area that attracted considerable interest was the Manufacturers’ Pavilion, where the two OEM exhibits – a Hawkei protected mobility vehicle from Thales, and a prime mover from trucks giant Paccar – provided an eye-catching

centrepiece that drew continual crowds. This area of the exhibition also provided the showcase for the real strength and diversity of Australian manufacturing, with more than 20 manufacturing businesses showcasing their capabilities.

Elsewhere in the exhibition, the full breadth of cutting-edge manufacturing technology was on display, from enormous laser cutters and press brakes, down to the tiniest precision cutting tools, as well as the latest state-of-the-art support systems, software and accessories, along with the myriad services that are essential to enabling the manufacturing industry to function.

The latest developments at the cutting edge of manufacturing technology were given a detailed showcase in the Digitalisation Pavilion, a new feature of this year’s exhibition dedicated to exploring areas such as robotics & automation, the interconnectivity of devices, big data and Cloud computing. The Digitalisation Pavilion was also the venue for a wide-ranging speaker program that ran for two days during Austech week and drew consistent interest.

Meanwhile, the Additive Pavilion was the place to see the very latest advances in the fast-evolving world of additive manufacturing, with exhibits running the gamut from small, desktop 3D printers for prototyping and hobbyists, right through to advanced systems for printing in metals and composites. The Additive Pavilion was accompanied by a fascinating two-day conference held in conjunction with Inside 3D Printing.

“We’re delighted that key factors used to measure Austech have been so positive,” said AMTIL Events Manager and Austech organiser Kim Banks. “The space sales were very healthy – we were struggling to fit everyone in towards the end. Exhibitors on the whole were happy with the event, from the smooth move-in process to the quality of enquiries they received. And visitor numbers were very healthy. All these factors are a good indicator that moving to a two-year cycle was a good decision, and we are now all reaping the rewards.” www.amtil.com.au/Austech

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Okuma – Moving towards multi-function Okuma was showing the diversity of its technology on its stand, striking a balance between the company’s more conventional equipment and its more advanced multi-function systems.

“We’ve got four machines. Two are the more routine type of machines that we’ve been used to for the last 20 years,” said Phil Hayes, Managing Director at Okuma Australia & Okuma New Zealand. “There’s a small vertical machining centre, the Genos m560-v-e, and we’ve got a standard four-axis lathe, the LB3000 EX II, which is also coupled with a robot system from RoboJob in Belgium – we’re the exclusive distributors. Coupled with that is the big move on multi-function machines, so we’ve got two multifunction machines on the stand.”

Those two machines were the MULTUS U4000 lathe and the MU5000 vertical machining center. The U4000 is the middle-sized machine in the Multus range, with two spindles, two turrets, and one B-axis turret, along with the capacity to do simple turning and milling tasks. It is also equipped with InvoMilling, a new form of gear profile generation, and the machine on display also has skiving capability. The MU5000 on display was a two-pallet, five-axis machine that also boasted a turning function.

“So the Multus has turning with milling, and the MU has milling with turning. They’re sort of inverses of each other,” Hayes added . “They’re incredibly popular – we’re selling both series of multifunction machines very strongly at the moment into a multiplicity of different areas. It’s not just aerospace, it’s general engineering right through to die moulds, everywhere.”

With an eyecatching banner above a large stand, Okuma had enjoyed a strong level of visitor traffic throughout Austech. Hayes had been enjoying the opportunity to interact with existing and potential customers and get a sense of what their concerns are.

“It’s been great,” he said. “It’s really interesting to hear the comments from the customers. Whether they want to look at our Okuma machines or they want to look at someone else’s, that doesn’t affect us; what we want to know is what their attitude to the market is. They’re all noting a big improvement this last year, they’re more

confident about the future, and their investment plans are heading for higher levels of technology to improve productivity. And that’s where Australia has to go.”

For Hayes, this all added up to very positive news about the current direction of Australian manufacturing.

“Look, it’s moving really well,” he said. “The ones who are really kicking goals are the ones who can move with the times and go looking for new opportunities. We’re seeing lots of businesses who are developing a product and sending it now to the most remote places – places I would never have thought of. Namibia, into Chile, all over South America, all over Africa. This is good.

“For a market the size of Australia, we can’t do huge volumes so you need to pick markets that need stuff but not in huge volumes.

So this is where the successful guys have been going. And to do that you need technology, otherwise you’re not competitive.” www.okumaaustralia.com.au

MTI Qualos – Quality is job #1

A collection of coordinate measuring machines (CMMs) were the star at MTI Qualos’ exhibition stand, led by the Mitutoyo CRYSTA-Apex S Series machine.

A small company of around 30 headquartered in West Heidelberg, Melbourne, MTI celebrated its 70th anniversary last year and – according to Managing Director Andrew Smith – “is still here and still going strong”. Austech 2017 was a success for MTI Qualos, both in terms of the quantity and quality of visits to their stand.

“The volume of people through and the quality of people through have been really good, and having it every two years is the key to that, I think,” said Smith. “Not so much changes over one year, but over two years…”

Smith is optimistic about the industry’s state and MTI’s place within it.

“Obviously the demise of the car industry probably has taken everyone a while to work out where they fit within what’s left of the manufacturing industry,” he said. “But there’s certainly been a lot of good companies going into aerospace, and fortunately we’ve been taken along with those people, because of the Mitutoyo reputation. And that’s been a big

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positive for us.” Within the remaining auto industry, MTI’s customers include success story Nissan Casting, making components for export using the CASTvac technology developed with the CSIRO. “We’ve got five machines at Nissan Casting, where they’re casting a lot of parts for cars made in Japan, predominantly the Leaf electric car,” Smith added.

MTI has a fairly unique insight into the manufacturing industry and its transitions in Australia. Besides its offering of precision machine tools and accessories from several countries, since 1970 it has also been a maker of PVC doors for the food, pharmaceutical and cold storage industries.

“I think with Australia not manufacturing as much as we used to we’ve become a lot more of a warehouse,” Smith added. “And with warehousing our doors fit right into that sector.” www.mtiqualos.com.au

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Austech 2017 review

Alfex & Haas– Demonstrating a diverse range Alfex CNC Australia and Haas Automation took adjacent stands at Austech 2017 to showcase a diverse array of products, including a ground-breaking new machine from Epilog Laser.

“This Epilog G2 Galvo is a world-first machine of its kind,” said Alfex CNC’s Business Development Manager Christian Buhagiar. “It contains the best of high-speed galvo lasers, with large working areas to maximise productivity.

The machines are produced in Denver, Colorado.”

A large crowd gathers around to watch the Haas UMC-750SS high-speed fiveaxis universal machining centre in action, with the company’s technical staff on hand to answer any potential customer’s enquiries.

“Here we are demonstrating a few of the many different tools it has for a relatively complex job, explained George. “It shows a combination of conventional machining strategies and high-speed simultaneous five-axis machining.

This machine is able to make complex intricate components.

A finely cut wooden miniature F1 racing car stands proudly on display in the middle of the stand, and Christian explains that it was cut on an Epilog CO2 laser.

“We are also showing off the Epilog dual-source lasers, which combine CO2 and fibre laser technology, into the one machine,” Christian added. “This offers customers the most flexibility from an engraving machine and cutting laser.”

Christian’s father George Buhagiar is the Director and Owner of Alfex CNC and its Haas Factory Outlet division, all located in Melbourne’s north. According to George, they have seen a lot of interest from potential customers on both the Alfex (stand 610) and Haas (stand 612) exhibits.

“We are starting to get a steady flow of customers through our two stands,” said George.

“What we have done this year at Austech is to demonstrate our machines, running a minimum of 12 tools. As they are complicated programs, we are able to give customers samples of components produced in some of our machines.”

It’s a strategy that has proven to be very popular with visitors to the stand.

“One of the benefits of exhibiting at Austech is having customers come to one location for us to show them our latest machine models,” said George. “Sometimes you may close a sale here, and we are receiving a combination of existing and new enquiries.” www.alfexcnc.com.au www.haas-australia.com

Nichol Industries – Making a mark

Nichol Industries have been a regular presence at Austech, exhibiting at the show since it started, and the company was back this year showcasing its range of advanced marking technology.

“Sometimes it can also be legislation, such as vehicle identification numbers (VIN). VIN numbers are a good example of legislation which says it has to be marked. There’s also things like the oil & gas industry, for example gas tanks, fire extinguishers. All that stuff the Government says has to be marked – they’re good customers for us.”

The centrepiece of the Nichol stand was the NanoViz laser machine, a compact unit capable of marking a whole lot of different products, which was on display with an Arena enclosure. Nichol supplies a range of lasers and of enclosures, matching them up to suit the customer’s specific application needs.

Also in operation was a dot-peening machine doing embossed tags.

Nichols added that, despite conditions in the overall market not being as promising as they could be lately, exhibiting at Austech 2017 had been worthwhile for his company.

“This is typically suitable for the galvanising industry, painters and the powder coaters because it gives you a raised character,” said the company’s Managing Director, Adam Nichol. “And then we have the other dot peen machines, which are the traditional machines that mark onto or into the product.”

Nichol explained that his company’s products are suitable for any sort of marking across a number of industries: “So it could be medical, it could be general engineering. We’ve had quite a few enquiries for rail because there’s a big push on for doing marking for rail at the moment. It can be anybody. What we do is mark the product for quality control, and that can be internal quality control, or it can be if a customer requires it.

“We didn’t come with a high expectation, but it’s been good,” he said. “We’ve had some good enquiries, and good volume enquiries.

It can be ongoing sort of stuff. That’s always good for business.”

Nichol also acknowledged that, while Austech is a demanding time for the exhibitors, it is also the beginning of a long process of following up on leads generated, with the work only really starting after the show.

“This week is hard work, but the next couple of weeks is the really hard work. If you’re going to get a return on investment on this, you’ve got to work for the next two weeks.” www.nichol.com.au

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Industrial Laser – Worth the investment

Industrial Laser’s product range is so extensive its exhibit occupied two distinction areas on the exhibition floor, separated by one of the main aisleways.

Taking such a large floor space was a risk for Richard Ladley, Technical Director at Industrial Laser, but the investment paid off in the end.

“We’ve got such a wide range of products,” he said. “But we invested in the stand, and we’ve been rewarded. It’s definitely been a good show for us.”

Dominating the larger stand was a massive flat sheet cutting system from Bodor capable of cutting 3mm mild steel, which Industrial Laser was selling for $150,000, including installation and training. According to Ladley, this opens up the market to small manufacturing companies that want to bring laser cutting in-house.

“Keeping their production times and their value-added in-house is a big saving to those sort of companies, and we’ve had 15-20 companies that are extremely interested,” said Ladley. “It’s all to do with time, cost-saving – they’re not worried about speed, it’s to do with bringing it in-house. While the $1m machines have their place, the less expensive machines with the same ability and with support that Industrial Laser gives have found their place as well. This has had exceptional interest due to the service support of Industrial Laser.”

Across the aisle on the smaller section of the exhibit, Industrial Laser was showcasing the latest pulsed fibre laser from IPG, which was brand new on the market and well suited to small holes and fine processing work. In addition, the stand featured Australia’s first pattern-recognition laser marker, the Sisma Smark 200F. This machine allows users to do repetitive markings within 20 microns.

Parts can be placed in the marking area without a jig, and can be rotated at different angles. The machine will work out the angle that it’s placed at and it will mark within 20 microns, time after time.

“It allows you to set up very high-value jobs, one-offs, and by looking through the magnifier through the camera, the visual system allows you to accurately place your marking text,” added Ladley. “What you see is where it marks, so you’re guaranteed a quality mark first time.”

Austech came at an exciting time for Industrial Laser, coinciding with the launch of a new website as the company consolidates its position in the market.

“We’re now Australia’s largest supplier of spare parts for the laser industry as an independent, which is good,” said Ladley. “We sell all brands, all lasers, consumables, at the right price. www.industriallaser.com.au

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The Additive Pavilion – Metal 3D printing edges towards mainstream

Now a regular feature of the Austech exhibition, the Additive Pavilion was again showcasing the latest developments in additive manufacturing, and this year 3D printing in metals was a dominant theme.

Printing in metal is continuing to move out of labs and into Australian factories, though for the moment it remains in high-value niches. According to Ben Batagol, Business Development Manager at Amaero, adopters of metals additive manufacturing are going to increasingly diverge into two distinct camps: those focussed on getting volume up and cost down; and those chasing high-quality applications. For Batagol’s company, the focus has always been on the second, particularly in aerospace.

“We took a conscious decision that highvalue aerospace work is really our niche,” said Batagol. “And four years ago that’s what we said we wanted to target.”

Amaero has earned a reputation as a success story in these early days of Australian companies using additive manufacturing. It opened a French facility last November, and has a growing collection of US companies in its order book.

“That’s a growing presence for us,” Batagol added. “Ironically, the Australian market is one of the smallest markets we deal with in the world. We’re based in Australia but addressing a global market.”

Metals-based 3D printing is too slow and too expensive for many businesses and classrooms, according to Tim Barker, Marketing and Sales Assistant at Perth’s Aurora Labs.

“Our target markets are mainly universities,” said Barker. “There’s a few professors that have come and spoken to us.”

The company is currently making a smallscale S-Titanium machine, which started shipping in December, and which it sells for around US$50,000. It is scheduled to release medium- and large-format machines this year and next, respectively, and Barker claims the latter will have a build rate of one tonne per 24 hours.

RMIT University’s work with additive manufacturing includes some impressive medical applications, as well as high-level aerospace work. RMIT Technical Officer Aaron Pateras said an issue among enterprises curious about 3D printing had been getting them to think creatively about applications.

It should not be approached as simply a replacement for older production methods – a trap into which people often fall.

“Once we actually have a case it’s not too hard to say this technology could benefit you by doing this,” Pateras explained. “The hard part is getting people to realise that you can benefit in doing it [different to] the way they’ve been doing it for 100 years and allow things they couldn’t possibly do.” www.amaero.com.au www.auroralabs3d.com www.rmit.edu.au

ANCA – Leading Australian innovation ANCA has grown to become one of the world’s foremost CNC tool grinding machine manufacturers and has gained global industry recognition as a leading technology innovator.

Pat Boland, Co-Founder and Joint Managing Director of Anca, spoke to AMT beside a towering machine that dominates the company’s stand, located with the Manufacturers’ Pavilion section of the Austech exhibition. Boland believes that this year’s Austech has been good for ANCA: “There’s been several leads generated so far and it’s great for establishing contacts in the industry.”

Moving around the stand, Boland pointed out an ANCA MX7 Linear manufacturing machine on display. It’s a powerful and versatile CNC tool grinder, designed for production grinding, and built to meet the demand for high output. ANCA’s key customers include Sutton Tools, one of Australia’s leading suppliers of industrial cutting tools.

“Our machines are used for both manufacturing and resharpening tools,” said Boland. “The majority of our machines are made in Australia, and we also have a plant in Taiwan as well as an assembly operation in Thailand. The key components assembled in Thailand are all made in Australia.”

Co-exhibiting with ANCA on the stand, ANCA Motion is a division of the ANCA group, with its own management team and General

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Manager, that designs and manufactures flexible control systems, specialising in highprecision solutions. The control systems are flexible and suitable for a range of applications from five axis machine tools, two axis profile cutters or single stand-alone applications.

“A typical ANCA Motion customer would be a machine tool builder who wants to purchase a control system,” Boland explained. “We are selling the CNC control system, which fits in the eco-system of a customer’s machine.”

As ANCA designs and manufactures its own machines, the company can provide solutions for key components such as CNC controls, spindle and servo drives. Boland noted proudly that ANCA would shortly be demonstrating and promoting several of its machines at the Ligne 2017 trade show in Hannover, the world’s leading trade fair for machinery, plant and tools for the woodworking and timber processing industry.

Boland sees Austech as a valuable way to display ANCA’s technology and promote the company’s name. He also hopes that the show attracts talented engineers interested in working at ANCA. www.anca.com www.ancamotion.com

Austech 2017 review

Bystronic – A vision of one-piece flow Bystronic is currently increasing its presence in Australia, and it was making a statement with its Austech stand – a two-storey structure that could be seen from every corner of the exhibition.

This was matched with a diverse display of equipment. The centrepiece of the stand was the new Bystar Fiber laser cutting machine, and Johan Elster, President – Business Units at Bystronic, had flown in for its Australian launch.

“It’s a 10kW, high-dynamic laser cutting machine,” said Elster. “3m x by 1.5m, and 10kW. We launched it in October last at Euroblech in Hannover, and we are just launching it in Australia now. So it’s the first time we’ve show it here, and it’s the most powerful machine on the market.” Alongside the Bystar Fiber, Bystronic had two press brakes on show: the smaller Xpert 40 model, and the 1m Xact system. In addition, the company was running demonstrations of its latest software.

“It’s not only machines,” added Elster. “It’s now very important to have integrated solutions where you can program the machines with one software. With such productive machines, with automation, it’s even more important to have an integrated software solution to run your smart factory.”

Elster described Bystronic’s ambition to achieve “one-piece flow”, where the automation of processes was becoming viable for very small batch sizes, rather than being confined to large production run with 20 or more sheets of metal that had to be cut with the same cutting plan. “These jobs are all gone today – there are very few jobs like that,” he said. “Now our customers produce on time, they deliver on time, they get a time slot to deliver. Nobody wants to sit on stock, nobody produces to forecast. Almost in all industry now, you produce now to orders. So it comes down to very small volumes. “Our vision is to have one-piece flow, automated. And that’s a challenge when it comes to laser cutting and bending. But that’s where it’s heading. And we feel the commitment to develop the right solution.”

Johan Elster, President – Business Units at Bystronic, in front of the Bystar Fiber laser cutting machine.

Elster believes exhibitions are vital in enabling companies like his to reach their customers and showcase their products: “Firstly the value is in meeting customers and showing them the latest technology, in terms of machines and also software. That’s the main goal – to meet customers and show them the new technology, show them where we are heading.”

This was Elster’s first time at Austech, and he was impressed with the show and the positive atmosphere among the visitors.

“We had been working with an agent before, and now we have our own subsidiary here that we’re building up,” he concluded. “We want to show our presence here in Australia, and so far it’s been good. I feel the interest is there. I think Australia has had many years of low activity, but now we can feel the industry is coming back. We feel positive.” www.bystronic.com

Bolts & Industrial – Stop acting like ASIO Confidence is picking up among Australian manufacturers, but they need to start talking about themselves a little more, according to Andrew Rodgers, Managing Director of Bolts & Industrial Supplies.

Bolts’ first Austech show was an overwhelming success and Rodgers believes the company will be sure to return in 2019.

centres – everybody looks at them and says ‘You don’t make these here in this country because you can’t compete.’ Yes we do!

Made in Brisbane,” he said. “It’s a product that might normally be made in China or some European country. Daintree’s been going for 15 years.

“This is our first time we’ve been here and we’ll definitely come again,” said Rodgers.

“The target market of customers coming in is exactly where we want to be… Our target is specifically for machine shops and engineering companies, whether that’s an OEM or a maintenance facility. And definitely manufacturing.”

Established in 1973, Bolts supplies Australia’s engineering community, with three branches in Queensland and two in NSW. Rodgers, who has been in charge for the last 25 years, thinks confidence has returned to his customer base.

“I think overall it’s just a better feeling in the industry that things are on the improve,” he observed.

The business’ Austech stand displayed a variety of “general workshop product”, with a strong Australian representation, including live centres from Daintree Tools and drills from Sutton Tools. A keen booster of Australian manufacturing, Rodgers points proudly at the live centres as an example that it can be done here.

“Even something as simple as these things here – the Daintree live

“If you’re not in the industry you’d never come across it, but even people who are in the industry have sometimes not heard of them.”

Rodgers believes one thing the industry needs to do better is to share its contribution to the economy and the many good news stories that are out there. Australian manufacturers, as other have said, can be a secretive – or at least a shy bunch. Rodgers jokes that they behave like ASIO. “They don’t tell any bloke anything; they’re all keeping secrets,” he said. “The best thing we can do is run an ad on TV. We just need better marketing. We do some things in this country that are mindblowing, but we don’t tell anyone.

“Manufacturing in Australia? We all need to get our head out of the sand as far as marketing and advertising goes.” www.bolt.com.au

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Benson Machines – Showcasing the latest technology

Benson Machines’ stand boasted a diverse array of technology on display, and according to Managing Director Paul Philips, it was attracting plenty of interest. small piece of carbide rod and the saw blade, which uses a diamond wheel.

“We are very busy on our stand and pleased with the number of visitors,” said Philips.

“There is a good feeling in the market.”

Benson adds that being at show is about promoting your products and at past events there have been sales resulting from Austech: “Our job here at the show, is to disseminate information and assist people with solutions to their problems.

We are also distributing a lot of machines from Japan, with brand names like Dainichi, Shigiya, Micron and Nissei.”

One of the centrepieces of the Benson stand was the JIH-I CNC6500M machine centre from JIH-I Machinery, which has been running a demonstration cutting and drilling long aluminium sheets.

The machine offers high levels accuracy and high production rates, with the added value of being compatible with extra-long materials and suitable for multi-stage machining on short workpieces.

“The JIH-I machine centre is a very cost-effective solution for machining aluminium doors and windows, extruded aluminium and long material parts,” Philips explained.

Also on display is a small cut-off machine from Chia Lern, for carbide rod and similar hard to cut materials. Philips points to the

“Carbide rod is used for cutting tools, drills and similar tools and if you want to cut carbide rod, you need a machine like this,” Philips added.

The Filter Mist range from the UK is also in action on the Benson stand. This device collects airborne mist at its source and keeps the factory clean. Meanwhile, at the front of the stand sits the Primacy CNC training machine. This is a simulated training machine with all the operational dials set out exactly like a real CNC machine.

“It’s like the simulated training used in the aviation industry. We are selling these machines so that trainees can safely learn how to use CNC machines,” Philips explained. “Large organisations that have a lot of CNC machines or training colleges use this training simulator.

Trainees are learning about CNC machines from books initially and then using one of these machines to ensure they can safely practise their learnt skills.” www.bensonmachines.com

Headland – Buzzing with high-tech machinery

Headland Machinery’s stand was buzzing with activity and a constant flow of interested Austech visitors. The company’s product portfolio consists of leading machine brands from Germany, Italy, Japan and USA, some of which were on display and being demonstrated at the show.

Annaliese Kloe, Managing Director of Headland and CEO of Klugo, the company’s five star NetSuite Solution Partner, arranged for Headland’s operators to explain the machines on display. The Trumpf TruLaser 5030 machine is manufactured by the German family-owned business Trumpf, which has been producing highquality precision laser machines for over 30 years. The TruLaser Series 5000 can handle both thin and thick sheets of material, with a laser power of up to 8,000W. This solid-state laser even cuts stainless steel up to 40mm thick. Designed for maximum capacity utilisation, the machines reach axis speeds of 300m/min.

The 5030 operator programmed a flower design and then demonstrated the machine’s laser in action, changing the laser tools and cutting the piece of aluminium into a flower. He then programmed it to laser a piece of steel into an intricate butterfly, much to the amazement of the onlookers.

The demonstration then moved on to the Trumpf TruPrint 1000, a compact, precise and robust 3D-printing machine, which produces components of almost any geometrical shape. Complex shapes can be easily and rapidly transformed from the CAD drawing to required industrial parts.

The machine’s operator showed a typical application, where a dental plate of implants and a hip replacement part have separately been 3D printed on the TruPrint 1000. The machine progressively added a thin layer of metal powder to a built cylinder on the middle

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plate, the laser melting the powders together layer by layer. The machine can be used for any laser-meltable metal.

Next, we moved to the Japanese NakamuraTome AS 200LMYS CNC turning machine.

The operator explained that it has a 12-station turret and a highperformance milling, Y-axis and sub-spindle.

Annaliese Kloe, Managing Kloe explained that Director of Headland and CEO of Klugo, which she also Klugo, with the Trumpf TruLaser heads, grew from 5030 machine.

Headland’s experience of consolidating its systems onto the NetSuite platform, a leading cloud-computing business software. Klugo’s consultancy services team is now assisting wholesale distributors, manufacturers and retailers to streamline their operations on the NetSuite platform.

www.headland.com.au

Austech 2017Heading review

Digitalisation – See the future factory through VR goggles

Industry 4.0 is not one technology but a group of nine or so, according to the experts. These include the cloud, robotics and augmented/virtual reality, which all featured at the Digitalisation Pavilion.

According to Nital Shah, Regional Sales Manager – Southern Region at SICK, a “mixed bag” of old and new customers visited their stand and overall it was a “very good show” in terms of interest. Visitors were particularly drawn to the company’s Flexi Soft safety controllers and the range of safety laser scanners. Regarding Industry 4.0, SICK’s pitch focussed on “smart tasks” enabled by their sensors – which can process detection and measurement signals, simplifying control programs and processing elsewhere – and on getting away from Programmable Logic Controllers.

“The information from the sensor will be available to the cloud or to the browser, and that’s what Industry 4.0 is all about,” said Shah.

ABB’s stand featured YuMi, its contribution to the booming collaborative robot market.

Adopting cobots effectively takes training as well as a little imagination, explained Paolo Maggi, Product Specialist for Robotics. It’s important to understand the strengths of humans as well as those of robots.

“If you have a production line, you break assembly tasks down into different sub-tasks and have a close look at which ones you would automate with a collaborative robot and which ones you would leave with the operator,” said Maggi. “Humans are far superior when it comes to tactile sensitivity, and our vision is second to none.”

One Tasmanian customer has seen success using the robot as a temp when demand bumps up.

“They had issues with temporary staff, so whenever they have a spike in demand for certain components, they wheel YuMi in to pre-assemble - essentially lending a hand to the production line,” Maggi added.

Head-mounted virtual reality sets hit the consumer market in a big way last year, with product releases including Oculus Rift, HTC Vive and others. VR is currently being used by some manufacturers, but will be widely adopted soon, believes Autodesk’s Richard Elving. He says it’s currently proving useful in three main areas: as a sales tool, in design collaboration, and for training. Elving predicts VR will be commonplace in local manufacturing within 12-24 months.

www.sick.com.au www.abb.com/au www.autodesk.com.au

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AMTjunjul2017

“We just came from a large naval manufacturer in Melbourne this morning and they’re using it between offices in Melbourne, Adelaide and Perth, so they make sure designers are looking at the same thing,” said Elving. “It doesn’t matter where you are in the world, you’re looking at the same thing – and then you can do things like mark-ups, different versions, revisions.”

As seen At Austech

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Hi-Tech Metrology – A laser focus

From bionic ear implants to massive mining components, equipment sold by Hi-Tech Metrology end up in a huge variety of places. Serving such a wide cross-section of manufacturers, the company believes things are looking up within the industry.

At Austech Hi-Tech focused its display around the latest laser scanning technologies available in the country, including products from Hexagon Metrology and Microview. Craig Leckie, National Sales Manager explained: “On every piece of equipment here we’ve got laser scanning, which enables us to capture points and capture them very rapidly”.

The stand also featured the Australian debut of Creaform’s new robotic laser scanner MetraSCAN. Creaform says the MetraSCAN robotic metrology system is easily integrated into a production line and brings higher reliability and speed to quality control, as well as other advantages.

“Creaform has been posting it on their different social media sites that it’s being released into Australia,” said Leckie. “That’s a bit of a coup for us and I’m very proud.”

Besides laser scanning, HTM’s offerings include tactile coordinate measuring machines (CMMs), video CMMs, surface and form systems, photogrammetry and various motion tracking systems.

Based in Hallam, Victoria, the company’s history goes back to 1992, and its operations are split into products, services and projects divisions.

Leckie has been at the firm for 11 years. Asked his opinion on the mood at the show and across manufacturing, Leckie believes things are better now than 12 months ago, when things were “patchy”. Overall, they’re currently “relatively buoyant”. He cites positive developments in Adelaide, for example, where the end of production at the Holden factory in October has been accepted. Though it’s obviously painful, he sees echoes of Newcastle’s refocusing due to the end of BHP’s steelworks.

“I think that’s quelled a lot of worry and people realise they can actually step forward and create viable business opportunities without the automotive sector being there,” said Leckie. “Obviously it’s still affecting a large number of people, but I feel that Australia’s a fairly resilient bunch of people. They tackle a task in a positive way and they actually invest in technology to make sure they’re competitive.” www.hitechmetrology.com.au

John Hart – Revolutionary performance At Austech 2017 John Hart demonstrated its commitment to providing advanced solutions to make Australian manufacturers more productive, efficient and competitive.

The headline acts were Mazak’s Variaxis i-700, VCN-530C, QT Compact 300 MY and the Integrex i-200S, showcasing Mazatrol Smooth CNC Controls, as well as John Hart’s CellPro Modular Robotic System.

Smooth Technology has revolutionised the way Mazak machine tools perform. Spanning the entire part-production landscape – from programming to metal removal to data collection – this technology platform boosts productivity at every stage of the metal cutting process. Intuitive hardware, new highspeed servo systems, enhanced ergonomics and highly optimised Mazatrol Smooth CNC programming are key components of Smooth Technology. Engineering support also complements the platform by factoring in automation integration and plant-wide connectivity as the Industrial Internet of Things (IIoT) transforms our industry.

Smooth Technology allows modern Mazak machine tools to offer manufacturers complete ease of use, lightning fast machining and unbeatable accuracy. As manufacturing technologies advance, Smooth Technology will evolve with them too. Among Smooth Technology’s most notable features are the Mazatrol Smooth X and Smooth G CNC units, which provide impressive programming speed and convenience. Moreover, Mazak’s reimagined control layouts bring an intuitive, flexible human-machine interface.

The Mazak Variaxis i-700 is a high speed simultaneous five-axis machining centre with ‘done-in-one’ capability. Double column construction and tilting rotary table supported on both ends ensure high accuracy machining over extended periods of operation.

The Mazak VCN-530C offers the highest productivity in this vertical machining class. High-rigidity construction, ball screw core cooling

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and temperature compensation ensure high accuracy machining.

The Mazak QT Compact 300 MY turning centre features an integral spindle/motor and milling capability with Y-Axis. Linear roller guides assure high rigidity for high-productivity machining. The floor space requirement for the 500U is only 4.39sqm, and 5.96sqm for the 1000U. The Mazak Integrex i-200s is a multi-tasking machine for ‘done-inone’ processing with high-power cutting performance comparable to machining centres. Orthogonal design provides a large operation area and high accuracy machining.

Finally CellPro is a pre-engineered, modular robotic machine tending solution for CNC machines with a state-of-the-art user interface that requires no robot programming knowledge and is specifically designed to be intuitive for the machine tool operator. CellPro control software features drag-and-drop functionality, which allows production sequences to be defined in seconds. The CellPro Process Builder then guides the operator to complete complex robot motion and sequence configurations in mere minutes. CellPro is both easy to use and amazingly flexible. It’s not limited by workpiece size and weight, and can be set up to tend one or more CNC machines. CellPro is the only machine tending system that can match exact manufacturing requirements and therefore offer true unmanned operation.

Scan the QR Code to see CellPro in action. www.johnhart.com.au

I’D BE HAPPY TO RECOMMEND THE HYDRAFEED TO ANY COMPANY. Kennewell CNC Machining, a contract machine shop in South Australia manufactures everything from parts for agricultural machinery to motorsport and tattooing equipment. It’s also heavily involved with the production of prototype parts to assist companies bring products to market.

Brett Klose, Leading Hand Kennewell CNC Machining

Owner Brett Kennewell and Leading Hand Brett Klose, recently invested in a servo-driven Hydrafeed Barfeeder to retrofit to an existing CNC lathe and replace the existing pneumatic unit. Taking advantage of its user friendly nature and the set and forget facility, the Hydrafeed has increased productivity and reduced their workload.

Kennewell also benefitted from the one-on-one training that Dimac provided, to ensure the barfeeder was installed correctly and operated at optimum performance.

Dimac Tooling, Australia and New Zealand’s leading supplier of accessories and workholding solutions provides a range of cutting edge equipment designed to assist companies increase their efficiency and productivity.

To find out how we can boost your productivity visit www.dimac.com.au

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Successful show for DMG MORI

DMG MORI as always took a large, eye-catching stand at Austech, and the strategy paid off in attracting visitors.

“So far, the show has been fantastic,” said Paul McDermott, Managing Director of DMG MORI A&NZ. “A lot of our customers have visited our booth and have been informed about DMG MORI’s latest technologies.

“We are keen to sell all of our machines on display and plan to increase the backlog of machines on order,” McDermott added with a smile.

McDermott described the company’s NLX universal turning centre on display: “The NLX stands for top performance in universal turning. Achieving first-class turning production results requires machines of sturdy design and a respective performance. With the universal turning centres of the NLX, DMG MORI has created a product range that meets the high demands in this field. This machine can do hob cutting, gear hobbing, polygon turning and traditional turning and milling.”

The NLX 2500 is a high-rigidity, high-precision, CNC turning centre able to handle various workpieces at a time. It features the BMT (built-in motor turret) to achieve powerful turning capabilities and outstanding milling performance.

Paul McDermott, Managing Director of DMG MORI A&NZ.

“The machine offers high-tech at an attractive price, while setting a new benchmark in its class with its convincing performance features,” said McDermott. “In its flexible extension ranges, encompassing the five-axis machine with its dynamic NC swivel rotary table, the DMU 65 monoBLOCK masters all disciplines in milling technology, from roughing through to finishing at an uncompromisingly high level. With its ‘Machine Protection Control’ Technology Cycle, it is also detecting vibration and spindle load to prevent damage to the machine before it happens.

The NVX 5100 vertical machining centre on display has directdrive force axis, with solid slideways on all axes. Other highlights of the machine include: 23% higher rigidity, achieved by using a spindle with a large-diameter bearing: an environmental thermal displacement control device (optional); and a new spindle that achieves speeds of up to 15,000rpm.

The machine allows unrestricted crane loading of up to 6,000kg and has a large door opening giving the operator access to the working

area. It also offers comprehensive cooling measures, provided by a high-performance coolant unit.

Moving to DMG MORI’s Industry 4.0 Area, McDermott pointed to a TV screen on the wall: “We are broadcasting here the live machine statuses from our global factory located in Iga City in Mie, Japan.” www.dmgmori.com

Renishaw – Attracting serious interest

Australian customers are keen on upgrading coordinate measuring machines (CMMs), while the local market looks “on the precipice” concerning major investment in production-grade additive manufacturing systems, believes Mike Brown, General Manager at Renishaw Oceania.

“It’s pretty good. It’s probably been our best show for a number of years,” said Brown when asked what interest had been like at Austech, Renishaw is a diversified engineering business serving the coordinate measuring machine, machine tool, medical, encoder and 3D printing sectors. With a presence in Australia in the last 16 years, demand has been such that its headcount has grown from four to 11 employees at its Mulgrave headquarters in the last three years. Recently the local market has been demanding retrofits of old CMMs, an effective – and cheaper – option than buying an entirely new machine.

“There’s a lot of customers with an old CMM with electronics that are 20 or 30 years old; the structure of the machine is good but the electronics are old hat,” said Brown. “So we’ll take the structure, update it, put new encoders on, put new controls on, new sensors on and bring it up to modern technology.”

Almost half of Renishaw’s stand was devoted to additive manufacturing. The company makes top-of-the-line production

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machines for metal powder fusion, with an emphasis on production rather than research or education. It also prides itself of making and supplying parts in-house as a point of difference over competitors.

A highlight of the Renishaw stand was the new RenAM 500M unit, the first of its kind in Australia, which cuts out handling and increases safety through automated sieving and recirculation of powder.

“It’s got a whole bunch of new Renishaw components,” Brown added. “The laser optics are Renishaw-made, the machine is Renishaw-made, the sieving station is Renishaw-manufactured.”

Brown believes the hype around 3D printing has thankfully dissipated and what’s left are people such as those at Austech.

“What’s left are the people that we’re seeing here, who have an idea of what’s going on, know what they want to do, and want to do something sensible with it,” he continued. “So that’s been the real thrust of this show: people who are far more serious and have a much better idea of what they’re doing. That’s been good.

Refreshing.” www.renishaw.com

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Dimac Tooling – Less is more

Dimac Tooling took a slightly different approach with its stand this year, omitting a lot of the smaller, lower-value items that it had exhibited at previous shows, to instead concentrate on a handful of larger pieces of equipment.

“We’ve gone for a less-is-more approach,” says Dimac’s Managing Director Paul Fowler. “More sort of capital-type equipment, and lot of new products. We still do the small items – soft jaws, vices and chucks and so on – but those are moving over to be more webbased products, they’re commodities almost. We’ve really tried to get the message out, under our theme of productivity, about products that help you manage your coolant, keep your coolant clean, reduce the amount of maintenance and so on.”

One product on the stand that had proved a talking point was a new barfeeder from Hydrafeed, based in the UK. It marked a departure for Dimac, which hadn’t stocked a barfeeder in the past, and comes equipped with a programmable work stop – a feature Fowler believes sets it apart from other products on the market.

Another new product was the latest mist extractor from Reven in Germany, which introduces a degree of Industry 4.0 smart functionality, albeit through a deceptively simple approach.

“What they’re doing is connecting the mist extractor to a machine tool in a way we haven’t done before, and monitoring the door on the machine,” Fowler explained. “It’s got a variable speed drive in it, so when the system is idling, it’s slowly turning over, we’re just drawing a small amount of air, to create some negative ventilation in the machine so mist and steam can’t escape. But once we open the doors, the butterfly valve opens and it speeds up and draws all the air out. The nice thing about that is that you’re not wasting energy sucking all that mist when the doors are closed.”

While there had been some enquiries from customers about some of the smaller items, Fowler believed that the shift in emphasis to the higher-value items had been a success.

“It’s been impressive. The quality of the leads has been good,” he said. “A few people ask ‘Where’s all that, are you still doing that?’

But what I’m seeing is that customers coming on the stand are

in a more serious mode. They’re looking to improve and invest in their workshop. Maybe they don’t know exactly what they want and how to get there, but they want to do things, they’re just trying to understand what the right thing to do is.”

Fowler was impressed with the overall mood at Austech 2017, regarding it as indicative of a broader upturn in the state of Australian manufacturing.

“I’m really happy with it,” he says. “I’m happy with our two-year cycle. I think it builds up more anticipation, with the visitors, so they’re more inclined to come and have a look. The show being fully booked is a great thing. There’s a certain vibrancy. There’s certainly not the gloom and doom we’ve seen in years gone by.” www.dimac.com.au

Sheet Metal Machinery – Emphasising efficiency Sheet Metal Machinery’s stand had a strong focus on energy-efficient electric press brakes, with machines on display from Safran Darley of The Netherlands, and also from Coastone in Switzerland.

“Electric press brakes are the future basically – a lot of companies are focusing on energy-efficient electric press brakes,” said Ed Stavar, Director of Sheet Metal Machinery. “The standard in the industry has been hydraulic-driven press brakes. Hydraulic press brakes use a lot of energy, and they’re not environmentally friendly due to the oil used. There’s none of that service required on electric press brakes.

They’re much more clean and efficient, more eco-friendly.”

In addition the company was showcasing the latest coil-handling systems from Krasser in Austria. The Krasser machines are equipped to automatically pick up the coil and bring it to a slitting machine, reducing the need for forklifts and eliminating a lot of the risk of damage to the coil.

Stavar said the Sheet Metal Machinery stand had seen a strong flow of visitors throughout Austech, and he was confident that the leads generated would be converted into sales.

“I must admit this year has been very good,” he said. “There’s a lot of confidence in the market again, which is nice to see. I’m very happy with this year’s outcome. There’ll definitely be some sales in the pipeline.”

All in all, Stavar believes this pointed to a brighter outlook for Australian manufacturing than we’ve seen in the last few years.

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“The confidence is there, and obviously Austech is showing that the industry is picking up a bit” he remarked. “I’m hoping that is the case.

The show has definitely been a good show. Australian manufacturing has still got a little way to go I think, but the confidence is there so hopefully it’s going to increase.” www.sheetmetalmachinery.com.au

Austech 2017 review

Manufacturers Pavilion showcases a sector looking up

The Manufacturers’ Pavilion provided a showcase for a diverse range of Australian manufacturing companies, and generally they seemed optimistic about the outlook for the industry.

Romar Engineering is involved in medical device development and manufacture, with former and current partners including Cochlear, Resmed and Vaxxas. Although its stand featured everything from surgical aids to microfluidics, it had seen strong interest in its new DMG Mori Lasertec 65, a hybrid laser deposition welding and fiveaxis milling machine.

“It’ll bring a lot of value to medical devices, to defence, across the industry, because we can print up to 15 different materials at once with this and we can print up to three different materials in the one component,” said Managing Director Neil Wilson.

The machine is a $1.25m co-investment between Wilson’s company and the CSIRO. Wilson believes collaboration with public researchers is “critical”, noting Romar’s links with universities including University of Wollongong, Deakin and ANU. Andrew Donald Design Engineering (ADDE) had brought its new end-of-line palletiser, based on a Universal Robot UR10 machine mounted on a column and swing mechanism. General Manager Barry Hendy said the system only took hours to integrate and while the UR10 was able to work with European pallet sizes, this solution had been adapted for Australian-standard CHEP pallets. Interest in ADDE’s core offering of automation solutions had been strong during the show, Hendy said.

“Our projects are sometimes quite significant, so we really only need one job to come from a show and it’s been worthwhile,” he added.

“This is probably not our core space,” he said of the show, where the Rae-Line stand was situated next to a big Kenworth rig. “But you never know where your next lead will come from, so we were happy to embrace it.”

Carthew said that the mood in the industry appeared mixed, but predicted things were picking up. His evidence? Truck builds are on the up. This is good news for Rae-Line, but it could also be good news for the rest of the industry – as an indicator of logistics activity, probably driven by consumer demand.

“There’s a correlation between truck builds and the economy - there really is,” explained Carthew. “But maybe something else is driving it. Hopefully it’s a sign that things are on the mend.” www.romareng.com.au www.adde.com.au www.rae-line.com.au

Rae-Line primarily makes interior trim for Kenworth trucks, though it has recently diversified into areas such as sports and safety padding, said Christian Carthew, the company’s Business Development Manager.

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Precision Specialty Tooling – Twenty years and still going strong

A constant presence at almost every Austech since the start, Precision Specialty Tooling (PST) was in a celebratory mood at this year’s event, as it marked 20 years in business.

Ted Flynn, Neil Creagh and Bruce Price founded the business back in 1997, operating initially from a Preston office warehouse facility.

“I had an idea about what I wanted to do and spoke to Neil, who put me in touch with Bruce,” Fynn recalled. “We approached various manufacturers around the world and secured some agencies. One of them was Noga deburring tools, which we’ve now been selling through distributors like Blackwoods and Total Tools and all the independents around the place. And over the years we’ve built up new agency lines through various manufacturers, we’ve introduced products into Australia via our distribution network. And 20 years on we’re still here.”

The company’s main focus was workholding in the beginning, selling almost exclusively into the industrial sector, to manufacturing or engineering. However, the three founders knew they had to diversify, so over the years they branched out into automotive aftermarket products. Today Flynn estimates PST’s business is about 60% industrial products and 40% automotive, with a strong line in welding equipment cutting across both.

“We started with the Stronghand range about five years ago, and that’s been very strong for us,” said Flynn. “That’s welding, fixturing, holding, clamping, pipeholding, but mainly for welding. So we’re across a few different markets.”

As a long-time exhibitor at Austech, PST has seen how the event has changed over the years. Flynn is adamant that the being part of the show has been a success for the company.

“It’s the best vehicle for finding out from end-users if your product’s going to sell through or not,” he explained. “I’m not an engineer, I’m from an accounting background, so I can see a product and think it’s the next big thing, but until you show it to the guys who actually

Precision Specialty Tooling founders Ted Flynn, Bruce Price and Neil Creagh.

use it, you don’t really know. At these shows you get a chance to talk to those guys and find out what they do and how they do it, and whether or not the product’s really going to fly.”

And this year’s show?

“Really good. Good attendance and good people, interested in what we’re doing, and genuine users of the products. We’ve had a really good show,” says Flynn, adding that Austech 2017 reflected a more positive mood throughout the industry. “I think it’s better than people think. There’s no shortage of doomsayers, but we’re still here. The same exhibitors are always here, and the same sort of people. We think there’s a lot of upside. Bruce has been talking to a lot of people who’ve got a lot of work on over the next five or six months. I think it’s pretty optimistic.” www.pretooling.com.au

Applied Machinery – Covering the manufacturing spectrum

Applied Machinery had a big stand in the middle of the Austech exhibition floor, and it was packed with equipment covering a diverse spectrum of manufacturing processes.

Applied’s Marketing Manager Daniel Fisher explained what products were on display: “So we’ve got the Hurco BMX five-axis precision CNC machining centre. At the front of the stand we’ve got the Yawei PBH 160-tonne, 4m CNC press brake, along with the latest addition from Yawei, their 4kW HLF 1530 fibre laser. And we’ve got the Akyapak 101 section-&-tube rolling machine, along with the Cosen C320NC automatic bandsaw.”

The Yawei HLF fibre laser in particular was generating a lot of interest, and according to Fisher “it’s the future of laser cutting”. The machines features an IPG resonator, a Precitec auto focus cutting head, along with a Siemens 840D SL CNC control – features and precision components normally expected on a much more expensive machine, packaged in a relatively affordable unit.

“For the last 12 years we’ve been representing Yawei in the

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Australian industry,” said Fisher. “Over 200 CNC press brakes sold in the country, nearly 40 turret punch presses, along with guillotines.

A fibre laser is the latest addition, recently launched at the Euroblech exhibition, and we’re happy to say it’s the first one in the country.”

Pinning down Fisher just to talk about Applied’s activities at Austech 2017 had proven difficult as the stand was consistently busy throughout the exhibition. When he finally had a moment to spare, Fisher was said the show had exceeded their expectations.

“It’s been fantastic,” he said. “It’s been crazy, but that’s a good crazy to have. We’ve been really happy with the visitor numbers.

We’ve been putting together quotes to customers, we’ve got very serious meetings with customers for the fibre laser. We really hope to put business together as a direct result of Austech. The real work starts next week!” www.appliedmachinery.com.au

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one-on-one

David Chuter is the Chief Executive Officer of the Innovative Manufacturing Co-operative Research Centre (IMCRC).

He spoke to William Poole AMT: What is the IMCRC and what are its objectives?

David Chuter: Well the IMCRC stands for Innovative Manufacturing Cooperative Research Centre. We carry on the great legacy that these CRCs have been doing for 20-plus years in Australia. We were formed officially in 2015. After a bit of a slow start-up we have just really got ourselves running since the back-end of last year into this year. This month sees our team fully recruited; we’ve got two more project research officers joining us later this month, and our direct staff will then be our full complement.

We see our role as very much helping to champion the transformation of manufacturing in Australia. And that’s a pretty broad agenda which many parties are working on. At our core, we cofund and de-risk industry investment in research projects. We try and focus on manufacturing companies: small, medium and large. We encourage them to work with the Australian universities and CSIRO to conduct manufacturing research projects.

AMT: Can you give an example or few examples of what those projects are?

DC: Yes, I have to be slightly careful because some are more confidential than others. We’re funding projects today that basically involve research into advanced manufacturing technologies, and that’s a fairly broad spectrum. We’ve got projects today in: advanced robotics; vision systems; virtual reality and virtualisation; advanced materials; nano-technologies and others. We have projects spanning equipment manufacturers, we have medical technologies, we’re doing projects in 3D printing and additive manufacturing. So we’ve got quite a broad range of projects.

I guess if there’s one thing that binds them together, all of those projects have to meet our project selection criteria and that criteria is really driven around manufacturing outcomes, so it’s not purely the research per se. It’s actually creating outcomes that benefit the industry participants, that demonstrate high levels of collaboration, and demonstrate innovation. And every project also has a requirement that they need to identify in some form how

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they are going to access global supply chains. This is not just about creating little pockets of excellence here in Australia, but understanding that we’ve got to be playing on a global playing field if we’re going to have some relevance and competitiveness.

AMT: How might one of those projects take shape, and who are the participants?

DC: First of all, a project has to be led by industry. Expressions of interest will come to us, companies may want to undertake research, but they may not know which university or universities they could work with. Others may come to us through universities, through engagement they’ve already got with industry. But basically we will seek expressions of interest for research into manufacturing technologies. As those concepts mature, and people start filling in application forms, we will coach them through the process to make sure they’re a good fit to the criteria. We weed out ones that don’t, and if possible and if necessary, we’ll redirect people towards other forms of government assistance where they may not fit the criteria of our CRC. What we’re trying to do is bridge that “valley of death” between a proof of concept and commercialisation. We don’t really fund programs that are “blue sky” pure research; we’re more applied research. So once you’ve got proof of concept, but you have so many questions left to answer in terms of how you’re actually going to manufacture this and how you take it to market. What we will do is we will co-fund the research on a dollar-for-dollar basis with industry, solving all those problems, answering questions to the point whereby you have an extremely robust business case. You know how much it’s going to cost, you know how you’re going to make it, what sort of equipment, people and skills you’re going to need, and you know your commercialisation plan that you’re going to implement. And at that point we’ll end the project and back away, and let them take forward that commercialisation plan.

We talk about manufacturing readiness levels, similar to technology readiness levels or TRLs. We operate ideally in a manufacturing readiness level of 4 to 7 – level 3 being you have a proof of concept, and level 8 is that you’re starting to gear up

for serial, volume or large-scale production.

We fund the research in between to help take industry from that proof of concept through to the point where they’re ready to commercialise.

AMT: How do you identify the value of a project in order to take it forward?

DC: Good question. It’s been fairly well documented that Australia has some of the highest intellectual capital sitting within its universities but one of the lowest levels of collaboration between industry and universities. I’ve just come back from 10 days in Europe, and I’ve seen what appears to be a much higher level of collaboration that is quite normal between industry and universities. Having said that, a number of the projects that we’ve got on the table have been introduced to us by the universities through relationships and engagements that they already have with industry.

What we want to do is make it much more normal, much more accepted and much more desirable for manufacturers to want to work with Australian universities as a legitimate arm of their research and development activities. And what we’re finding is that some projects come directly to us, and that might be through understanding of what we’re doing through our website, or word of mouth. But a number of projects will actually come to us through some of our partner universities.

Not every project at the outset will meet the criteria we have, and that’s why we go through the process of coaching and mentoring and really trying to understand what is the problem or the challenge that the industry participant is trying to resolve through doing a research program. We will then encourage them to bring other SMEs to the table as collaborants or participants in the project. Can they work with more than one university to bring the smartest brains across Australia to the table? What sort of commercialisation opportunities do they have? What do they intend to do with any intellectual property (IP) they create?

And we will work our way through an application form, with very much an open dialogue as to how they are going to solve those problems.

We have an independent committee that

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is set up that is separate from the staff at the IMCRC and separate from the CRC Board, which then reviews those project applications, scores them on a weighted basis, and either can approve outright depending on the value of those projects, or can make a recommendation to our Board that that project is approved or requires further development to get it approved, or is outright rejected. And I have to say we’ve had a pretty good success rate going through that process – when projects come to us, if they’re put up to the committee, there’s a good chance they’re going to get approved because we tend to do the weeding-out process quite early on. We don’t want to waste anybody’s time; we’d rather point industry towards other funding opportunities that may suit them better than our CRC. AMT: In terms of collaboration, we often hear that, because Australia’s industry is so SME-dominated, there’s that tendency to not share information, to keep things in-house and not seek out ways of collaborating. That must be one of the harder things you have to overcome.

DC: It is. And we have, by design, tried very hard to remove all sorts of barriers – real or perceived – that prevent SMEs from working within universities or even talking to other companies or conducting their own research. I’m not from academia or from government. I’ve come from 25 years of manufacturing experience. And there is absolutely a perception of competition out there that is not real. The competition is China, Asia, Europe. The competition is not often the company next door. And yet that’s often the perception that people have that stops them collaborating.

project opportunities so that it’s beneficial to the SME or manufacturer involved. So by design we’re trying to remove any of those perceived or real barriers that exist.

The one challenge that still exists is that a lot of SMEs don’t have spare cash.

And naturally the way these research programs work is that in effect the industry is contracting a university or universities to conduct their R&D on their behalf or in parallel with them, and cash is basically a prerequisite for that process to take place.

Now we de-risk that, we fund half of that cost, but at the end of the day it still requires that manufacturer to have the wherewithal, the willingness, the commitment and the cash availability to conduct research with a third party. The reality is that with the rapidly changing pace of technology in the world, companies are having to invest in R&D, and using external researchers is a very credible way of doing it. And if they do that, we can help with half the cost. So I think it’s a very good value proposition for those companies that have the right mindset.

AMT: So what would your advice be to a regular manufacturing firm who feel they’ve got a great idea for a product, but they have no idea how to start getting that into the marketplace?

the key sectors in Australia. If it’s a medical company that also does manufacturing, actually there are two Growth Centres that could potentially help them. Depending on whether they’re looking for business improvement or research programs, others such as the Entrepreneurs’ Programme, which AiGroup and AMTIL have business advisors in – they can help them. There may be State Government funds. If it’s access to capital equipment, or production tooling, then perhaps some of the State Government programs such as the Future Industries Fund in Victoria may be better suited to them. If it’s core research that they want to do and they’re prepared to work for with universities then that’s the sweet spot that we work in.

So I think the key thing is to engage them in conversation to understand what problems they’re trying to solve, where they need some help. Trade associations are another good way to help. AMTIL, AiGroup, prefabAUS – they’re all partners to our CRC, and we encourage companies to join those organisations because of their collaborative nature.

Continued next page

DC: The first thing you have to do is understand where they are in that process and what are their barriers, because there are a number of bodies set up who can help them with that process. We’ve got the Advanced Manufacturing Growth Centre that is fully up and running.

There are Growth Centres in each of

I’ll give you some examples: we’ve determined that, even though we fund half the cash cost of research programs, our CRC will have no share of any IP that’s created, because we don’t want an argument or discussion around IP at the outset to be a barrier for people wanting to conduct research. Our view is that the IP should be owned by those who are best placed to commercialise it, and that might quite often be the industry participant in the project.

We don’t have an online application process.

We use a fairly basic Word document process, but one that is comfortable and familiar for SMEs to use. We try and coach people through the process, as opposed to simply applying online and then the first thing you hear two months later is a Yes or a No. What we try and do is expand the

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one-on-one Continued from previous page

You can talk to other manufacturers and realise that the problems are often shared and there may be some collaborative opportunities to work together.

But first things first… it’s the willingness to come out and have a conversation with people about how you grow your business.

And there are lots of organisations that can help that are perhaps separate from consulting companies who are also very credible, but there are a number of government organisations set up to do that as well, particularly in the manufacturing space.

AMT: Tell us about your professional background and you came into the IMCRC. DC: I’ve come out of the best part of 25 years in the automotive industry. So I’m obviously watching with great interest how the next few months unfold and I have a particular passion to make sure the legacy and investment we’ve made in automotive in Australia, particularly at supply level… that this knowhow gets carried forward in some form into other sectors. I did 10 years working in the UK with a company called Magna, which is one of the world’s largest Tier 1 suppliers. I worked on car interiors – dashboards, door panels, floor carpets, headliners.

I migrated to Australia in 1999 and did a stint with Deloitte Consulting and got to see a range of other industries, but a bit like a ‘bad drug’, automotive sucks you back in. I spent 13 years with Futuris and helped play a role in taking that business from an Australian-only business to now operating in multiple countries around the world. Then I spent two years in Thailand running Futuris’ business there, which was an exciting time seeing the growth of the Thailand automotive industry. I came back and had an opportunity to take the helm at MHG AsiaPacific, one of Australia’s largest suppliers in the automotive industry.

I ran that business from 2014 to 2016. We went through a diversification program and successfully acquired a business in the construction industry space – so a great example of an automotive company finding a life in Australia beyond automotive production.

I’ve always played a bit of a role through industry associations with both state and federal government, helping to advocate for manufacturing in Australia and the continuity of the automotive industry, and we know how those cards have played out. But when this opportunity came up to lead the CRC, and in effect lead a lot of the investment and strategy around research in manufacturing, it seemed to be a good fit for a background in manufacturing but also

AMT Jun/Jul 2017

a passion for Australian manufacturing to continue beyond the end of automotive. It was something I found of personal interest and the opportunity to do something quite different and hopefully influential in terms of the landscape of manufacturing here in Australia.

I think there’s been a bit of shift in the approach across a range of governmentfacilitated organisations, such as the Growth Centres for example. We have people with deep industry experience who are now running these organisations and who have the ability to effect change across manufacturing and other landscapes in Australia. I’m playing that role within the CRC, we have Jens Goennemann in the Advanced Manufacturing Growth Centre, Sue MacLeman at MTP Connect. All of these individuals have come into strategic, government-influencing roles, but they’re not politicians or bureaucrats – they’ve come from deep-seated experience in industry. What we’re finding is that between our respective organisations, even we are finding great opportunities to collaborate because we’re very industry-focussed, we’re strategically focussed, we’re looking at outcomes and impact. We’re not just managing the funds that we’re managing – we all wear industry hats, with a passion for the industry that sits above the business cards that we hand out and the roles that we do day by day. And that’s a powerful force for change at a time when manufacturing is going through huge changes. None of us really know what new technology is going to look like in 5-10 years time. None of us know how this digital transformation of industry is going to play out. But at least we’ve got organisations led by people who have got the right background who can apply that knowledge and keep a focus on industry outcomes going forward.

AMT: So what are the major opportunities and challenges facing Australian manufacturing today?

DC: I think the perennial challenge for manufacturing in Australia has always been our limited scale. We’re extremely fragmented when you look at the proportion of SMEs compared to some of the big industry primes. And that situation is only going to be compounded by the end of vehicle production in Australia. Because even the big Tier 1’s will be diminished and diluted because of that.

The tyranny of distance is often spoken about, but I actually think with those companies who have found a way to compete globally either through export or partnering or licensing – the one thing that the whole digital revolution allows you to do – that distance disappears. Therefore for those companies who have found their

way into global supply chains the hard way, perhaps this opens up immense opportunities for them by applying digital tools and looking at different service models in addition to supplying actual physical products. For those companies that have found it difficult to do anything outside Australia, again that whole digital world and moving toward a servitisation process may actually create new business opportunities through apps, multi-media, virtual reality, additive manufacturing… basically through business model innovations they might not have otherwise seen.

It ends up being a bit of cliché, but words such as innovation, collaboration, and being technology-driven actually are the recipes for success as we go through this transition. Not just moving away from being a country that makes cars, but one where the manufacturing world, including Australia, is looking at this Fourth Industrial Revolution, Industry 4.0, and trying to sort out the reality from the hype.

There’s no doubt a lot of companies can find benefit inside the walls of their factory by applying some of these digital tools and building on Lean implementation and so on.

I think the real opportunity is in looking at the business model as a whole and seeing “where can I find new business, market and partnership opportunities, that the digital age actually opens up for me”. It’s going to be a challenging time, but we’re seeing a wave of new technologies coming in at an unprecedented rate in manufacturing. It’s a real opportunity for companies to get on the journey and see how they can grow their businesses.

AMT: So where do you see the industry in 10-20 years?

DC: I would love to see it as thriving and relevant… relevant globally. We talk about being competitive a lot, but I talk about sustainable relevance. In other words, that you’ve built yourself up to such a platform that other parts of the world cannot do without you. And that would be fantastic to see Australian manufacturing as having that place in the world. You look at the reputation of Silicon Valley for example, or you hear of phrases such as “Danish by Design”. I’m not sure what the right phrase is for Australia, but wouldn’t it be great in 10-20 years to have that kind of reputation, of Australia being trusted, high-tech, valueadd manufacturing, with really smart people, and an exemplar of how to collaborate and innovate. That would be a great vision for us to have for the industry, and one that is perfectly possible by adopting the right technologies and working together. www.imcrc.org

Real Business Real People Real Members John Hart is proud to be a founding member of AMTIL. Our continued and active participation is fostered by the enthusiastic and engaging staff at AMTIL. Their staff have an intimate understanding of our industry from all perspectives and provide a valuable resource of skill, knowledge, and experience. There are many benefits that come from AMTIL membership, the most valuable of which is its people.

Mark Dobrich, John Hart

Since 1999, AMTIL has been connecting business, informing of opportunities and growing the manufacturing community.

To be become an AMTIL member contact our Corporate Servcies Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

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Cutting Tools

Awards crown centenary year for Sutton Tools

In the midst of Sutton Tools planning its centenary celebrations, the latest awards from Business Victoria are the ‘icing on the cake’ for this manufacturing icon.

As one of Australia’s longest-established manufacturing businesses, Sutton Tools is no stranger to being recognised for its achievements. The latest of these are the company’s induction to the prestigious 2017 Victorian Manufacturing Hall of Fame, and the 2017 “Manufacturer of The Year: Large Business” award.

The awards were presented recently at the Manufacturing Hall of Fame 2017 Gala Dinner and Awards Ceremony, held in Melbourne on 9 May by Business Victoria. The theme of ‘Growing Advanced Manufacturing’ recognised outstanding achievements by Victorian businesses and individuals who uphold a high standard of excellence in Victorian manufacturing.

“The awards were unexpected,” said Sutton Tools’ Managing Director Peter Sutton.

“We were incredibly proud and honoured to receive them on behalf of every Sutton Tools staff member who has contributed so much to our successes of today.”

A century of manufacturing achievement William Henry Sutton’s journey of entrepreneurial enterprise is typical of many skilled early Australian immigrants.

Moreover, he achieved success while maintaining family management of a business that has grown and prospered throughout its first 100 years. The Sutton Tools story starts with William’s arrival in Australia, having left England in 1911, accompanied by his wife and three children.

Already recognised as a leading tool engineer who had worked on the development and production of the Wolseley car, his intention was to establish a new business in the US. Abandoning his plans for America, William decided to settle in Victoria, and at the mature age of 48, he opened a toolroom at Thompson’s Foundry at Castlemaine, more than 128kms north-west of Melbourne.

Sutton Tools’ Managing Director Peter Sutton (left) with State Minister for Industry and Employment Wade Noonan at the 2017 Victorian Manufacturing Hall of Fame Awards.

Rapid expansion By 1925 the original factory had quadrupled in size to satisfy a market demand that had been fuelled by an immediate and enthusiastic customer acceptance of the Sutton products. By 1930 the flood of orders made it necessary to move to larger premises.

Around this time, William’s two sons: Henry George and Leslie, joined the business, their early experiences enriched by serving an apprenticeship training program and

His new employment was interrupted by the outbreak of World War I. The British government had need of his technical skills and unique talents, and he was asked to return to England to help establish the many munitions plants in support of the war effort.

Apart from being a master craftsman, William was gifted with business acumen and guided by sound and prudent management principles. He recognised that a successful and growing business depended on being a market leader and firmly believed in the principle of ‘survival of the fittest’. He clearly understood the value of profitability to business growth and took pride in the fact that no month ever reflected a trading deficit.

Innovation key to growth

Towards the end of the war in 1917, William returned to Melbourne and established the Sutton Tools and Gauge Manufacturing Company in a converted stable at Westgarth in suburban Melbourne. Initial capital investments included a lathe and a small grinder with a milling attachment, while the family bath provided the quenching facility.

Sutton Tools’ founder William Henry Sutton.

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working diligently, often 10 to 15 hours a day, happily taking on tasks that included sweeping the factory floors. They were quickly introduced to William’s philosophy of perfectionism and personal pride in one’s work – core values that without doubt contributed significantly to the production of a range of tools that were quickly recognised as being of equal or better quality than those sourced from overseas.

Similarly to many companies of today, William firmly believed that updating to the latest techniques and materials technology would keep his flourishing business ahead of the competition. As a result, he was always keenly attuned to the latest developments in new manufacturing techniques. New ideas and techniques were actively explored, and better, more efficient processes supported the production of better tools. Innovation

Cutting Heading Tools

Sutton Tools’ workshop over the years.

and technology continue to drive the company’s growth and development as it commences its second century.

By 1940 Henry George and Leslie became joint Managing Directors, continuing the focus on core values and strategy that resulted in ever-increasing sales. While originally the company had begun by manufacturing threads and gauges, it progressively expanded its expertise into a broader portfolio of cutting tools, addressing the needs of diverse industrial applications.

By 1959, the company had outgrown its location and expanded into a 4,180 sqm factory in the northern suburb of Thomastown. Sutton’s investment in quality, research, technology and product development has enabled 100 years of innovation with a number of industry-first solutions. Typical of this approach was a worldwide investigation undertaken in 1960 to adopt the best method of producing the finest drill in the world. Henry George’s son Bill was assigned the task and headed overseas, returning to Australia armed with a “ground-from-solid” manufacturing process that would become best practice globally for premium drill production. The result of adopting this process was a newgeneration drill that was marketed under the name “Silver Bullet”, which remains one of Sutton’s flagship products to this day.

By 1970 it was time for the third generation of Suttons: Bill and Jim, to consolidate and extend Sutton Tools’ position as market leader by following the business’ core commitment to quality, innovation and persistence.

Growth through innovation and acquisitions Until 1989, physical vapour deposition (PVD)-coated tools sold in Australia had to be imported. That year, Sutton Tools established its Surface Technology Coatings business, enabling the company to offer a high-quality Australian product at a competitive price.

The second and third generations of Suttons: (from left) Bill, Henry George, Jim and Leslie Sutton.

The fourth Sutton generation: Peter and Robert, joined the family business in the 1990s, where their combined experience and passion in cutting tools continued the tradition of positioning the company as an Australian champion in manufacturing.

The company began to focus on strategic expansion into export markets, which resulted in the acquisition in 1994 of Patience & Nicholson in New Zealand, followed in 2001 by the acquisition of Patience & Nicholson Australia. By 2006 the company’s export drive had gathered pace, and in that year Sutton Tools sold its fivemillionth drill bit to Germany. So successful was the company’s export initiative into key European markets that in 2009, Sutton Tools Europe was established with an office and warehouse base in the Netherlands.

The family-owned company has always been a champion of Australian manufacturing.

In 2008 Sutton Tools received official accreditation by the Australian Made campaign, and in 2009 Bill and Jim Sutton were inducted into the Victorian Manufacturing Hall of Fame Honour Roll.

The last 23 years has seen production of Sutton Tools’ products audited and certified under ISO 9001 Quality Management Systems, which demands the highest level of systems excellence and quality control.

These strict manufacturing processes are paired with the finest high-speed steel, which is imported from Austria, France and Japan, and far exceeds the quality of imported cutting tools.

A commitment to catering for specific and often unmet industry needs is one of the foundations for Sutton Tools’ commitment to excellence. Its engineering department operates on a platform of class-leading design and measuring technology that simulates, tests and retests tools in the actual conditions in which they will be used, to optimise design, benchmark performance and produce a product that exceeds market standards.

Global partnerships Employing 350 people globally, the company produces 15,000 product lines and exports its tools to Europe and Asia through its own European and New Zealand offices. Its customer industries span precision engineering, automotive, aviation, energy, medical, mining and more, which are supplied with blades, drills, threading taps and end mills.

Alignment with global industrial cutting solutions organisations that have an equivalent commitment to quality and service has been recognised as critical to the success of the company. These include Tapmatic, a 75-year-old firm that is a world leader in the design and development of tapping products.

Sutton Tools has also established a partnership with Ceratizit, the 1921-founded carbide cutting solutions specialist. This joint venture enabled Sutton Tools the ability to offer its Australasian customers a complete range of cutting tools and services that includes carbide inserts and tooling. With the product portfolio of both companies complementing each other in designated cutting tool applications, the partnership leverages the strengths of their respective product lines to offer a broad range of high-performance carbide cutting solutions to the Australian industry.

Another important partner is with the 75-year-old Allied Machine and Engineering (AMEC), a manufacturer of metal-cutting tooling. Serving all facets of manufacturing industries such as aerospace, defence, agriculture, automotive and mining, Allied’s precision engineering and expert applications make it the supplier of choice for complex metal-cutting challenges. This alliance expands Sutton Tools’ cutting tool portfolio with the inclusion of replaceable-tip drilling systems.Building on the knowledge and skills of previous generations Sutton Tools is well poised to continue its command of the tool industry into its second century. www.suttontools.com

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Cutting Tools

Sandvik Coromant unveils a revolution in turning Sandvik Coromant has unveiled PrimeTurning, a new turning concept that offers improved machining flexibility and the potential for significant productivity gains, providing manufacturers – particularly in aerospace and automotive – with the industry’s first true ‘all-directional turning’ solution.

While conventional turning operations have remained largely unchanged for decades, PrimeTurning allows machine shops to complete longitudinal (forward and back), facing and profiling operations with a single tool. The methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This allows application of a small entering angle, higher lead angle and the possibility of machining with higher cutting parameters. Furthermore, conventional turning (from part-end to chuck) can be performed using the same tools.

Sandvik Coromant believes some applications could see productivity increases in excess of 50% through deployment of PrimeTurning.

Some of these improvements are due to the small entering angle and higher lead angle, which creates thinner, wider chips that spread the load and heat away from the nose radius. The result is both increased cutting data and extended tool life. In addition, as cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming (a common, unwanted effect of conventional longitudinal turning). Higher machine utilisation due to reduced set-up time and fewer production stops for tool changes also enhances overall productivity.

PrimeTurning will be particularly beneficial to manufacturing industries such as aerospace and automotive where there is a need to perform external turning operations in big batch productions or where multiple set-ups and tool changes are often required.

“Experienced operators know that a small entering angle allows for increased feed rates,” says Håkan Ericksson, Global Product Specialist at Sandvik Coromant. “However, in conventional turning they are restricted to using entering angles of around 90 degrees to reach the shoulder and avoid the long, curved chips that a small entering angle characteristically delivers. PrimeTurning solves these problems by combining a perfect reach at the shoulder and the application of 25-30-degree entering angles with excellent chip control and maintained tolerances. This innovation presents countless possibilities to perform turning operations in much more efficient and productive ways. It’s not just a new tool, but a totally new way of turning.”

PrimeTurning is initially supported by the introduction of two dedicated CoroTurn Prime turning tools and the PrimeTurning code generator, which supplies optimised programming codes and techniques. CoroTurn Prime inserts have three edges/corners: one for longitudinal turning, one for facing and one for profiling, thus delivering efficient edge utilisation and longer tool life.

Two unique and dedicated inserts are offered: CoroTurn Prime A-type features three 35-degree corners and is designed for light roughing, finishing and profiling, while CoroTurn Prime B-type with its ultra-strong corners is designed specifically for rough machining. Suitable for ISO P (steel), S (heat-resistant super alloys and titanium) and M (stainless steel) category materials, nine CoroTurn Prime A-type and six CoroTurn Prime B-type inserts are currently available, with expansion to other materials envisioned for the future. The inserts are supported by 52 variants of tool holder, including Coromant Capto, CoroTurn QS and shanks.

The PrimeTurning code generator not only ensures maximum output but also process security with suitably adjusted feed rate and entry radius parameters. It creates ISO codes that are compatible with various CNC systems. www.sandvik.coromant.com/primeturning

AMT Jun/Jul 2017

Partnership to advance Digital Manufacturing

Sandvik Coromant has signed a strategic research agreement with PARC aimed at strengthening its capabilities in digital manufacturing.

PARC will provide Sandvik Coromant with a footprint in Silicon Valley and expert resources for R&D in the field of digital manufacturing. PARC will allocate resources to conduct research and develop technologies for Sandvik Coromant.

Sandvik Coromant will also acquire all intellectual property (IP) and technology related to PARC’s software for highlevel process planning and automated manufacturing cost estimation for subtractive manufacturing.

“This partnership is a natural step and in line with Sandvik Coromant’s long-term strategy to develop attractive solutions in the field of digital manufacturing and Industry 4.0,” said Magnus Ekbäck, Vice-President and Head of Business Development and Digital Machining for Sandvik Coromant.

“With this cooperation we will significantly strengthen our capabilities within digital machining.”

“Manufacturing is entering a dynamic new phase as the cyber and physical worlds converge, and the complex and diverse industry needs significant innovation to truly progress,” said PARC CEO Tolga Kurtoglu. “The missing piece for complete design automation and manufacturing of complex products has been the integrated coupling of design and manufacturing, which we have been developing at PARC for many years.

We’re pleased to partner with Sandvik Coromant to see these innovations come to life on the global stage.”

PARC has been developing digital manufacturing technologies for government agencies and commercial clients for almost a decade. Its suite of technologies helps designers and manufacturers understand real-world manufacturing process constraints during digital product design and identifies potential limitations of a supply chain early in the design phase, minimising time-to-market and improving product quality.

Tolga Kurtoglu (left), CEO of PARC, and Magnus Ekbäck, Vice-President and Head of Business Development and Digital Machining at Sandvik Coromant.

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Cutting Tools

Iscar – A welcome power cut

The quest for reducing levels of power consumption in the global metal cutting sector is not a new trend; today it has become an essential technical requirement. Industry’s greater understanding of its environmental protection and sustainability responsibilities has ensured the development of processes, materials and machines that significantly reduce power consumption during machining operations.

In addition to ensuring more efficient machining strategies, when compared to their heavy-duty predecessors, modern machining centres require less power while delivering improved performance capabilities.

Previously, a typical production process was divided into primary and final cutting tasks that were performed on two machines. The first powerful machine removed most of the stock, and a more precise procedure was then used to achieve the final required shape and to create the necessary surface finish. Today, a single process often achieves these results in half the time.

Fast machining with less load results in increased productivity and consumes less cutting power. In addition, the reduction of power means that the forces acting on the machine’s main units (spindle, guidelines, etc.) are cut, which improves tool life and makes machining much more accurate and predictable.

are defined by the topology of the insert rake face and the insert positioning in the cutter. The topology is a key factor in varying rake angles.

In the early 1990s, Iscar introduced the HeliMill – a family of milling tools carrying indexable inserts with a helical cutting edge. The highly effective edge was generated by the intersection of the shaped insert top (rake) face and the helical insert side (relief) surface. The design of the HeliMill tools formed a constant positive normal rake and a positive axial rake along all cutting lengths. This feature immediately caused a significant reduction in power consumption and ensured a smooth cut.

Thus, the HeliMill heralded a new design

Leading-edge cutting geometry

The standard rake significantly affects the tangential cutting force and is the main determinant of the cutting power required if all other parameters are equal. The axial rake has an effect on resolving the total cutting forces into components and, therefore, acts on the tangential cutting force as well. With respect to milling cutters carrying indexable inserts, the rake angles

AMT Jun/Jul 2017

The increasing use of the term “high positive”, when describing modern milling inserts, emphasises the dynamic changes in indexable topology. Such a definition reflects the current state of the art. As the production of tools with cemented carbide inserts does not deplete topology resources, we may assume that the “high positive” of today will be considered as “normal” tomorrow. Increased optimisation of the topology will lead to an additional reduction in cutting power.

Run faster with less power demand

Cutting tools have a major role to play in this area.

Total power requirements can be moderated by the use of advanced new tools, in particular, innovative milling tools offer promising opportunities.

When milling, power consumption depends on several parameters, including workpiece material, depth and width of cut, cutting speeds and feeds. A combination of these influences defines the material’s resistance to machining, and therefore the total cutting force generated during the process. There is one more important factor closely connected with these forces – the geometry of the tool being used; more specifically, the tool rake angles in both normal and axial directions.

increasing both the inclination of the rake face and the helix angle of the cutting edge, all without loss of strength. Iscar’s insert H690 WNMU 0705 is a good example of the steeply inclined different-in-heights rake face of an insert that enables lower power consumption.

approach that is considered today as the acknowledged format in indexable milling, and put the shaped rake face of an insert into the forefront.

When attempting to increase the rake, a tool designer seeks to incline the rake face of an insert more aggressively with respect to its cutting edge. However, in this area there is a serious limitation in that this incline weakens the insert’s cutting wedge and therefore has a negative impact on strength. The helically-formed edge causes a difference between the heights, which are measured in adjacent corners of the insert.

Producing such uneven sintered products is not a simple task and its creation requires serious technological efforts.

Today, advances in powder metallurgy provides many more opportunities for

It is commonly believed that machining at full capacity is an effective means for improving productivity. Rough milling deep cavities with the use of extended flute cutters or face milling by large-sized shell mills at a large axial depth of cut, when stock per pass is considerable, are typical examples of such an approach. These operations provide a high metal removal rate (MRR) but are evidently power-intensive, as milling under such conditions requires a significant cutting force and necessitates the utilisation of machine tools with heavy-duty main and low feed drives. In this case, high efficiency is ensured by removing material of maximum possible cross-section at lowto-medium feeds.

At the same time, another rough milling technique proposes a diametrically opposite principle: the combination of a rapidly running tool with a shallow depth of cut. In this case, power consumption drops dramatically with no loss in productivity – the tool works at extremely high feeds guaranteeing efficient metal removal. This energy-saving shallowcut “fast” technology provides a good alternative to power consuming deep-cut “slow” technology. High feed milling (HFM), which can be successfully realised on

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impact 20.02% modern, light-duty fast moving machines, has delivered a serious and sustainable alternative to the traditional yet powerconsuming approach.

HFM (“fast feed”) tools feature specific geometry. Iscar offers them in all of the company’s milling lines: indexable, solid carbide and Multi-Master (a family of assembled tools with replaceable cutting heads produced from cemented carbides).

In addition, Iscar has introduced inserts that, when mounted on general-use indexable endmills or face mills, turn into HFM tools. Such a transformation is a way to simply adjust various cutters from Iscar’s standard line for fast feed milling.

Alternative machining strategies challenge deep-rooted techniques Substantially expanded opportunities for modern machining tools have led to new milling strategies that, amongst other advantages, reduce power consumption.

An example is turning heavy-weight parts. When turning, cutting speeds are traditionally ensured by rotating a part. If the main drive of a machine tool is unable to rotate a part of large mass with the required velocity, the achieved cutting speed will fall short of the necessary range. Such a limitation causes a loss in performance in turning operations.

It is no wonder that trochoidal milling has been utilised successfully in manufacturing parts with complicated slots and grooves, such as blisks (bladed disks), blings (bladed rings), impellers, etc., especially those with relatively thin walls. Iscar has recently introduced Ti-Turbo – a family of solid carbide endmills ECK H7/9-CFR that have a unique cutting geometry with seven or nine flutes, different helix and a variable angular pitch. The main application of the new family is trochoidal milling workpieces, which are made from difficult-to-cut titanium grades.

Applying new machining strategies with correctly chosen milling tools creates new opportunities for power-saving. Reducing machining power is one of the necessary conditions of modern manufacturing.

The latest machine tools provide the metalworking industry with the means suitable for high performance and energyefficient technology. The sustainable cutting tool not only cuts metal productively but also cuts power consumption – a major factor in Iscar’s success. www.iscar.com.au

outcome 4.89%

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AMTIL PRODUCT E-BLASTS call anne samuelsson on 0400 115 525 or email asamuelsson@amtil.com.au for all enquiries.

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AMTIL1305

Today, advanced multifunctional machining tools offer an effective solution: turnmilling, a method combining milling and turning, where a milling tool cuts a rotating workpiece. The majority of Iscar indexable face mills and endmills can be applied to turn-milling; however, correct tool positioning and the calculation of cutting data require a more profound understanding of the specific features of this process.

The conventional milling of slots or grooves starts from the machining of solid material directly at full tool engagement. Milling with full tool engagement requires increased cutting forces and, as a consequence, consumes more power. A high speed trochoidal milling technique can be a worthy alternative to the common slot milling strategy. In trochoidal milling, a rapidly rotated tool machines the slot by arc motion at a significant depth of cut and very small width of cut. The tool slices thin layers of material with both high speed and high feed rates. This productive method features a noticeable reduction in power consumption.

average open rates

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Cutting Tools

Ten simple steps to peak performance and productivity

All machining shops face the same task: converting raw material into finished workpieces, to a specified quality, in the required quantity, and delivered on time, with sustainability and environmental issues resolved as well. By Patrick de Vos, Corporate Technical Education Manager, Seco Tools.

To remain competitive and profitable, shops continually seek economical, productive ways to accomplish their work. The ultimate example of those process improvement efforts today is in Europe called “Industry 4.0”. Integrating state-of-the-art data acquisition, storage and sharing technologies into the manufacturing process, Industry 4.0 is presently the top level of manufacturing’s evolution, requiring strong management commitment, specialised personnel and significant investment.

Unfortunately, shops that lack the resources of global industrial giants such as General Electric or General Motors may feel that productivity improvements are out of reach. However, simple, cost-effective analyses and actions can have a large positive effect on the productivity of any operation. Before investing in new computers, robots or personnel, any shop – large or small – should perform basic process analysis and organise current equipment and practices. Computerisation of disorganised shop operations results only in computerised disorder.

Organisation of shop practices begins by viewing the production process as three phases. First is a selection phase, involving choices of cutting strategy, tools and cutting conditions. The next phase is collection, in which selected tools and strategies are grouped together in a machining process. Realisation is the third phase and puts the process into action. In many cases, phase three fails to meet expectations, and certain steps are needed to bring reality in line with preparation. The steps can be technical in nature, such as seeking ways to moderate cutting forces, or economic, including actions to reduce costs.

Fortunately, there are ten simple steps that will enable a shop to analyse and improve its metalworking operations. They are as follows:

Intelligent budget control A common approach to budgeting in metalworking operations is to acquire every element of the process at the lowest price possible. However, it is best not to base tool selection on price alone. Before discussing prices, a shop should consider the desired end results. If a tight-tolerance, top-quality part is the goal, moreexpensive precision tooling will be required to machine it. The cost of struggling with bargain tools to achieve high part quality and producing unacceptable parts will exceed the expense of higherpriced tooling. On the other hand, when quality demands are less stringent, a portion of the capabilities of high-precision tools will be wasted. Recognising the ultimate goal of the process is the first step in cost-effective purchasing decisions.

Intelligent handling of constraints Real-world metalworking operations, as opposed to theoretical discussions of metalworking theory, are bound by practical constraints that include machine power and stability and customer demands regarding dimensions and surface finish quality. Cutting conditions can be varied over a wide range, but the effects of different combinations of parameters on cutting forces and surface finish may limit some choices. Nonetheless, simply reducing cutting parameters overall is not an intelligent way to deal with process constraints. For example, changes in depth of cut have a greater effect on the consumption of machine power than changes in feed rate. The combination of decreasing depths of cut and increasing

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feed rate can improve productivity within the constraint of limited machine power.

Tool application rationalisation Considering the massive number of tool geometries, sizes and materials available, the possible configurations of metal-cutting tools are practically endless. Machine shops typically make tool application choices one operation at a time, choosing a specific tool to create a certain feature on a part and then picking another tool to machine another different feature.

In an example case, two separate tools would be used to turn a shaft and produce a wide groove with two square shoulders.

Specifically, one tool turns the shaft to the desired diameter and cuts one shoulder and the width of the groove, followed by a second tool that cuts the other shoulder. Each tool is programmed and optimised separately, representing separate programming and administrative costs.

A contrasting tool selection strategy is to develop a highlyspecialised custom tool that can create multiple features in one machining pass. The strategy is convenient but the design and manufacturing of special tools is expensive.

Between the two extremes is an approach that utilises a standard tool engineered to perform more than one operation (multidirectional tooling). A perfect example of this approach is a Seco’s MDT tooling. The tool’s features enable it to turn the diameter, plunge in to create one shoulder, move across the shaft to cut the groove, then withdraw to form the second shoulder. Even if such a multidirectional tool does not operate at the optimised cutting parameters of the two separate tools, the savings in tooling, programming, tool change time and inventory costs make the multidirectional tool the preferred choice.

Cutting Tools

Complex workpiece approach (group technology)

Practical work analysis

Comparable to the technique of applying tools that combine two or more operations, a shop can choose tools that are capable of creating similar features across a range of workpieces. A shop may machine a wide range of different workpieces, but the workpieces will share common features such as holes, slots and milled surfaces.

In his 1907 book ‘On the Art of Cutting Metals’, American engineer and work analysis pioneer Fredrick Winslow Taylor noted that some of the activities in a workshop, such as milling a surface, clearly add value to a workpiece. On the other hand, he noted that many activities that are necessary for the production of a finished workpiece do not directly add value. These include fixturing the workpiece on the machine or writing the machining program. Taylor said that non-value-adding tasks should be completed as fast as possible and in a way that minimise their effects on the total costs of production. Automation can accomplish tasks such as part loading and fixturing and save time and money.

To expedite the machining of complex parts, a shop can view similar features as a group and choose a tool optimised for a certain operation, such as hole-making, that is repeated on different parts.

The optimised tool maximises productivity and also reduces cost when considering the engineering time that goes into repetitively programming tools for each separate part. The group technology approach also helps reduce tool inventory.

Achieving minimal functional workpiece quality Although the concept initially may seem strange, shops must realise that it is necessary to achieve only the lowest possible workpiece quality that meets customer specifications and functional requirements. There is no need to exceed those requirements. If a part tolerance is five microns, achieving three microns is a waste of time and money. Higher quality tooling and more precise operating processes will be required to achieve the tighter tolerance. But customers will refuse to pay for such unrequested higher quality, and the job will be a money-losing proposition for the shop.

Some quality issues, such as burrs, obviously must be resolved.

And there are situations where minor cost considerations are irrelevant – tool cost differences of a few cents are meaningless when compared to the value of a large titanium aerospace component the tool will machine. To maximise cost efficiency, a shop should tailor production quality to the functional and quality requirements of the workpiece.

Predictive tool maintenance Traditional tool maintenance is reactive. When a tool wears out or breaks, it is replaced. That approach, however, generates costs beyond those of the tool itself, including manufacturing process downtime and possible damage to the workpiece. Preventive tool maintenance is a step beyond reactive maintenance.

The useful lives of even identical tools usually vary above and below an average length of time. Preventive tool maintenance is based on replacing the tool before it reaches its shortest expected working life to be sure that the change is made before the tool wears out too much or breaks. That approach, however, wastes tools with a tool life that is at or above average.

A relatively new approach, based on tool life modelling, uses computer calculation and simulation to provide predictive data on tool deterioration and to indicate when replacement is due. At a somewhat greater expense, use of sensors can further fine-tune the results by tracking tool wear in real time. Use of predictive tool maintenance has the potential to reduce tooling costs by 20% or more.

Tool inventory control When dealing with the second– collection – phase of metalworking production, it is important to note that tool inventory control is different than tool management. Tool management refers to organising an existing tool inventory and making it available for production. For that task, a variety of automated tool management systems is available. Tool inventory control, on the other hand, is an effort to rationalise and consolidate the number of tools a shop possesses to focus on what is really needed. If tools are not rationalised before being loaded into an automated tool dispenser, the result is simply automated disarray.

Manufacturers typically believe that the best way to reduce processing time is to increase machining parameters. Most shops do not fully recognise the time consumed by activities such as engineering, a task that can represent as much as 40% of the total time for a part to travel from drawing to delivery. Unplanned downtime caused by tool failure, quality issues or chip control problems also may be overlooked. When analysing work activities and costs, it is essential to consider all the contributors to part production time.

Practical application of optimisation The third phase of metalworking part production, the realisation phase, puts into action the tools and strategies selected in phase one and collected in phase two. Rarely if ever does a process work exactly as planned, and it is at this point where optimisation of the operations in terms of speed, reliability and other factors is necessary. Additionally, most shops also seek to improve ongoing processes. After carrying out the organisation and rationalisation steps of phases one and two, practical optimisation enables a shop to find technical and economic benefits in a combination of feed, speed and depth of cut that produces the desired results.

Intelligent introduction of new technology Manufacturers today face a range of relatively new challenges including mandates for sustainability and environmental protection.

Intelligent introduction of new technologies and processes enables shops to fulfil the challenges. Dry machining, for example, permits a facility to reduce the use of coolants, which in turn reduces the potential effects of the fluids on the environment as well as the cost of safely disposing them. Growing use of lead-free workpiece materials is aimed at removing the harmful metals from the environment. Improving process parameters and production tooling performance will result in measureable savings in energy expenditures.

Conclusion: Phase 4 and STEP education As manufacturers of any size utilise the ten simple steps to improve their operations, a fourth phase of the production process involves ongoing internal education. The goal of that education is to ensure shop personnel realise solutions to productivity issues do not always necessitate huge investments, high technology and expanded workforces.

The lessons learned while improving an operation or a family of operations can be reapplied and expanded to include similar situations throughout an entire shop. These lessons can be supplemented with organised education such as the Seco Technical Education Program (STEP), a well-developed and practical program designed to familiarise users with the latest tooling systems and techniques. Combined with practical experience in process analysis and improvement, education is the key to establishing a culture of problem-solving and process improvement that will result in ongoing manufacturing success. www.secotools.com

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Company Focus

Avtech Engineering – Thriving despite the downturn

While the current downturn in Western Australia’s mining and resources industry is undoubtedly having an impact on local manufacturers, Perth-based Avtech Engineering is still finding strategies to succeed. By Carole Goldsmith.

Avtech’s owner and Managing Director Steve Delfos, with the company’s new Mazak Quick Turn Smart 300M turning centre.

Avtech manufactures precision components and tools for companies that supply the subsea, mining and resources industries. It also produces parts for local and international manufacturers of CNC machinery, and for industrial safety switch component businesses. Nonetheless, according to Avtech’s owner and Managing Director Steve Delfos, the extractive sector inevitably casts a major influence on local manufacturing.

“Being WA-based, most manufacturers are connected somehow to the mining industry,” he says. “Avtech makes components for the companies that manufacture products for the mining, oil & gas industry. We produce tools to support exploration and drilling areas for mining.

This includes ‘down-the-hole’ equipment and tools used in the surveying of drilled holes.”

For its oil & gas industry clients, Avtech produces various traceable components for subsea, maintenance, exploration, production and recovery tools. These will end up being used worldwide by some of the largest subsea companies.

“We also precision manufacture cylinders, rams, manifolds and valve blocks for the hydraulics industry and cases, standoffs, brackets, chassis and electro-mechanical components for the mechatronics and electronics industry,” Delfos adds.

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Avtech has extensive experience in machining high-strength alloy steels, stainless steels, titanium, aluminium, brass/ bronze, cast iron, Inconel, plastics and exotic materials for local and overseas industries who rely on consistent, highquality precision components manufactured on time, every time.

“In 2005, I became a partner in Avtech, and in 20O7, I bought the business outright and became the Managing Director. With this opportunity, I carried on the same philosophy as Geoff, building the company, purchasing the latest equipment, and growing the business by taking on the challenges that others would say no to.”

From machinist to MD

Delfos proudly describes some of machines that enable his company to produce custom-manufactured products. Avtech uses the latest quality CNC machines and tooling, with features that provide customers flexibility and efficiency for the manufacture of their components.

Delfos is a success story in himself. After his apprenticeship, he spent several years selling CNC machines, before going back into the industry as a machinist at one of the largest repetition machining companies in Perth. He worked his way up to become the Production Manager, and finally spent four years as General Manager, steering that company through a change from mass production to smaller volumes as the market changed.

On the lookout for a fresh challenge, Delfos took the General Manager’s position at Avtech when the company’s founder, Geoff Mullet, offered him the role in 2002.

“Geoff started the business in 1979, and built it by taking on the impossible jobs and getting them done efficiently,” says Delfos. “He bought the latest equipment at the time, that was needed to complete the wide range of ongoing projects. In this way, he placed the company ahead of the competition.

“We continually invest in CNC machining technology, including a large selection of high-tech machine tools for precision component manufacturing,” says Delfos.

“The majority of our CNC lathes have ‘live’ tooling with Y-axis ability and bar feeds to some. Our Mazak five-axis Integrex machine gives Avtech’s customers freedom for design. We do a lot of prototype and complex work on this machine, which would otherwise take several operations or not be possible at all.”

Avtech’s CNC milling department has fourand five-axis capability, supported by the SolidWorks-based Camworks software, which has significantly improved the company’s ability to turn its customers’ models into reality.

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“To further support the design department, we have also introduced a Faro arm, for the reverse engineering of complex shapes as well as the checking of finished parts,” Delfos adds. Avtech was also awarded ISO 9001 accreditation in 2016 with all systems and processes approved.

“We believe this gives our customers the comfort that their components will be made under a recognised system,” says Delfos.

“And that all certification of materials and as-built measurement reports can be supplied as required.”

Bouncing back Delfos says that these days the company is going strong.

“We went through a downturn in 2015 with a 40% reduction in turnover and our staff numbers dropped from 16 to 10 people,” he says. “Since then, we have bounced back, and we are making parts for a diverse range of companies that export their products. We have used the downturn as an opportunity to address how we do things, and have become more efficient in the process. We also identified our markets and kept them as diverse as possible.”

One example of its diverse client base is a manufacturer of mining surveying equipment. Sold around the world, this equipment is used to ensure the drilled hole they drill is in the right spot and in the correct direction. It’s also used in the tunnelling industry.

Another major client conveyor safety switches.

manufactures

“We make the machined components for their safety switch,” says Delfos. “These switches are used to switch off the conveyors in the case of emergency, and to detect when large rocks or poor belt tracking occurs. “With this client, we have built a very strong relationship. When they come up with the ideas, we assist in the design and manufacture the component.”

Delfos adds: “We also make a lot of tools for the subsea industry operators.

They use these tools together with a subsea ROVs (remotely operated vehicles) to remotely cut or install and maintain components on the sea floor in oil exploration. These tools are designed by the tooling design team (our client), who then gets the final customer’s approval, and then needs us to produce them in a very small window of time, often with fixed deadlines. This can be very challenging. It has been said that we are successful in the supply of such tools due to our accuracy and on-time delivery.”

Assistance in improvement Since 2009, Avtech has received several government grants to assist the business.

With some of them, Delfos was alerted to

“As a priority to move the business forward, Avtech’s business plan, website and logo were developed soon after,” Delfos adds.

“This has helped with marketing and business expansion.”

A selection of components produced from various materials

the possibility by AMTIL. A member since 2005, Delfos believes AMTIL has helped contributed to Avtech’s business success.

“AMTIL’s (Corporate Service Manager) Greg Chalker assisted Avtech to get Federal Government funding, on a 90%-government/10 %-Avtech basis, in 2009,” Delfos says. “This grant was for system training on the 5S program, to assist the company to streamline the factory floor.

The 5S system, Delfos explains, is: ‘Sort the factory out’; ‘Set in order’; ‘Shine’ (i.e. keep the factory clean); ‘Standardise’ (having everything in place for each workstation); and Sustain (keeping the system going).

The process was quite daunting, but the change it brought in Avtech’s operations was very rewarding.

“Further to this we learnt about our process inefficiencies in the paper trail from quote to invoice,” Delfos adds. “With the implementation of new software ‘Job Commander’, we were able to reduce our office staff, and have real-time planning for job completion, all in the one system. Now, via my mobile phone, I can show my client the progress of his job whilst in his office.

Impressive!”

The Federal Government’s Enterprise Connect program (now superseded by the Entrepreneurs’ Programme) conducted a free business review for Avtech in 2009.

Delfos advises: “This review revealed that we needed a business plan, a website and a logo, all of which we did not have at the time. Enterprise Connect provided a $25,000 grant on a 50-50 basis to get these three business additions developed.

This was in a tough time (during the GFC) to come up with the extra cash, but the end result was very rewarding.

AMTIL also assisted Avtech in 2015, by arranging an AusIndustry representative site visit to see how the business was progressing. This was after the previous business review and to offer further business advice. It was through this visit that Avtech received 50-50 assistance in gaining its ISO accreditation.

Delfos handles the company’s sales and marketing, with the Production Manager responsible for the factory’s day to day operations.

“Most of our sales come from word of mouth and from our website,” says Delfos. “We thrive on challenges and everyone in our team works together to achieve success by providing custom-made products for our clients, on time. Our strengths lie in working with clients to design components and tools in line with our CNC machines’ capabilities.”

On the export front, Avtech has been making model jet engine components for a Singapore company, as well as parts for diving re-breathing equipment units for a UK business. Manufacturing 10,000 brass standoffs for China, was a surprise project, reveals Delfos.

“Whilst exporting is not high on our priority list, we have had surprising success in areas that we are good at, and as usual, the exchange rate has a huge effect on being commercially viable,” he says. “We built our business by providing value to our customer. By encouraging and supporting our employees to gain more knowledge, in turn they help the company grow.

“If you look at our logo, there are two grey lines that make up the right-hand side of the letter A. The higher darker stripe is us, being at the pinnacle of our industry, and the other lighter one is our client. As we come down the path together we work to achieve success at the crossover, which now puts the customer on the top, and being longer than the darker line, now places them ahead of their field.”

Avtech puts a lot of effort into this and sees customer relations and its skilled employees among the main reasons for its ongoing success.

“Our forward plans are to continue to improve our systems and conduct staff training to meet our expanding markets,” Delfos says. “We will continue to look at and invest in the latest equipment to support our clients’ increasing level of requirements.” www.avtech-eng.com

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State Spotlight Western Australia

High-tech manufacturing advances Western Australia economy Three Western Australian advanced manufacturers are successfully adjusting to a changing economic climate in the state, helped by the latest high-tech equipment from Okuma Australia.

‘No Till’ farming is a new crop planting technology that gained momentum in the early 1990s. Brothers Geoff and Mike Glenn were instrumental in developing this cutting edge technology that revolutionised and brought significant changes to the industry. In 1993 Geoff and Mike founded Agmaster, a company dedicated to the manufacture and distribution of advanced No Till seeding systems, press wheels and rotary harrows for larger-scale crop production farming enterprises across Australia.

With extensive farming backgrounds, Geoff and Mike both embarked on an extensive education/seminar program, initially throughout Western Australia before expanding their activities to the cropping regions in the eastern states. From the initial ‘No Till’ concept there has been a continuous stream of agricultural innovations emanating from AgMaster such as Star Harrows, Steel Coil Harrows, Slip and Clip Points, Presswheels, precision seed placement boots and more recently kwik fit systems.

Located in Welshpool, in Perth’s inner south-eastern suburbs, Agmaster remains a privately owned family business. Its workshop is equipped with some of the latest manufacturing technology enabling the company to carry out advanced production processes with automated machinery including robot welding, CNC plasma cutting and other technology.

Castings are also predominant throughout the company’s extensive range of products. Agmaster press wheels has adopted 3D printing in plastics for the production of prototypes prior to committing to casting patterns and moulds, with the expression ‘A picture is worth a thousand words’ proving itself time and again for the company. All 3D printing activity is carried out in house, and has been instrumental in the rapid development of prototypes. This process has also fasttracked developments enabling new products and modifications to existing components to be brought to market faster, providing a distinct edge over competitors.

Nonetheless, despite such innovations, Agmaster also depends on more traditional subtractive manufacturing processes, and in this area the brothers do not hesitate in stressing the importance of its line-up of state-of-the-art machinery from Okuma Australia.

“Okuma machines have played a significant part in the success of Agmaster,” says Geoff. “Their reliability, along with outstanding consistent quality and the precision of components over the last 17 years, has seen the company to now invest singularly in Okuma.”

Indeed the company has just added a sixth machine, with the recent commissioning of an Okuma Millac 800VH machining centre with OPS-P3000MA control.

“The machines, product support, service and training offered by Okuma are excellent and go well beyond reasonable commercial expectations,” Geoff adds. “There may be a lot of good machines out there, but for us, it is all about what stands behind the machines.

It has been a fantastic experience, hence the loyalty to Okuma, with Agmaster considering Okuma to be more a business partner than a supplier of machines.”

Parts produced or processed on the Okuma machines include press wheel components and associated products, castings, ground engaging equipment, seeding points, seed placement tools as well as fertiliser compound and liquid fertiliser componentry.

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According to Geoff, the Okuma machines’ capabilities have enabled Agmaster to further redesign/refine components to meet market-specific needs, consolidating its status as market leader. Furthermore the company has been able to develop more sophisticated products, providing a distinct market advantage over its competitors, particularly those trying to copy or imitate Agmaster’s developments. Geoff goes on to say that, in his and Mike’s experience, the Okuma machines have opened their manufacturing processes up to fast, extremely reliable and very complex machining capabilities.

Whilst the economy in Western Australia overall is making conditions tough for some businesses, the agricultural market is very good for this progressive company. Heavy investment in sophisticated advanced equipment to gain a strong market advantage have been instrumental in the company being recognised as a national leader in the agricultural industry. Approximately 30% of sales for the company are achieved within Western Australia and 70% across the southern parts of Australia. While export sales have not been a focus for the company it has product in South Africa, Brazil, Argentina, Chile and New Zealand.

ALL-Go Engineering – Investing in capacity Based at Naval Base, a heavy industrial suburb south of Perth, ALL-Go Engineering is a quality assured specialist in the supply and repair of a wide range of mining and oil and gas components with more than 28 years’ experience. Key services provided for the oil and gas industry include drill tool refurbishment, restriction nozzles, pump parts and frames, heat exchanges, orifice flanges, spectacle blinds/spades, ring type joint (RTJ) and custom-made flanges, and fittings and manifolds. For the mining industry the company’s services include the repair and manufacture of cone and jaw crusher components, conveyor pullies and shafts.

The capacity and range of machinery, particularly large capacity machines, enables ALL-Go engineering to complete jobs that competitors cannot undertake. This, combined with highly skilled tradesmen, makes the company a one-stop shop for large and small mechanical engineering work.

Western Australia Heading

Over the last 10 years Okuma machines’ quality output have been fundamental to the development of the business, and the commissioning of the latest CNC MCR-A5CII double column machining centre with OPS-P300M Control has resulted in machining times dropping by up to 30-40%, along with drastically reduced set-up times.

“Our 30-plus staff at ALL-Go consider it a privilege to work on the Okuma machines which are user-friendly, easy to program and have unparalleled service back-up,” says ALL-Go Managing Director Phil Vergone. “Whilst the economy in Western Australia has been negative there has been a marked turnaround in business confidence due to increased iron ore prices and new naval and defence contracts.”

Such is the confidence within this company in servicing the West Australian market that a new building is underway that will further lift capacity by more than 50% with further investment in heavier and larger machines.

Future Engineering – Expansion ahead Currently based in Cockburn Central, 24 kms south of Perth’s central business district, Future Engineering is another precision engineering company with confidence in the economy, with relocation plans set to double the size of the plant and take on more staff. Future Engineering has been servicing a wide range of industries for more than 26 years and has invested heavily over the years in up-to-the-minute high-performance CNC machinery to keep abreast of industry standards.

The diverse customer base for this company covers industries such as oil and gas, railway maintenance, mining, building , food, automotive and defence, all of which are reliant on accuracy and reliability, catered for with skilled operators and a range of Okuma machines. The company offers CNC milling, CNC turning, wire cutting, welding and fabrication, engraving and surface grinding from one-off prototypes to large production runs.

Future Engineering has achieved Quad Certification and is certified to the new ISO 9001:2015 Quality Assurance Standards. It has recently commissioned new computerised laser CMM inspection equipment to meet any inspection requirements and offers quality document packages for traceability. Future Engineering is increasing investment in new technologies to ensure it meets and exceeds future manufacturing standards.

“Future Engineering has enjoyed a wonderful business relationship with Okuma over the last 20 years and new business has grown as a result once our customers know that we have invested in highprecision plant such as Okuma machines,” says Future Engineering’s Managing Director, Alex Ardizzone. “I have visited the Okuma factory in Japan, and the solid and rigid construction provides us with consistent precision results in fine-tolerance outcomes.

The technical expertise of the company flows down to Australia where service is excellent and modern advances in software programmes continually move ahead providing further advantages.”

The latest Okuma machine installed by the company is the multitasking Multus U4000-2SC x 1500 model CNC lathe with OSP-P300S control.

“There has been a noticeable improvement in the Western Australian economy and we are experiencing increases in production and have a busy year ahead with upward trends requiring extra shifts and additional skilled staff,” says Alex. “Whilst the bulk of our business is in Western Australia, we are also enjoying indirect export business and new defence contracts as we head into the future on a very positive note.”

Examples such as Agmaster, ALL-Go and Future Engineering reflect the experiences of Okuma users in other states. Highly successful Australian manufacturing companies are enjoying benefits such as the strength of the machine builder and its continuous development; the long-term quality the equipment achieves; local partnership support above and beyond the usual “buyer and seller” relationship; and the clarity of operation of the equipment. These factors put these owners in the prime position to build and grow their businesses. Since 1991 Okuma Australia has followed a path of customer engagement, consultative support, and a policy of attracting and keeping high-level experienced engineers within its ranks, reinforcing the importance of the business partnership between supplier and customer. www.agmaster.com.au www.allgo.com.au www.futureeng.com.au www.okumaaustralia.com.au

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State Spotlight Western Australia

3D printing in the deep blue sea

Subsea equipment manufacturer i-Tech Services has begun 3D printing injection tools using direct digital manufacturing at its operation in Perth.

From laying underwater cables and pipes to offshore oil and gas exploration, modern subsea operations involve some of the most complex systems, constantly challenged by changing ocean environments. Driven by government regulations and market pressure to control oil production and maintain environmentally friendly practices, subsea equipment manufacturers are actively looking for solutions to reduce development and operation costs. i-Tech is one of the leading global providers of remotely operated vehicles (ROVs) and intervention tooling solutions for offshore engineering. It operates one of the world’s largest and most advanced fleets of ROVs to support major global energy companies in many flagship projects in the depths of the ocean.

Pipeline engineers and designers at i-Tech are confronted with problems caused by underwater pressure, unpredictable weather conditions and strong ocean currents in their deep-water operations.

Equipment reliability is of the utmost importance to ensure that tools can be used for extended periods of time with minimal corrosion and damage. To optimise the design, performance and application of its Chemical Stick Injection Tool (CSIT), i-Tech turned to 3D printing.

A Remotely Operated Vehicle (ROV) developed by i-Tech.

Precision enabled by direct digital manufacturing Mounted on an ROV, the CSIT is a modular tool that houses and injects a maximum of eight chemical sticks to protect subsea pipelines and spools up to 86cm in size from corrosion, rust and damage. For larger spools, it takes 60 chemical sticks to provide sufficient protection, and requires eight deployments of the ROV, resulting in high financial and time costs.

In order to improve that process, i-Tech fabricated a new tool that could carry different chemical stick configurations for various spool sizes, and be able to inject the required amount of sticks without multiple ROV launches and recoveries. In addition, the team wanted to design new tools that would enable them to deploy the chemical sticks within four hours at depth.

To fabricate the injection tool – which consists of a deployment head, a main body and an injection head – in different sizes, i-Tech first considered using traditional CNC machining because of the versatility in available materials. However, i-Tech quickly rejected this method due to the prolonged production time and the high volume of material waste, especially when creating the intricate injection heads. The team researched other manufacturing methods, and chose a PolyJet 3D Production System for its capability to build multiple parts with mixed and composite materials in one single print.

Multi-material for enhanced strength and toughness “The injection head is a critical part of the CSIT because it is responsible for protecting the chemical sticks,” said Keith Burch, Engineering Manager at i-Tech. “The system is extremely helpful as we were able to print different end-use parts of a tiny twoinch injection tool in high precision while maintaining strength and durability, such that the small head would not bend or break when it was inserted into the subsea pipelines.”

To strengthen the injection heads and to stabilise the chemical sticks within, i-Tech engineers used a rigid material, VeroBlue, for areas that needed to interface with the tool, and the composite

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Digital ABS material, which delivers high temperature resistance, dimensional stability and smooth surfaces, for the larger injection heads. Engineers printed the smaller heads of the main body by mixing a rubber-like translucent material, TangoPlus, with Digital ABS for better shock absorbance and flexibility.

The i-Tech team was not only surprised by the strength, surface finishing and impact resistance of the printed injection tools, but were also excited about the reduction in production costs and turnaround time, as it meant that they could accommodate more iteration cycles to perfect their design.

“It would take us six to eight days to produce a 66cm injection head through CNC machining,” said Burch. “Now, the same part can be completed within two days. Moreover, we are able to fabricate designs with a customised blend of materials to solve our complex challenges.”

From injection tools to functional prototypes Today, i-Tech has printed more than 35 injection tools, which have been performing well 0n the North West Shelf, off the coast of Western Australia. The team has also enjoyed additional benefits, such as reducing machine-shop backlogs as the injection tools can be printed on demand. Burch has also 3D-printed prototypes for other ROV components, including manipulator jaws for functional tests.

“In subsea operations, we are often presented with a full gamut of real-world complexities. We need to react and improve our designs promptly to catch up with the ever-changing ocean conditions,” said Burch. “Stratasys’s 3D printing solution has never placed any limit on what we want to model and was able to do it quickly and effectively.” www.i-tech7.com www.objective3d.com.au

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Composite 3D printing: A high-strength solution from prototypes to fixtures Arow Global is a small, innovative US manufacturer of window systems for the transportation industry, and is making its first foray into continuous fibre composite materials – by 3D printing them.

“What we’ve used so far is fibreglass and the carbon fibre. Basically to help make our parts a little more rigid – especially some of our drill jigs,” says Joseph Walters, New Product Design Engineer at Arow Global.

“We’ll do carbon fibre inlay around the corners that stiffens the part up to the point that it’s as stiff as aluminium, but it’s also a lot lighter than aluminium.”

Everyday, Walters and the rest of the Arow team know that they made the right call – 3D-printed composite materials can affordably provide the mechanical properties that Arow could previously only obtain with machined metal.

A few months prior, Walters had been faced with a dilemma – to deliver robust, affordable tools and fixtures, as well as to prototype new design concepts for Arow.

His best choice was to outsource parts to a CNC machine shop — using Arow’s own CNC equipment would divert essential production resources. Yet, the cost was still too high and the time too long — parts were hundreds to thousands of dollars, and took weeks.

“There’s no good way to do prototyping quickly without spending a couple hundred dollars for a four-inch tall piece.”

3D printing was an attractive solution for Walters, but had many shortcomings.

While conventional 3D printers complement engineering effort, at factories doing routine machine fixturing, ordinary plastic 3D printing is often too weak or fragile. Metal 3D printing, on the other hand, is simply inaccessible — most solutions of this type are nearly a million US dollars.

In describing his search for an affordable 3D printer to replace aluminium parts, Walters emphasises: “We wanted parts that were useful, so we didn’t want to have a 3D printer that can do only common plastics like PLA and ABS, which are very brittle.

‘Useful’ was one of our requirements.”

Arow’s fixtures and prototypes need to be not merely inexpensive, but reliable. It’s not surprising that Walters initially overlooked composites to fill the role. Although materials like carbon fibre provide incredible benefits, full composites production automation has been available only to first-rank aerospace companies using multimillion dollar robots capable of ATL (Automated Tape Laying) and AFP (Automated Fibre Placement).

Without automation, difficult traditional layup techniques are often beyond the

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reach of modest manufacturing businesses needing affordable parts. Continuous fibre composites have been exotic for 50 years — too expensive and too elaborate for everyday use. Until recently, Walters would have considered an automatic carbon fibre printer to be science fiction.

However, the world is changing quickly for composites. For several years, 3D printed parts made of reinforced plastics have been available from 3D printing service bureaus using laser sintering to melt thermoplastics. However, since 2015, the availability of automatic, on-site composites manufacturing has exploded. New desktop 3D printers marry the tough, non-marring properties of thermoplastic with short chopped fibres — or in some cases continuous strand carbon fibre, Kevlar or glass — to inject high-end aerospace materials into commonplace shop jigs and tools. Users of these new 3D printers are often unfamiliar with composites, and are not displacing composites in their work or making inroads into historical composites areas. Instead, they are switching away from reliance on metal processes — especially CNC milling of aluminium, as well as forging, moulding, or sheet metal bending.

Arow Global finally settled on one of these new composite 3D printers. The use of a desktop composite 3D printer — a Mark Two from Markforged — has given their engineers more agility in prototyping new concepts in real-world environments. Even machinists on the shop-floor can make their own manufacturing jigs, multitasking

in parallel with production work. 3D printing requires no CAM — the parts are simply printed, often while the machinist is doing other work.

“We’re able to take a part that would have cost US$400, with a two-and-a-half week lead time of machining from one of our local vendors,” Walters comments. “Instead we printed it over the weekend, and the manufacturing floor likes it just as much, if not a little better... and they’re using it to this day.”

Some of their jigs have now been extensively used in the assembly process, nearing 1000 cycles.

“We see no visible signs of wear on any of the nylon parts, and it adds the benefit of not scratching the parts that we’re producing, where with aluminium you can get scratching in the extrusion if one is a little harder than the other. With nylon, that’s basically eliminated.

“The last time I did a new outsourced latch design I had six prototype extrusions costing well over US$1,500” adds Walters.

“What we’re able to do with the Mark Two is really dial in some of the tolerances and also some of the features to make a feature like snap fitting as simple as possible and easy as possible for the assemblers ... before, a lot of that would have been based off of guess work.”

Now with its composite 3D printer, Arow Global can afford the time and money to go through many more rounds of prototyping than before.

Additive Manufacturing

“With the 3D printer, we’re now able to do this with three or four revisions in a week whereas before you’d have to cut dies, which takes time and money,” Walters continues. “Overall the printer has helped dramatically in terms of reducing wasted material inventory and time.”

With the Mark Two, the prototypes that Walters designed could be easily printed with high strength reinforcement, without the need for a costly and time consuming third party manufacturer. As a result, the composites 3D printer was able to easily able to pay for itself within 15 jobs.

“I would estimate that we have seen a full return from printing five parts each of three different plastic injection-moulded prototype components, specifically from not having to invest in the soft tooling traditionally used to create injection moulded parts,” Walters explains.

A number of prototypes that otherwise needed to be machined could now be made just as strong for a fraction of the price, proving the Mark Two an invaluable resource to Arow Global.

Marrying carbon fibre composites to 3D printing is not just about cost savings – in some cases it enables the previously impossible. Now Walters and Arow Global are exploring their new ‘superpower’.

“We’re looking at basically rethinking how we can do drill jigs. Now we can do more complicated machining designs that we simply couldn’t do in the past because you physically can’t machine those designs.

With Markforged, because it’s an additive technique, not subtractive machine, we don’t have to worry about the limitations of CNC milling.”

Arow Global’s composite 3D printer is capable of printing a wide variety of fibre reinforcement patterns, creating both anisotropic and quasi-isotropic ply constructions. As with traditional composite layups, although each individual layer contains a high degree of anisotropy, the addition of multiple layers of composite with rotating orientations results in a part which is quasi-isotropic as a bulk entity.

The printer’s software interface gives users control and optimisation of the layout of internal continuous strand composite fibres – users can adjust the fibre layout pattern, customise fibre orientation codes,

and select fibre layer placement in their 3D model. By adjusting fibre orientations and plastic infill, users can emulate traditional unidirectional and quasi-isotropic fibre laminates, and can build dense structures or weight-optimised sandwich panels including automatic honeycombs. Users can also create continuous fibre/plastic structures never before possible, such as concentric loops.

Markforged currently offers the only commercial 3D printer in the world that automatically lays continuous strand fibre — carbon, Kevlar, or glass — into nearly any shape that can be 3D-printed or machined. The printer is also the only commercial 3D printer that combines continuous strand fibre strength and

toughness with chopped fibre stiffness, serving worldwide markets. The Mark Two composite printer is a compact desktop printer impeccably designed for ease of use, targeted at engineering and manufacturing professionals, equally in the office or on the shop floor, and in many cases gives a return on investment measured in a few months.

Any manufacturing or engineering facility that needs strength, toughness, stiffness, environmental resistance or dimensional stability in everyday tools and fixtures can cost-effectively augment, complement, or replace CNC machining or conventional 3D printing jobs with fully automatic composite 3D printing.

And that’s just the beginning … www.emona.com.au

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Making the most of additive manufacturing Injection moulding is an example of a mature industry where 3D printing with metals offers a great deal of potential to improve production.

Thermo-plastic injection moulding is used for large-scale mass production of a wide range of mass-produced items, from plastic car parts, homewares and furniture, medical parts, electrical tool cases, toothbrushes, toys, caps, pipes and grommets – to name just a few. The processes used for injection moulding have a direct bearing on productivity and the quality of the end product.

Challenges faced by moulders and mould-makers include guarding against warping, the appearance of flow lines, sink marks, the occurrence of vacuum voids, burn marks, jetting and flash and where uneven cooling occurs, thermal stresses in particular sections can reduce tool life. Any of these issues can result in losses through rejects, part-failure and recalls. However, 3D printing with metals could have a revolutionary impact on the industry, through the design and production of conformal cooling inserts.

Why is conformal cooling considered such a game changer? Put simply, conformal cooling makes use of cooling lines that follow the geometry of the part including curves allowing for uniform cooling providing better product outcomes while reducing cooling times.

Attaining uniform cooling rates in all sections of the mould is not always achievable in the current form of mould production. The traditional method of securing cooling channels in close proximity to the mould cavity in injection moulds is through drilling in secondary machining operations. But drilling is linear in nature, and straight lines can present challenges with cooling efficiencies particularly when complex moulds are required.

Toolmakers can build inserts in channels with baffles to create more cooling and in some instances the mould is split into segments, milled and soldered together again. Unfortunately soldering can deteriorate over time shortening the mould life. 3D metal printing offers solutions through specifically designed mould inserts of completely redesigned core moulds. Mould inserts are less costly but a highly effective process.

Conformal cooling is a proven technology, following a study undertaken at RMIT’s Advanced Manufacturing Precinct in Melbourne. After experimentation to identify the optimal material suitable for 3D building, a conformal mould insert was generated using the selective laser melting (SLM) process in the Precinct’s SLM 250HL machine. Later machined to get the desired finish, the insert was tested under research conditions with cooling temperatures recorded throughout the process. The outcome indicated a decrease of 10 degrees Celsius recorded from the baffle-cooled insert, demonstrating cooling advantages.

Recently the VTT Technical Research Centre of Finland ran tests in conjunction with SLM Solutions for ABB Oy Drives and Controls,

The cabling grommet produced by ABB Oy Drives and Controls.

a company that produces cabling grommets from thermoplastic elastomer (TPE). Using an SLM280 laser system, six different tooling inserts were first designed and optimised in CAD, then 3D-printed.

The channel profiles optimised at the design phase, were to take account of factors such as the angles of surfaces facing down – reducing the need for supports, to achieve a minimum wall thickness between channels and to effectively enhance the dimensions and shapes of the channels. The tooling inserts were built in the SLM280 build chamber using metal-powdered steel 1.2709, then heat-treated for the desired hardness of 54HRC, after which the outer shape was conventionally machined.

The six profiles were each tested for cooling effectiveness to determine the ‘best’ design and then placed in the injection mould tool. The results were significant, with reductions in cooling times from 60 seconds to less than 15 seconds. On implementing the ‘best’ design ABB Oy calculated they would achieve an overall reduced cooling time of the (plastic) TPE of some 80%, reducing production time and cost. Additionally the company identified less defective products due to a more equal cooling surface. These advantages amounted to significant benefits to ABB Oy, who produce millions of cabling grommets annually for world-wide distribution.

Cost-saving technology is welcome in any manufacturing capacity, and the use of 3D-printed injection mould inserts is a way of improving an already well developed process. Recognised as a potential industry growth opportunity by the European Union Final Report (2016) on current and future applications of additive manufacturing in Europe, a number of case studies have since been identified in Europe and the USA where successful applications of 3D-printed inserts are reducing costs and production times, and encouraging injection moulders to take on more complex tasks, never before possible. This opportunity is available to Australian injection moulders too. www.raymax.com.au

The six different channel profiles: (from left) a thin U-profile with better reach towards tip; a thick U-profile with turbulent rib; a slim spiral profile with larger cross section area; a robust spiral profile with larger pitch; a fountain profile (very experimental); and a conventional drilled profile (not optimised).

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Additive Manufacturing Heading

RAM3D – Beyond the hype New Zealand-based Rapid Advanced Manufacturing (RAM3D) has opened a new facility in Tauranga’s Tauriko Business Park, aimed at making metal additive manufacturing more accessible to the Australian and NZ markets.

The additive manufacturing market is on the rise in Australia and New Zealand.

More and more companies are moving from printing one or two prototypes and are now incorporating metal 3D printing as part of their production methodology. Many people ask the question “Can anything be 3D printed”? The short answer is “Yes”, theoretically anything can be 3D printed, but not everything should be 3D printed.

However, with the right design, it can be a very economic manufacturing technique.

RAM3D was spun out of the research organisation Titanium Industry Development Association (now TiDA) and it has the biggest Australasian centre for 3D metal printing. RAM3D’s new facility allows companies from a range of sectors, including aerospace, defence, consumer and industrial, to explore the benefits of metal additive manufacturing. The diversity of the parts RAM3D manufactures ranges from titanium knives used by the Team Emirates America’s Cup crew to customised handlebar extensions for the New Zealand Olympics cycling team, as well as titanium lugs for high-end Australian custom bike maker Bastion Cycles.

RAM3D prints in a wide variety of materials.

Titanium 64 (Ti 6Al 4V) is the most common titanium alloy used for medical and aerospace applications. Several of its clients prefer 15-5Ph stainless steel as it has a high strength and is food-grade, which makes it a good generally accepted stainless steel. The third material is Inconel 718, which is a nickel super alloy used for high-temperature applications such as some firearm suppressors used in the defence sector. Metal 3D printing adds another string to the bow of the designer.

Items that are cheap to machine will often be better-off being machined. However, there are often parts where the designer is limited by what the machinist can do and this is where metal 3D printing excels.

When using conventional machining, the focus and cost are directly related to material removal (‘subtractive’ manufacturing). The

machinist spends time and money on removing material from a blank to make a finished part. To make the part cheaper the designer must leave as much material in the part as possible so the machinist doesn’t have to remove it.

3D Printing High Strength Composite Carbon Fibre

With 3D printing, the focus is flipped around the other way. RAM3D starts with nothing and spends time and money putting material on the part. Therefore, to design for metal 3D printing the designer must look carefully at the function and loads being placed on the part.

Two approaches can then be taken. For an existing part the designer should look at how they can remove all unnecessary material. Areas of load and function should be identified and material removed from all other areas. Adding cutaways, hollowing and pocketing leaves the part looking like Swiss cheese, but with each piece of material removed, the cost will decrease.

For a new part the designer should again look at the areas of function and load but they have the ability to only place material where it is needed. This can afford the designer more scope into how the part looks. Organic shapes, non-uniform sections and hollow areas become possible leading to a part optimised for function and cost using metal 3D printing.

RAM3d can design your part from scratch and include lattice integration into your design. Bastion Cycles has embraced adding lattice to its production parts, such as a lug that has had a lattice structure added to it, resulting in less volume of metal and hence a reduction in cost. With the lattice added, the part still maintains its strength while upholding thin walls.

RAM3D has recently expanded its finishing facilities to include a bowl vibratory polisher.

This enables the company to provide a range of finishing options, from the raw as printed, through to polished. Its standard and most popular finish is a matt finish achieved by ceramic bead blasting.

“Markforged Print Amazing High Strength Parts” =Continuous Carbon Fibre

Reinforcement With The Strength of Metal

=Micro-Carbon Fibre With Twice the Strength of Plastics Tools, Jigs & Fixtures

End Use Products

Prototypes

www.ram3d.co.nz

Call us now on

1800 632 953 and discuss how you can print high strength parts instead of milling Rapid Advanced Manufacturing (RAM3D)’s new facility in Tauranga’s Tauriko Business Park.

EMONA

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Moving to a regional hub can bolster your business When you think about the location of 3D printing companies, it’s understandable you wouldn’t immediately think of Wollongong, but it’s now the base of Me3D, a manufacturer of Australian-made ‘student-friendly’ 3D printers. Here, Me3D co-founder Leanne Connelly explains what drew her to base her business in ‘The Gong’.

Me3D was founded in late 2013 and originally it was just three old university friends tinkering in the garage. We were trying to figure out how to show everyone the incredible possibilities of 3D printing. Me3D set out with the goal of designing the world’s best educational 3D printer, the Me2.

Today, we have launched a ground-breaking program, Seed3D, which helps Australian schools to ride the massive wave of growth in 3D printing and we are going to make sure this technology ends up in the hands of every kid, as early as possible. We are quickly expanding throughout the school networks – we’re already in more than 200 schools and have reached more than 120,000 students and you’ll find our printers all across the world. We’re establishing an exceptional reputation for being an inspiring company, and I credit being in Wollongong as integral to the success we’ve had at Me3D. Our collaboration with local schools about this technology has also seen the development of the first-of-its-kind school programs. Just recently Scarborough Public School, a coastal primary school with over 70 students, set-up the “Enterprise” program.

The program aims to help kids learn entrepreneurial lessons and build their Science, Technology, Engineering and Maths (STEM) skills with the end goal of starting business venturers. Old computer rooms are being transformed into ‘Makerspaces’ that harbour technologies such as 3D printers –impressively the whole program has been crowdfunded and led by Principal Chris Hopkins.

Traditional manufacturing is the largest sector in Wollongong, representing $7.9bn of industry output. Wollongong is home to a number of leading companies successfully competing in both domestic and international markets, such as BlueScope and MM Kembla. It makes sense, therefore, that a city such as Wollongong, which is so experienced in supporting these traditional manufacturing companies, is well-placed to support advanced manufacturing companies such as Me3D and can mobilise advanced manufacturing across Australia.

Advanced manufacturing employs around 11,000 people in Wollongong, which represents an 11% increase in the past 12 months. The city sees 600 students graduate from the University of Wollongong with an engineering-related degree annually, which is said to benefit from the city’s rich manufacturing legacy. In addition, there are experienced traditional manufacturing employees looking for a new challenge and to re-skill into advanced manufacturing.

On a personal level, I started my career working in traditional manufacturing at Bluescope and it provided the bedrock to my move into advanced manufacturing.

Wollongong is also a fantastic place to get support if you’re an innovative start-up. Early on in the Me3D journey, we were accepted onto the iAccelerate programme. iAccelerate is a University of Wollongong (UOW) business incubator program which helps local start-ups to build and grow their business. iAccelerate includes a shared working space, a robust educational program and oneto-one mentoring. As the name suggests, the programme literally accelerated our business – it transformed Me3D from three friends tinkering in a garage to a legitimate enterprise with the focus, drive and support necessary to succeed.

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There are some other regional hubs that are also set up to support advanced manufacturing companies but I feel, Wollongong is particularly well-placed (literally). Geographically, Wollongong is within easy access of Sydney for those necessary meetings and networking opportunities, but thanks to the NBN it also has global reach. As a business, we feel hugely supported in Wollongong, obviously by iAccelerate, but also by the Council, University and the broader manufacturing community.

Me3D is making waves in additive manufacturing. We made profit in our first year and have an abundance of both local and interstate customers. We’ve also started exporting our 3D printers internationally, to countries including Ireland, Finland, Malaysia and China. All of that is in no small part due to our location. So if you’re an additive manufacturing start-up you’d do well to consider basing your operations in a regional hub such as Wollongong. www.me3d.com.au. www.advantagewollongong.com.au

Delivering solutions for additive manufacturing

Renishaw’s metal powder bed fusion is an advanced additive manufacturing process that builds complex metal parts direct from 3D CAD data in a variety of metals. Benefits of the additive manufacturing process include: • Rapid design iterations • Bespoke or customised items • Reduce tooling costs • Build complex geometries such as thin walls, lattices and internal features • Increased design freedom - AM is not constrained by traditional design rules We offer a range of solutions for metal additive manufacturing, from systems, metal powders, ancillaries and software through to expert advice and support service.

For more information visit www.renishaw.com/additive

Renishaw Oceania Pty Ltd Unit 4, 6 – 7 Gilda Court, Mulgrave, Vic 3170, Australia T +61 3 9521 0922 F +61 3 9521 0932 E australia@renishaw.com

www.renishaw.com

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Skilling up for a shipbuilding boom Preparing the defence industry’s future workforce for the biggest series of naval projects in Australia’s history has universities and training providers working together to match the skill supply with the predicted demand.

By Andrew Spence.

South Australia’s three public universities have partnered with TAFE SA and peak industry body the Defence Teaming Centre to help deliver a defence-ready, and especially maritime-ready, workforce with skills in engineering, information and computer technology, and a range of trades. The new Defence Industry Education and Skills Consortium will work closely with multinational, national and local defence companies to ensure Australian jobs are at the forefront in defence projects worth $195bn over the next 20 years.

This includes the Federal Government’s $89bn investment in naval ships and submarines, the bulk of which are expected to be built at Techport Australia in Adelaide.

The University of South Australia (UniSA) in early May announced a partnership with University College London (UCL) to jointly run three Masters programs. As part of the collaboration, UCL Naval Architecture Professor Paul Wrobel recently visited Adelaide to discuss bringing modules from the British course to be taught at UniSA. UniSA also announced it is partnering with Saab Australia to open a defence technologies institute in Adelaide to provide a key education and research pipeline for highly skilled systems engineers.

The move comes at a time when the defence industry, particularly shipbuilding, is facing a “Valley of Death” as the Air Warfare Destroyer project (AWD) nears completion while the next wave of construction work including the Offshore Patrol Vessels (OPVs), Future Frigates and DCNS submarine projects are still in planning stages. According to Professor Simon Beecham, Pro Vice-Chancellor of UniSA’s Division of Information, Engineering and the Environment, now is an ideal time to be ramping up defence training pathways as it took up to six years for students to progress from new undergraduates to being workforce ready. He believes many study pathways into defence careers start with general engineering or IT degrees before specialising in Military Systems Integration, Project Management in Complex Defence Systems or Naval Architecture at the post graduate level.

“It’s a very attractive career opportunity particularly in SA where the investments in defence are going to be over the next 30 years – it’s not a five-or-10-year project,” says Beecham. “What we will have is through the UCL partnership and the Saab relationship is very specialised defence-related modules and programs that good engineering and IT graduates can go into and hone their defence skills.

“Both of them are good examples of how our partnerships can lead to enriched experiences for the students – rather than being artificial academic exercises, they are real defence problems that are happening now.”

Earlier this year the Federal Government announced it would invest $25m in a maritime technical college to be headquartered in Adelaide. In the meantime, University of New South Wales has announced it is suspending its Bachelor of Engineering in Naval Architecture in 2017 while it is reviewed for possible closure. Flinders University offers Engineering (Naval Architecture) and Engineering (Maritime) degrees in conjunction with the Australian Maritime College, a part of the University of Tasmania. Flinders expects to enrol a few students each year from NSW into its Naval Architecture course, which takes in about 15 students a year.

However, Professor John Roddick, Dean of Computer Science, Engineering and Mathematics at Flinders, says the bulk of the defence jobs would come in less specialised fields.

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“You only need a few specialist people to design the boats themselves – a lot of the other work is done by mechanical engineers, electrical engineers and people who are trade qualified,” says Roddick. “Importantly though, what we’ve established through the consortium is a mechanism for making sure all graduates that come out of engineering and other disciplines understand what it is to work in the defence industry.”

Mechanical engineering students at Flinders can take a shipbuilding subject as part of their general degree to help prepare them for work in the industry. Roddick says the university also trains engineers to have an understanding of practical skills such as welding so they can work more effectively with tradespeople.

“What we’re trying to do is develop an awareness in our graduates that enables them to consider the defence industry as a destination for their skills,” he adds. “We try to produce blue and white-striped collar workers.”

Margot Forster, CEO of the Defence Teaming Centre, says the unprecedented decision to establish a continuous-build program for surface ships and submarines in SA provided security for the workforce. She says the majority of the 5,500 new defence jobs expected to be created in the continuous build would be in SA. “Major shipbuilding projects up to this point haven’t been sequenced to optimise the use of the workforce,” Forster says. “The consortium focuses on working together to make sure that the universities and TAFE really are giving the defence industry exactly what it needs in terms of the skills and qualifications. By having the consortium and having it directly linked with the industry through the Defence Teaming Centre it can be really responsive.” www.tafesa.edu.au www.dtc.org.au www.unisa.edu.au www.flinders.edu.au www.adelaide.edu.au www.dtc.org.au

Shipping & Logistics Heading

Direct metal deposition gets driveshafts up to speed on container ships OR Lasertechnologie develops and builds robot-assisted laser systems for direct metal deposition (DMD) that take the production and repair of the sliding bearings in container ship driveshafts to an innovative new level.

The enormous container ships that criss-cross the world’s seas need powerful drives: diesel engines with outputs of up to 110,000 PS and as many as 14 cylinders. The shaft that drives the propeller has a diameter of about 600mm, weighs up to 300 tons, and rotates 84 times a minute. The shaft rests inside hydrodynamic bearings that are subject to heavy wear because the shaft is in direct contact with, and slides over the bearing’s surface.

A film of lubricant reduces the inevitable friction, but doesn’t develop fully until the oil pressure rises. Especially when engaging or disengaging the shaft, the protective film of oil is not sufficient to prevent direct contact between the surfaces. The affected parts of the bearing are therefore subjected to considerable friction and wear, which significantly reduces their life expectancy.

A commonly used way to improve the performance of these bearings is to cast their halves with an unbroken surface layer of a tribological (in other words wear-reducing) alloy. The conventional process used for this is extremely labour-intensive: the metals are melted and worked at 700 degrees Celsius. Then, in a laborious finishing phase, around 90% of the material is removed again to obtain the desired final shape. Little has changed in this process over the last century.

Today, latest-generation lasers can be used with a powder nozzle for DMD, yielding considerable benefits: the metal alloy is fed in the form of a dry powder via the nozzle coaxially to the laser and melted onto the inside of the concave steel bearing shells. The laser permits accurate partial attachment of the alloy. It is only necessary to apply the expensive alloy to about 20% of the surface using this technique, compared with 100% with the traditional casting method. Use of a laser also saves time and energy, since only a small amount of metal needs to be melted in each case.

The new generation of additive manufacturing is especially wellsuited for bearings that are in constant use, have a large diameter, and are subjected to large bearing forces and high rotational speeds. It can also be used to inexpensively repair defective bearing shells and restore them to a like-new condition. The ability to quickly change the alloy and apply coatings of nearly any kind of metal opens up incredible prospects for developing new products.

Additive manufacturing enables completely new production processes that can flexibly accommodate customer wishes in a minimum of time.

Recently, Berlin-based ADMOS Gleitlager began using a laser system from OR Lasertechnologie. In addition to more than 100 years of experience producing cast compound hydrodynamic sliding bearings, ADMOS is constantly engaged in improving its products and methods. It is now taking a new approach to making sliding bearings: with a robot-assisted laser system, a 6kW fibre laser and two high-power coating heads in the form of powder nozzles. Something that was impossible with the conventional casting process is now becoming reality: the use of copper-based materials such as CuSn and CuPb. One of the many advantages of the new approach is that different materials now bind more firmly to one another. All in all, the new method makes it possible to completely eliminate several steps while minimising the required finishing work afterward.

Right after powering up the laser system for the first time, it became clear that it reduced materials costs by between 50% and 80% thanks to resource-efficient application. The energy costs are also 50% to 70% less than for conventional casting of alloys.

“The new laser system opens up a whole new world of possibilities for us,” said Jörg Hosemann, CEO of ADMOS. “Faster production and delivery at short notice, as well as enormous potential for slashing costs. I expect the investment in new laser equipment to pay for itself in no time.” www.or-laser.com

Integral part of your business

Quality Transport Solutions

17 Freight Road, Tullamarine,VIC 3043 AusTRAlIA. Tel: 03 8676 5693 • www.eif.co.nz

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Advanced materials & Composites

Graphene – Finding a commercial sweet spot Graphene has finally gotten out of lab and into products, and those products are Australian-made. It will play an important part of our Industry 4.0 future, but there’s a lot of work to be done to get there. By Brent Balinski.

In April and May, over two stages, more than 10,000 sqm of “smart” Australian-made geotextile liner was installed in a Queensland coal seam gas evaporation pond. The non-woven, polyethylene terephthalate (PET) geotextile, made by Geofabrics Australasia, was a first, in a number of respects.

It was coated with a graphene-based conductive coating named imgne X3, produced by Imagine Intelligent Materials. The liner is able to “self-report” in the case of even a small hole being sprung.

(Before a coal seam gas evaporation pond can be commissioned, leaks have to be identified and fixed, to prevent leakage of toxic leachate into groundwater.)

Graphene – the “wonder material” one-third of a nanometre thick – has been a source of much hype in recent years, but has currently delivered few breakthroughs outside laboratories. Despite exciting results in scientific journals, graphene has not as yet delivered fantastic wealth to those at the commercial end of things.

“We are not a profitable organisation,” said Ray Gibbs, CEO of Haydale, one of the UK’s better-known graphene companies, in April last year. “Actually, I don’t think anyone in the graphene space today is.”

However, with the Queensland installation for Geofabrics, graphene has finally found a place where it might actually deliver industrialscale advantages. It also saw Imagine IM, which opened its pilot plant in Geelong in June last year, write its first product invoice.

Geosynthetics is a large market – growing at about 9% and expected to be worth US$21.8bn by 2023, according to Markets and Markets. If graphene coatings can prove their value as a means to make those textiles “smart” and capture even a small portion of that, then graphene might finally find its commercial sweet spot.

“Geosynthetics is a very high-volume business,” explains Chris Gilbey, Imagine IM’s CEO. “It’s also a business where the capability that we can deliver will not just deliver an incremental benefit. It also is highly disruptive from an economic standpoint. We can reduce cost in a number of places for the end user.”

This would only be the beginning, though, for Gilbey’s company and others. Many sectors are interested in Internet of Things (IoT) applications where graphene could play a major role. Whether it’s for sensors created via graphene’s conductivity or for its thermal or mechanical properties, there are labs and companies at all levels of the supply chain interested in getting graphene into profitable products.

Composite smart parts Earlier this year, Gilbey’s company was invited to compete at the Startup Booster, a pitch competition introduced at JEC World – the world’s biggest composites expo – and sponsored by Airbus and Daimler. The range of attendees at the event was vast, according to Dr Phillip Aitchison, Imagine IM’s Head of R&D, who represented the company at the booster. They included “everyone from automotive interior-type companies to… large industrials.”

Aitchison’s presentation included the firm’s concepts around graphene-based pressure, water and heat sensors for “smart composites” – based on detecting changes in resistance in a graphene product, and building on the leak-detection product developed for Geofabrics.

“We’re developing the future of materials – smart parts for anywhere where there’s a plastic or a composite, including epoxies, containing a textile as the base,” says Aitchison. “We’re still very much in the development phase with much of this stuff, demonstrating that you can make an injection-moulded part smart by integrating a graphene carbon fibre or graphene glass fibre composite into it first.

Then by embedding it into an epoxy resin or a thermoplastic like polypropylene or nylon, we can make that part ‘smart’. That part then responds if you bend it, flex it, crush it, break it, do something to it.”

Professor Bronwyn Fox, Director of Swinburne University’s Factory of The Future, is a well-known carbon fibre composites specialist.

The installation of a “smart” graphene-lined, geotextile liner in a Queensland coal seam gas evaporation pond this year.

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Advanced materials & Composites Dr Phillip Aitchison, Imagine IM’s Head of R&D.

Professor Bronwyn Fox, Director of Swinburne University’s Factory of The Future.

Her previous role was as Research Director at the Carbon Nexus centre within Deakin’s Geelong Innovation Precinct’s ‘carbon cluster’, home to Quickstep’s R&D headquarters and Carbon Revolution.

Certification collaboration

Fox says there has been great progress achieved in manufacturing processes over the last few years. The first composite part she made involved a 16-hour curing cycle in an autoclave. Curing can now be completed in around a minute. She leads “Industry 4.0” research at Swinburne, with a keen focus on composites manufacturing, and believes there’s an opportunity for Australian companies to play a leadership role in developing such processes for global supply chains. Fox believes graphene-enabled in-process sensing could fit within this work.

“Imagine IM, through their graphene technology, can create smart, sensing textiles that can be integrated into conventional carbon fibre composites to give you the ability to monitor and control the manufacturing,” she says. “So you have a smart part that’s reporting back on the specific conditions that it’s experiencing as it’s being manufactured.”

Your equipment tells you it’s broken Mining is the backbone of the Australian economy, and it’s an industry where smart materials have great potential. It is no secret that with huge capital and operating expenses – as well as huge resultant costs for unplanned downtime – knowing the limits equipment can have and the prospect of being able to extend its life is a non-trivial issue for mine sites. Imagine IM recently received a $20,000 grant from National Energy Resources Australia (NERA), one of six Federal Government-supported Industry Growth Centres, and concerned with oil, gas and uranium mining, to help bring the smart materials concept to mechanical screening of ore.

The Smart Screens project, with polymers and compounds company Duromer Australia, aims to establish a proof of concept for graphene-enhanced ore-processing screens. The move away from metal and towards plastic components – sometimes reinforced by glass fibre – means there could be a spot for “smart fibres” impregnated with a graphene formulation, says Aitchison, and will lead to parts that can sense.

“By making those parts smart... they will tell you ‘I’ve gone through a million bending cycles, and I’m probably getting towards the end of my life. At the next maintenance cycle swap me out.’ Or it can say ‘I’m broken’ before someone actually notices,” he explains.

“A part could be buried inside a large machine, and can say ‘I’m broken. Stop the machine’. Or ‘there’s only one arm broken out of a whole bunch of arms. You will probably be okay until a second one breaks.’ So it allows people to schedule maintenance in a much more productive way. It allows them to monitor the operational life of a part and be more efficient in the way they operate.’”

Mining screens are one of the next steps for smart, connected products and structures, but the applications beyond that are vast, says the company. Gilbey points to an IoT report from McKinsey, predicting the trend could create between US$0.2 trillion and US$0.9 trillion in value globally per year by 2025 at worksites applications alone. The total predicted impact is put at between US$4 trillion and US$9 trillion annually. With a little effort, graphene might have a role enabling communications within the connected industries of the future.

Graphene is, however, “substantially not understood” at the moment, Gilbey argues.

Part of the reason it is yet to live up to its much-hyped potential is the high amount of variability around the material. Monolayer, trilayer, few-layer, nanoribbons, nanoplatelets, nanoflakes, carbon nanotubes, buckyballs, nanotubes, nanoplatelets: these are all types of graphene or are made from graphene.

First isolated in 2004, graphene in its idealised form is extremely conductive of heat and electricity; it is the strongest material there is, impermeable to gas, and highly elastic. Those beautiful, chickenwirelike carbon hexagons imagined in cartoon diagrams are still largely imaginary. Real graphene sheets come with imperfections. Flakes (usually the way graphene is sold, and usually in a dispersion) are not homogenously-sized or shaped. And all graphene, to be useful for an intended purpose, must be expertly chemically functionalised, says Imagine IM. Another, related issue is the lack of standards and repeatability. This is huge barrier to usefulness, and not just in industry.

“In one of the research projects I was doing at Deakin we discovered some really significant properties through adding graphene to a particular polymer,” recalls Fox. “And when you’re doing research and you get a result like that, you think ‘Wow, that particular grade of graphene improves the performance enormously. What will all the other grades do?’

“And when we investigated every other grade of graphene we couldn’t find any that worked. So how do you invest in commercialising a technology and take it to the next stage when you’re not sure? What if your supplier goes broke, or something happens or they stop producing that particular product for some reason?”

To address the problem, Swinburne, Imagine IM and other industry partners began a three-year, $4m Cooperative Research Centre Projects (CRC-P) initiative this year focusing on certification and qualification, aiming to better understand how graphite sources and processing factors impact the final product. There are numerous efforts that claim to deliver certification elsewhere in the world.

However, according to Aitchison, most of these are from an academic perspective and will not have any commercial relevance for some time yet.

“It’s not hypothetical: we’re putting our graphene and our masterbatch materials into real commercial environments,” he explains. “We’ll use ours and any partner’s commercial products as the test beds, but we’ll use the full power of the academic research perspective – including things like using the Australian Synchrotron – to understand really what’s going on and which are the important bits and which are the less important bits.

“For example, what does industry need to know to use graphene, in terms of measurement? You can do dozens of different types of measurements which tell you things about graphene, but most of them are irrelevant to industrial application. What is the information that an industrial partner needs to know, what is the equipment they need to use, how will any of us conduct the measurements, and who will provide the services?”

In Australia scientists, engineers and business are leading the world in thinking and acting on these things. www.imgne.com www.swinburne.edu.au

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Advanced materials & Composites

Making light work of it: enhanced dynamics with CFRP

Ultra-high-strength materials are highly popular not only in aircraft and automobile manufacturing, but also in the mechanical engineering sector, because they are often comparatively light and at the same time very sturdy. Machine tools, however, frequently come up against their physical limits when processing these materials.

This can be remedied by using structural parts for machinery that are made of lightweight fibre-reinforced materials. This entails mastering some serious obstacles, as evidenced by an as-yet-uncompleted research project at the Fraunhofer Institute for Production Technology (IPT) in Aachen, Germany, which will also be on show at the EMO 2017 trade fair in Hannover .

Replacing steel: using CFRPs reduces the mass of the Z-axis by 60%.

CFRP replaces steel for enhanced dynamics The researchers in Aachen usually adopt a holistic approach to optimising designs. In other words: they consider the machine’s design as a coherent whole, thus also including the development of important drive elements in the machine tool. They have currently joined forces with Magdeburg-based machine tool manufacturer MAP Werkzeugmaschinen to examine how an innovative machine component for vertical movements (Z-axis) made of carbon-fibre-reinforced plastic (CFRP) behaves in a machine tool and how the Z-slide can be optimised.

“We began development work on the CFRP slide in 2013,” says Christoph Tischmann, Branch Manager of MAP Werkzeugmaschinen.

“We already possess plenty of experience with linear and rotary axes, for machining aluminium, for instance. But for high-strength materials like the titanium alloy Inconel they do not possess the requisite drive power.”

In response, MAP decided to develop a machine tool with very powerful drives: for example, 55- and 72-kilowatt spindles (torque 210Nm and 273Nm respectively in S1 or S6 mode) are now used, which are significantly heavier and larger.

“So as not to have to compromise on the dynamics, we were looking for a way to compensate for the greater weight,” explains Tischmann. “That’s why we opted for the CFRP variant.”

By way of comparison: the machine tool used to operate in the Z-axis with spindles rated at 28 to 36 kilowatts. So what’s involved here is roughly doubling the drive power. At the same time, using CFRP reduces the mass by around 60% compared to an axle made of steel.

“However, we’re not aiming for any particular weight, we’re targeting an optimum ratio between weight and mechanical strength,”

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“We then attempt to replace some of the existing components by their equivalents in aluminium or CFRP, or to improve the dynamic behaviour at certain critical points by means of reinforcements or ribs.”

explains Filippos Tzanetos, a member of the scientific staff of the Fraunhofer IPT. The question arises here of how the change-over from a steel guide slide to a CFRP design with a drive weighing around twice as much will affect the design as a whole. The Fraunhofer IPT has for this purpose analysed the thermal and dynamic reactions of the entire machine on the Z-guide slides.

“The machine was subjected to an exhaustive scrutiny,” reports Tischmann.

“We used these measurements to develop several solutional approaches, in order to improve the design.”

Matching the design to the material Because materials cannot be simply replaced on a one-for-one basis, the design needs to be modified to suit the new material concerned. Finite-element simulation has proved its practical worth in this context.

“At the computer, we take a detailed look at the specific points in the design that are the most yielding, in order to determine the causes involved,” explains Tzanetos.

Working with CFRP is a particular challenge for design engineers, since the material behaves anisotropically. “Anisotropy” is a term describing the direction-dependence of a property or an operation. This means that in the case of fibre-reinforced materials the mechanical strength or rigidity will depend on the direction of the fibres. A CFRP component, however, behaves differently in a simulation to its behaviour in reality.

Tzanetos lays out the details for specialists: “The meaningfulness of the simulation is estimated using the uncertainty propagation defined in DIN ISO 21748:2014-05. The uncertainty of the model’s parameters exerts a certain influence on the uncertainty of the model’s output variables. This is calculated using the Monte Carlo simulation method.”

In projects of this kind, the Fraunhofer Institute is often assisted by other institutes or spin-offs, but in this case the scientists found the support they needed in-house.

“In our institute, we have a department for fibre-reinforced-composite and lasersystem technologies”, reports Tzanetos.

“This department has over the course of many years accumulated a lot of can-do competences in the field of dimensioning machine tool components made of fibrereinforced plastics (FRPs), and provides

Advanced materials & Composites Heading

The Fraunhofer IPT examines how a machine component for vertical movements (Z-axis) made of carbonfibre composites (CFRP) behaves in a new machine tool and how the Z-slide can be optimised.

us with proactive support in the shape of simulation expertise for fibre-reinforced component dimensioning.”

Success through synergised competences Support of this kind is indispensable for solving questions encountered when it comes to using FRP components in plant and machinery construction, since these materials, by virtue of their anisotropic properties, are not often used here.

“Up to now, there has been a notable reluctance to use FRPs because in contrast to conventional materials there is no recourse available to existing design and dimensioning standards, ,” explains Tzanetos. “And therefore it’s not that easy to predict an FRP component’s dynamic behaviour in conjunction with the rest of the machine’s structure.

“Mistakes are made, for example, when a component is dimensioned in terms of its mechanical strength in just one axis direction, while ignoring the mechanical strength in the other axis directions.

But if we use simulation tools to finetune the interrelationship between the FRP component and the machine tool’s own dynamics, nothing can go wrong.

So to solve the problem, the requisite competences are brought together in our company within this project.”

Lazering, not bonding Another critical consideration is joining CFRPs to metals. Up to now, an adhesive bonding process has been used, which according to Tzanetos has four disadvantages:

Filippos Tzanetos, from the scientific staff of the Fraunhofer IPT in Aachen.

1. The CFRP surface has to be machined mechanically. This leads to unsteadiness and a weakening of the CFRP’s properties.

2. It guarantees only a low level of mechanical strength (per joint: 10 to 40 megapascal).

3. It is closely dependent on the ambient conditions (e.g. temperature, soiling, chips, cooling lubricant).

4. Bonded joints possess a low resistance to wear.

All these disadvantages are eliminated by a lazering process. But it’s not only the joining technology that MAP’s Branch Manager sees as problematic.

“In order to assure precise positioning and reproducibility accuracies in the machine, even in the case of high dynamic response, we scrape off the layers on the linear guides by hand,” says Tischmann. “It’s now an enormous challenge for us to accomplish this with CFRPs as well.”

Despite all these difficulties, the changeover to CFRP has been worth it, opines Tischmann, with a view to EMO Hannover.

The machine tool manufacturer is thinking about a shared information stand with the Fraunhofer IPT, in order to showcase the advances and procedures involved with this “new material”.

“Basically, at the end of this project we aim to be putting a dynamic, high-precision, and above all powerful machine on the market,” explains Tischmann. “We would like to see it becoming widely accepted in the aerospace sector, particularly.”

Christoph Tischmann, Branch Manager of MAP Werkzeugmaschinen.

Tzanetos also sees collaborative projects like that with MAP Werkzeugmaschinen as a good option for exploring new paths in a process of mutual feedback with the industrial sector. The project currently ongoing has encouraged the researchers in Aachen to press ahead with industrial partners in the field of CFRPs. Tzanetos and his colleagues from the academic community will be getting further input on comparable material-related questions and on lightweight construction in September at EMO Hannover. www.map-wzm.de ww.ipt.fraunhofer.de www.emo-hannover.de

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Advanced materials & Composites

High-tech machine enables new graphene purification technique

A revolutionary machine that can unboil an egg is being used to develop graphene purification technology.

Researchers from Flinders University in South Australia along with Western Australian company First Graphite Ltd will use the dynamic Vortex Fluidic Device (VFD) to produce high-quality graphene for industrial use.

Left: Professor Colin Raston with his invention, the Vortex Fluidic Device.

Graphene is the building block of graphite and is one of the most sought after materials in the world because of its robust nature. More than a million metric tons of graphite are mined globally each year. It is 200 times stronger than steel but remains flexible and impermeable, making it ideal for the development of a range of modern technology such as lithium-ion batteries, sensors and transparent-conducting electrodes for flexible solar cells.

Based on previous graphite research involving the VFD, First Graphite plans to scale up the process to a commercial level with the potential of delivering highvalue carbon materials to global markets.

First Graphite Managing Director Craig McGuckin says the potential uses of graphene cover a vast range of industries and he believed the material would eventually be used in most modern technology.

“What is required is creating high quality graphene from graphite, doing so quickly and efficiently and that is what we are trying to take up now,” says McGuckin. “We see the VFD partnering with our own processes to assist greatly in creating different types of graphene for different uses.”

In 2015, Flinders University scientists were awarded an Ig Nobel Award for creating the Vortex Fluidic Device and using it to unboil an egg. The device has also been used to slice carbon nanotubes accurately to an average length of 170 nanometres using only water, a solvent and a laser. It is now being tested to prove its potential as a commercially viable graphene producer.

Colin Raston, the VFD’s creator and Professor of Clean Technology at Flinders University, explains that graphite is made up of multiple crystalline layers of graphene that can be stripped off by his machine.

He says conventional methods use harsh chemicals, which generate defects and change the properties of the graphite.

“You can’t keep making graphene the same way anymore, you need to make it better and address the waste issues as well,” says Raston. “Given the capabilities of the VFD we are going to explore the operating parameters of producing graphite. An

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Left: First Graphite Ltd’s graphene cell in production.

Below: The Vortex Fluidic Device.

environmentally safe process of producing the graphene opens up more applications for it – it also makes it a cheaper option because you eliminate waste.”

The VFD that will be used to manufacture the graphene sheets is a suitcase-sized piece of equipment that applies very high sheer forces to liquids fed into the system through spinning a tube at high velocity.

“Graphite is a well-known solid lubricant because the sheets slip relative to each other,” Raston says. “The VFD would cut through the graphite with precision and could be scaled up by aligning a row of machines parallel to each other or creating a larger device.”

First Graphite aims to develop an underground mining operation in Sri Lanka to extract high-grade, crystalline vein graphite and plans to use the VFD to help extract high-value graphene. Graphite has seen a resurgence in price in recent times due to increased demand from applications such as lithium-ion battery technology for electric cars, but could now see itself replaced by graphene.

Graphene has the largest volume to surface area ratio of any material, weighing in at about 0.77 milligrams per square metre and capable of stretching up to 20% of its initial length. It is an isotropic heat conductor and has up to five times the conductivity of graphite. It also has the highest recorded electrical current density, about one million times that of copper. www.firstgraphite.com.au www.flinders.edu.au

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Motors & Drives

Technology inspired by ecology

Kaeser Compressors has announced a significant technological milestone. For the first time, its ASD series of variablespeed rotary screw compressors will be equipped with synchronous reluctance motors – a major efficiency advantage due to considerably lower losses in the crucial partial-load range, compared to asynchronous motors.

From moving to the high efficiency IE3 motors long before the current regulations came into effect, to more recently taking the next step to enhance energy efficiency further by upgrading all compressors from 30kW to 215 kW with the super-premium efficiency IE4 motors – Kaeser is committed to the ongoing optimisation of its compressed air production systems. As Peter Eckberg, Managing Director at Kaeser Compressors Australia said: “High-end compressor quality is directly coupled with maximum energy efficiency, so it’s only logical that we provide our customers with the best drive solutions possible.”

Kaeser is releasing its ASD series of variable-speed rotary screw compressors with a completely new drive technology. The major advantage of this complete solution, which was developed in close partnership with Siemens, is that it delivers efficiency gains of up to 10%in the partial-load range. As Eckberg explains, this is yet another milestone in Kaeser’s ongoing history of technological success.

“Although this drive principle has been understood for decades, only now has its implementation in production series motors attained the technical perfection required to benefit users throughout the world.”

Variable-speed drive with high system efficiency “From our perspective, implementation of such a systematic efficiency improvement – specifically in the partial-load range – is a logical step considering the climate protection efforts currently being codified by all governments around the world,” emphasises Eckberg.

Shifting to technological implementation, he continues: “With our variable-speed versions of the ASD series, we offer customers an opportunity to embark on a path of minimal energy consumption – and minimal operating costs.”

As an industry leader, Kaeser understands the huge significance of the new Siemens synchronous reluctance motors, which were developed, in part, as a result of new regulatory frameworks.

The new EN 50598 eco-design standard applies not only to the efficiency values of individual drives, as previous legislation did; but, it also represents a shift in regulatory emphasis to overall system efficiency. Consequently, the compliance of variable-speed drive solutions will now be assessed based on their overall system efficiency, not by the efficiency of each stand-alone component.

This is important because compressed air stations are often constructed on a modular basis. Continuously running compressor systems with IE3 and IE4 motors cover base load demand, whilst additional peak-load compressors respond flexibly to meet extra demand; the system as a whole is controlled and co-ordinated by a Sigma Air Manager 4.0 master controller to ensure maximum efficiency. With the Siemens synchronous reluctance drive systems, this will be performed with even greater efficiency, particularly in the all-important partial load range.

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Combining synchronous and asynchronous motors This new and innovative range of general-purpose motors combines the advantages of both asynchronous and synchronous motors in a single drive system. On the one hand, no aluminium, copper or expensive rare earth magnets are used in the rotors; instead they are made of electrical steel with a specialised profile and arranged in series – making the drive highly durable and maintenance-friendly, the characteristic advantages of asynchronous motors.

On the other hand, the control properties of the new motors are comparable to those of synchronous motors. Because of the special rotor design, reluctance motors deliver high speeds without additional rotor warming due to current flow. The key to this lies in optimised matching of the drive system elements, i.e. the motor and frequency converter, for which Kaeser selected the Sinamics G120 (also from Siemens).

This frequency converter has been individually adapted to the motor using a specially developed control algorithm – and it is the perfectly harmonised interplay between these two components that makes the new synchronous reluctance drive system so powerful – and allows it to deliver maximum energy savings.

Eckberg continues: “Together with our development partner, Siemens, we have optimised this innovative drive to such an extent that speeds of 4,000rpm are possible. Therefore, in addition to energy efficiency, users also benefit from even greater motor power – without any increase in the physical size of the motor.

“In fact, the housing and foot measurements of the synchronous reluctance motor are exactly the same as that for the asynchronous motor. In short, direct substitution is straightforward, requiring no major re-engineering effort, which provides users with the flexibility to decide which drive version they prefer for each application. It is this kind of systematic thinking that underscores our entire standardisation strategy.”

Same size – better performance With the variable-speed series and synchronous reluctance drive system, Kaeser believes it has achieved a technological milestone – even more remarkable considering that these compressors were previously equipped with a frequency converter and IE3 energysaving asynchronous motors, and therefore already represented the pinnacle of environmentally friendly compressed air production.

Kaeser aims to equip even more performance classes with reluctance motors in the coming years, which will deliver noticeably improved performance from a machine of the same dimensions.

Extending this to other performance classes promises to be a straightforward task thanks to the powerful partnership with Siemens, which delivers a fully tested, optimised and perfectly tuned system solution to Kaeser.

Motors & Drives The positive effects also extend to control cabinet cooling, since less heat needs to be dissipated. Moreover, Kaeser’s use of variable-speed fans in compressed air production systems delivers additional energy savings.

An innovative drive system for a sustainable future The new drive technology delivers efficiency gains of up to 10% in the partial-load range, top IES2 classification as per the new EN 50598 efficiency standard, as well as significantly lower energy costs. This translates into average energy cost savings of around $675 per year, according to Kaeser, based on 6,000 operating hours at a rate of 10 cents per kilowatt-hour.

These benefits are in no small part due to the innovative functional design employed by Siemens when developing these new synchronous reluctance motors. Dispensing with expensive materials such as aluminium, copper and rare earth magnets for rotor construction boosts cost-effectiveness and also yields significant thermal advantages – primarily in the partial-load range.

These motors, built on the platform of the energy-efficient 1LE1 asynchronous motor, are now available under the name Simotics GP/SD with aluminium and cast iron castings as standard.

Some of the technical advantages of the new motor design include near zero heat losses from the rotors, which keeps bearing temperatures noticeably lower. This in turn has a positive effect on service life, ease of maintenance, as well as drive availability.

“The optimal thermal capacity of the motors enables even longer service intervals than we had previously been able to offer,’ explains Eckberg.

Users therefore not only enjoy maximum flexibility for specific applications and varying environmental conditions, but also with regard to load response. Together with its high-efficiency IE4 asynchronous motors, Siemens has now raised the bar of drive technology efficiency to a new level, exerting environmentally friendly competitive pressure across the market.

“Environmental issues are key when it comes to high quality compressor solutions,” Eckberg concludes. “Because it is these issues that will drive industry toward a truly sustainable future.” www.kaeser.com.au

NORD DRIVESYSTEMS OFFERING ALUMINIUM GEAR UNITS AND MOTORS FOR AUSTRALIA´S INDUSTRY NORD Drivesystems (AU) Pty Ltd 18 Stoney Way, Derrimut , Victoria 3030 Australia Phone: +61 3 9394 0500 Fax: +61 3 9394 1525 www.nord.com.au National Customer Service 1300 00 NORD (6673) au-sales@nord.com Member of the NORD DRIVESYSTEMS Group

7 16 -19 July 201 Centre Sydney al Convention Internation bour Darling Har 2017

odPro Stand

Visit us at Fo The

Gear Units

n Strong bearings n Low noise n High power density

S17

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n High efficiency n Global Standards n All operating conditions

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Wide power range – Versatile system solutions – High overall efficiency

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Motors & Drives

New Rockwell Automation servo motor improves machine performance Speed is money, especially for manufacturers with processes such as converting, printing and web handling. With the new line of Allen Bradley Kinetix VPC servo motors from Rockwell Automation, manufacturers can run machines at higher speeds and higher torque, significantly improving machine throughput.

“The Kinetix VPC servo motor provides high continuous torque at high speeds over long periods of time,” says Gavin Black, Product Manager- CompactLogix, Kinetix, SLC & ICM, at Rockwell Automation. “Its interior, permanent magnets allow for field weakening, which reduces electromagnetic resistance so a machine can carry loads continuously and well above motorrated speeds. This allows manufacturers to keep web lines and winders running at high speeds and constant power.”

A cooling fan and cooling fins on the motor provide increased torque and power output. In addition, encoder options with improved resolution and accuracy provide more precise and responsive control, which is especially valuable for the printing industry.

The Kinetix VPC servo motor also helps reduce machine downtime in multiple ways. It uses larger, more robust bearings to improve L10 bearing life by up to 60%. An optional single cable for power and feedback helps reduce installation, setup and maintenance time compared to dualcable motors. In addition, a quick-change fan is field-replaceable, which helps maintain maximum machine uptime.

The new motor line meets or exceeds IE4 efficiency ratings, which can save energy costs compared with using an IE3 or lower-rated motor. When used with the Kinetix 5700 servo drive, the Kinetix VPC servo motor can also help manufacturers use less current than with larger, more energyintensive motor and drive solutions.

Rockwell Automation designed an integrated foot-mount option for the Kinetix VPC motor, which provides an alternative to the traditional, flangemount method. This is beneficial in many applications where foot mounting is preferred. The Kinetix VPC servo motor is currently designed only for use with the Kinetix 5700 servo drive. Rockwell Automation plans to evaluate functionality with other drives in the future.

As part of the Rockwell Automation Integrated Architecture platform, the Kinetix VPC servo motor and Kinetix 5700 drive are programmed using the Rockwell Software Studio 5000 design environment. This integrated design approach can help speed up machine deployments and reduce the likelihood of manual errors. www.rockwellautomation.com

nsd tupH aluminium drives – effective, economic, corrosion protection NORD Drivesystems will showcase its permanent corrosion-resistant drives during FoodPro 2017 in Sydney in July.

These aluminium drives, which sport a sealed surface conversion system, are given a smooth, ultra-hard surface that, in contrast to paint, is unaffected by blows or scratches. The drives are tested and proven in wet applications. In addition, they have proven their resilience against blistering and corrosion as per ASTM and ISO standards. According to the ASTM D3170 Gravelometer test, the unit showed absolutely no loss of adhesion or chipping, while the ASTM B117-9 salt spray test according to DIN EN ISO 9227 produced no corrosion even after 2,000 hours.

In demanding atmospheres, nsd tupH drives can be used beyond the usual service life of paint-coated systems. Their resilience and prolonged service life significantly reduces the service and maintenance requirements placed on customers.

In addition, the treatment ensures high process safety: since no coating is applied but the surface itself is hardened, there can be no pollution of products or process media as for instance with chipping paint. Even heavy impacts or scratches do not diminish the corrosion resistance. In contrast, scratches in paint or coatings can result in the damage spreading to adjoining areas, effectively rendering the protection useless. nsd tupH is approved for food applications according to FDA Title 21 CFR175.300.

Treated systems resist cleaning agents in the pH2 to pH12 range. nsd tupH is available for all aluminium-enclosed drives – four

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gearbox families, smooth-surface motors, and distributed drive electronics units.

As a prominent global developer and manufacturer of drive technology, NORD recognised a critical gap for drives specifically suited to the demands of the industry and its stringent requirements.

Today the nsd tupH drive delivers with its industry-unique surface protection system developed to withstand hostile and high hygiene environments. As a German-born company, NORD’s customers benefit from global trends in product development and new application methods coupled with advanced R&D to deliver on innovative and cost-effective solutions. www.nord.com.au

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98

Forming & Fabrication

Bending and cutting in a single step

Schwarze-Robitec has combined the bending and the final cutting of short bent tube components for large diameters – in one single working step. To do this, the cutting tool is integrated into the bending tool, making the whole process much more efficient and economical. Until now, this was only possible for smaller diameters.

For the user, benefits include a decrease in scrap material up to 90%, and significantly reduced production times. Consequently, the system of the integrated cutting tool is perfectly suited for producing parts in high quantities due to the immense material and time savings. Numerous users in the automotive sector or the supplier industry are already using this system successfully.

To enable these advantages to be used with tube diameters of up to 76mm, SchwarzeRobitec has optimised the cutting tool. The tools can process these precise cuts in the shortest time possible. At the same time, the material savings prove to be very high: until now, up to 100mm scrap accumulated for each part produced, depending on the bending system used – a high cost factor that is significantly reduced with the integrated cutting tool. Machining of longer pipe units instead of cut-off pipe sections is also possible thanks to the integrated cutting process. This also reduces the time required for loading and unloading the machine.

With the new cutting technology, all components receive a clean cutting edge and can be immediately processed further.

Therefore, this technology is particularly suitable for series production, for example, in the automotive sector or the supplier industry. This is where the savings of resources and time play an important role.

The controlled chip removal process keeps most of the chips produced during the cutting process away from the machine.

A prerequisite for integrating the technology into all-electric machines of the high-

performance series is the use of the CNC control NxG. The new controlling system enables the cutting at any bending angle between 0 and 90 degrees and is simply integrated into the bending program.

The cutting tool processes all common materials – including aluminised steels or hard-to-cut materials, such as chromenickel steels. www.schwarze-robitec.com

OMAX introduces new GlobalMAX abrasive waterjet line

OMAX Corporation has announced the launch of its new GlobalMAX abrasive waterjet line, reliable and practical machines capable of cutting virtually any material, available exclusively through international distribution.

The GlobalMAX line takes advantage of two and a half decades of waterjet industry research and development to offer a completely integrated system of pump, table, and advanced motion control system that is easy to use. International OMAX distributors are certified installers and servicers and are trained at OMAX headquarters.

“The GlobalMAX product line was created to extend our waterjet engineering and manufacturing technology base to more customers,” says Stephen Bruner, Vice-President of Marketing at OMAX Corporation. “The product line features our proven direct drive pump technology, easy-to-use software, and innovative drive technology. We build waterjet systems that help our customers make money in the short and long term and this product line is no exception. With GlobalMAX, OMAX

AMT Jun/Jul 2017

aims to redefine value-oriented waterjets.”

The GlobalMAX product line, which includes software, pumps, and tables, will be available in a 3.0 x 1.5m cutting bed size. There are also two direct drive pump sizes available, 20HP and 30HP. Like all OMAX abrasive waterjets, the GlobalMAX can cut almost any material and a wide

variety of material thicknesses without any heat-affected zone (HAZ). The machine does X/Y axis cutting with three degrees of freedom and has a number of compatible accessories, including a terrain follower, a pneumatic drill and a bulk garnet feed hopper. www.omax.com www.headland.com.au

Forming & Fabrication

CNC synchronised bending has never been easier If you are new to the bending game, or have been running torsion bar press brakes for years, you might want to consider how a CNC synchronised press brake could be the perfect machine for your company.

Each of the hydraulic rams (Y1 and Y2 axis) are synchronised via the CNC controller to allow for absolute precise delivery of pressure for your bending job – regardless of where you are bending across the bed. Bending performance will be equally as good at either end of the bed, as it will be for dead centre, allowing for tooling setups along the bed for more efficient processing of any multi-bend, multi-angle work.

Another advantage of a CNC press brake is their extreme accuracy in terms of delivery of bending force. CNC press brakes are inherently much more power efficient than the “always 100% on” force delivery from a torsion bar press brake. With the skyrocketing costs of energy in Australia, this can remove significant costs from a company’s power bills and increase its bottom line.

Yawei has always supplied an entry-level CNC synchronised press brake, and Applied Machinery has been providing Yawei’s PBH series of high-level CNC synchronised press brakes into the Australia market for well over 10 years. However, economic factors have meant that Applied was never able to competitively offer Yawei’s PBA series to its Australian customers… until now. Reductions in steel prices, along with increased production at Yawei, have combined to see the emergence of the PBA series machine as a legitimate option for companies looking to enter the market.

According to Applied, when comparing the prices of these machines to a torsion bar machine with similar specifications, the difference can come out to be only 15%. When you then take running and maintenance costs into account, the jump to PBA could actually save you money over the payback period.

The CNC controller is a Delem DA-52S, which is capable of fouraxis CNC control as standard. A USB interface enables quick and easy memory-stick backup of product and tool information and a 17cm colour display allows the user to get quick visual access to any critical bending information that is required. Quick one-page programming, a tool/material/product library and hotkey navigation make this control an impressive option for companies entering the CNC market.

A high-specification torsion bar machine will be priced not too far below a PBA, and the team at Applied believes PBA features such as CNC control, the machine’s high build quality and componentry, and the associated power savings will be enough to justify the upgrade. www.appliedmachinery.com.au

AustrAliA-wide solutions. tooling systems, accessories Bending, Punching, stamPing.

The machines also feature CNC control of three-axes – Y1, Y2 and X (back gauge) – as standard. To keep costs down, Applied is offering the PBA machine without CNC R-axis as standard, this is available an optional upgrade. All machines featuring Hoerbiger hydraulics, Heidenhain linear scales and Voith oil pumps, in addition to Lazersafe light guards and Rolleri tooling.

For the vast majority of customers looking at either 2,050mm or 2,550mm machines, deflection in the main beam will barely be a consideration. However, for 3,100mm machines, crowning compensation is usually included with the machine as standard.

According to Applied, the PBA series of CNC press brakes will never be the equal of the CNC5 and CNC7 available in the PBH series. However, they offer a legitimate entry point into CNCcontrolled, synchronised sheet metal bending, allowing customers in this area a much greater degree of choice.

Best Products. Best service

Punching • Bending • Software • tool acceSSorieS

Call Sheetmetal Tooling Tech on 1300 668 156 servicing your bending and punching solutions Australia wide. www.tooltech.com.au

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100

Material Removal

Hydrafeed Barfeeder lifts productivity Kennewell CNC Machining, a contract machine shop in South Australia, recently invested in a servo-driven Hydrafeed Barfeeder from Dimac Tooling.

Kennewell manufactures everything from parts for agricultural machinery to high-end motorsport and tattooing equipment, specialising in small batches.

It is also heavily involved with the production of prototype parts to assist companies bring products to market.

Established in 1995, the company has steadily grown and now has a total of 12 staff working over two shifts.

Owner Brett Kennewell and Leading Hand Brett Klose acquired the Hydrafeed Barfeeder to retrofit to an existing CNC lathe and replace the existing pneumatic unit that had come with the unit.

“Our old barfeeder had to be monitored constantly, so was very unproductive,” says Kennewell. “I really don’t like pneumatic equipment; the barfeeder we had has been unreliable and because it ran on compressed air, was expensive to run.

Hydrafeed UK has developed a user-friendly unit with an additional productivity benefit over other barfeeders on the market. Once the bar size is set and the setup has been

easy to use so it doesn’t take long for staff members to become proficient at operating it.”

saved, there’s no need to open the cover again. Simply by calling up the program from the touch screen, the HydraFeed will set itself on centreline automatically, thanks to the servo-drive bar-lifter mechanism.

“The key benefit of the Hydrafeed Barfeeder is that it has increased my productivity by allowing me to run the machine unattended,” adds Kennewell. “It’s essentially given our existing CNC lathe a new lease of life. One other feature is that the Hydrafeed is very

Standard features include servo control, fully automated set-up through a user friendly HMI screen and the versatility to accommodate different bar diameters and lengths including random bar lengths. A wide variety of models are available to suit any application.

Kennewell also benefitted from one-onone training from Dimac to ensure the barfeeder was installed correctly and operated at optimum performance.

“Dimac’s service was a breath of fresh air,” add Kennewell. “Competitive suppliers seemed reluctant or unable to bring in a machine for me to test, but Paul Fowler (Managing Director at Dimac) brought the Hydrafeed Barfeeeder in and demonstrated the unit. “It certainly ticked all the boxes. I would recommend the Hydrafeed Barfeeder without hesitation to any company.” www.kennewell.com www.dimac.com.au

Delivering complex tools fast

Polish cutting tool manufacturer Fanar met its goal of fulfilling customer orders within 72 hours with the acquisition of an ANCA MX7 Linear CNC tool grinder.

One of Europe’s top five tool manufacturers, Fanar is known for uncompromising quality.

The company supplies a wide range of tools for threading, drilling, milling and turning, specialising in shank tools for machining holes. Fanar’s global customer network encompasses the automotive, aerospace, medical and home appliances industries, among others.

Fanar has always invested in technology and machine tools. In 2016 Fanar realised that if it was going to remain ahead in the market it needed to improve the production time for manufacturing complex cutting tools.

Dariusz Ptaszkiewicz, Technical Director at Fanar said: “In the era of eBay people are accustomed to products delivered within two to three days. This mindset can be challenging when customers expect the same service when purchasing specialist cutting tools. We needed to find a way to meet customers’ expectations without compromising on quality.

“The more complex the tool, the longer it takes to produce and may require several machines and different set-ups as part of

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the grinding process. This process can be quite lengthy. However, at Fanar we are not afraid of a challenge and we set ourselves the ambitious goal of delivery to our customers within 72 hours from receipt of the order.”

Fanar looked for a supplier who could provide a solution that enabled fast changeovers, precision and repeatability.

Another important requirement was that the grinding machine had a software package that was intuitive to use and didn’t require highly skilled programmers.

“After reviewing what was available, we were confident that ANCA’s MX7 Linear was right for our business because of its numerous innovative features,” continues Ptaszkiewicz. “The polymer concrete base, linear motors, ability to prepare tools (wheels) on the machine and integrated measuring system meant we could achieve our goal of 72-hour delivery with a grinding machine of the highest standard.

“When investing in a new product, there is always some concern that the machine may not deliver what was promised. ANCA’s MX7 Linear exceeded our expectations and I am yet to find a product that offers

so many innovations and features that are unique to the market. Once we had the latest technology, combined with our years of experience in grinding and metalworking, we could quickly begin production of the most complex geometry and high dimensional precision tools.”

Special features such as RoboMate have enabled simple, accurate automation, and ANCA’s in-process measuring system Laser Plus means that Fanar has implemented unmanned production for the first time without concerns over defective products. The inclusion of the Statistical Process Control (SPC) software package enables Fanar to continue to meet ISO 9001, ISO / TS 16949 standards. Overall the investment has helped Fanar meet its goal of slashing lead times and production costs, while opening new potential markets.

“I am excited that Fanar is now in a position where we can consider orders that in the past we avoided,” adds Ptaszkiewicz. “The technology means we have the capacity to produce complex tools, even for individual orders, at the highest quality with minimal risk.” www.fanar.pl www.anca.com

Hotspots is proudly owned and managed

by AMTIL

All we think about about is manufacturing.

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You need a specific component made, but don’t have the capabilities in house.

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Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

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Your business is diversifying into an area where the expertise available within the company is not sufficient.

HotSpots is a service designed to connect AMTIL members with opportunities to help their businesses grow. That piece of work that you need done might be just the sort of opportunity they’re looking for. And by featuring that opportunity as a HotSpot, you gain access to a wealth of Australian manufacturing capability and expertise.

Our regular AMTIL HotSpots email goes out to over 1,000 people every month, making HotSpots an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector.

Provided your opportunity meets our criteria for listing, inclusion in AMTIL HotSpots is free. If you have something you feel will meet our criteria, please forward it to AMTIL for assessment by emailing info@amtil.com.au with the subject line HOTSPOT. www.amtil.com.au/Membership/Hotspots

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102

Material Removal

Some like it cold

Machining exotic materials creates heat – a lot of heat – that is detrimental to tool life, demands a slower removal rate, and creates a heat-affected zone on the material that often requires a downstream removal process. Cryogenic metal removal, in development for several years, has reached the point where it can efficiently reduce the temperature at the cutting edge to eliminate those issues. By Sue Roberts.

Cryogenic metal removal can be paired with just about any mill to extend tool life, speed machining, and all but eliminate the heat-affected zone and white layers. Pete Tecos, Executive Vice-President of 5ME, explains the technology’s progression.

Cryogenic tooling pairs with a through-coolant spindle to deliver the -321-degree-F liquid nitrogen to the cutting edge.

“Early experimentation in the field of cryogenic machining utilised a somewhat primitive approach,” says Tecos. “Liquid nitrogen would be externally sprayed at the tool in the hope of removing heat. While that was somewhat intuitive, when you dissect the process and examine how chips are formed, you realise that from an external perspective, there is no good way to get the liquid nitrogen to the cutting edge where it needs to be. It would dissipate during the spraying process and not effectively reduce the temperature at the cut.

“Another thing we discovered is that the external spray method exposed the workpieces to a temperature of minus-196 degrees Celsius that needs to be maintained to keep the nitrogen in a liquid state. In many cases, that makes the workpiece materials even harder to cut, which is self-defeating.”

A new, completely internal liquid nitrogen delivery system has evolved under the research and direction of 5ME, and is now being used by aerospace, defence, and heavy equipment manufacturers that regularly work with titanium, stainless steel, hardened steel, carbon-fibre composites, and other hard-to-machine metals. The process has received both roughing and finishing machining approvals for titanium components used in Lockheed Martin’s F35 jet fighter series.

“We have developed a way to route the liquid nitrogen not just through the machine and spindle, but actually inside through the tool to directly below the cutting edge,” says Tecos. “That’s where the process has the optimum opportunity to remove heat.

The liquid nitrogen is then routed to ports where it is back-vented away from the workpiece.”

The cold process touts several advantages, but increased tool life and faster cutting are the two that can add the most to a manufacturer’s bottom line. Tecos recommends viewing the two benefits on a sliding scale.

“You can optimise the process for much better tool life at the same cutting speeds,

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or you can optimise it for the same tool life with highly increased metal removal rates.

Sometimes there is a middle ground where a manufacturer can increase performance in both areas.”

Material removal rates were quoted as being anywhere between 1.5 and five times faster than conventional milling. In one case study, according to Tecos, a titanium component cycle time dropped from 44 hours to 21 hours, a cycle time reduction of 52%.

Other advantages are environmental. As the liquid nitrogen heats up during the cutting process, it turns into a harmless, inert nitrogen gas and is absorbed by the atmosphere. Coolant is eliminated from the process, and since the chips are dry, there is no need for a cleansing process before they can be reclaimed. In most cases, compressed air can be used to blow them away from the cutting zone.

“We see this as a very green, sustainable machining process,” says Tecos. “Nearly 80% of the air we breathe is composed of nitrogen. We look at it as simply borrowing nitrogen from the atmosphere, using it for a manufacturing process, and giving it back as a non-greenhouse gas.”

New or retrofit 5ME has worked with several OEMs to develop equipment specifically for the cryogenics system, but the majority of mills, particularly those that allow throughspindle coolant delivery, can be converted.

The conversion kit includes a liquid nitrogen source, feed system, subcooler, cryogenic controller, and cryogenic tooling.

“If a machine has been designed to use the inner diameter of the draw bar for throughspindle coolant, that is an advantage because there is less chance that any engineering or modifications will need to be done,” Tecos says.

Lee Johnston, Applications Engineer at Okuma, describes the mill conversion process: “Basically, you replace the through-spindle coolant system with the liquid nitrogen cryogenic system. A vacuum-insulated tube or lance runs down the centre of the spindle to deliver the nitrogen to the toolholder and through the tool.”

Any through-coolant spindle can be used for the cryogenic process.

A subcooler to re-chill the nitrogen and ensure the single-phase liquid state at minus-196 degrees Celsius during its flow to the cutting edge is attached to the top of the mill. The cryogenic controller is attached where the operator can easily adjust the flow rate.

Flexible, vacuum-jacketed lines – each a tube within a tube separated by an airless void – prevent the frigid temperatures from escaping from the inner tube while delivering liquid nitrogen from the tanks to the tooling.

This protects machine components and the spindle from the extreme cold.

Material Removal Left: Cryogenic milling of exotic, hard-to-cut materials can cut cycle times, reduce tooling wear, and virtually eliminate the heat-affected zone that creates the white layer.

Liquid nitrogen is routed to directly below the cutting edge to remove heat from the cutting process for hard-to-cut materials.

the cryogenic process. The only caution is that the operator has to be observant and check the temperature of the tool before grabbing it.”

Cryogenic gloves can be used if the tool needs to be physically removed immediately following use or it can be returned to the toolholder to warm up.

An infrared thermometer can determine if the tool is safe to be handled without protection.

Flexibility (if needed)

The system is low-pressure and selfpressurised, so it doesn’t require any auxiliary pumps or motors. If the converted machine will be used exclusively for cryogenic processing, systems that would have been used for coolant delivery can be removed. Liquid nitrogen tanks can be positioned behind the machine or outside the building.

Delivering the cool The tooling is application-specific. It is manufactured from a carbide grade that can withstand the cold and is designed to enable the liquid nitrogen to flow below the tool’s cutting edge and back-vent away from the workpiece. According to 5ME, the combination of the cryogenic process and its aerospace-grade cryogenic inserts have provided up to ten times longer tool life when compared with conventional milling and tooling used for the same application.

“The tool will have an internal hole that runs down the centre to the tip of the tool, and it

also has extra passageways that spiral up behind the flutes and vent above the cut edge,” says Johnston. “The idea is to use the cooling effect to release the heat from the cut zone without introducing the liquid nitrogen to the material itself.”

The liquid nitrogen flow adds one variable to be monitored. Mike Kerscher, National Applications Engineering Manager at Mazak, says: “The liquid nitrogen flow will need to be adjusted just like feeds and speeds in a conventional operation.

Providing more liquid nitrogen than necessary is not a problem except that it is wasteful. Supplying more will not make the process any colder. It will just evaporate.”

The tool balancing processes remain the same.

“It is kind of strange,” says Kerscher. “We use heat-shrink tooling for our cryogenic cutting so the tools are either very warm because they have just been heated up, or very cold because they have been used in

Once a machine is converted, chances are it will be dedicated to cryogenic processing, but it could still be used for coolant-based milling if the coolant-delivery pumps and motors are still in place and the manufacturer is willing to invest the time to make the switch. The trade-off is the loss of the through-spindle coolant delivery because the spindle passage would house the cryogenic fluid delivery tube. The return to traditional machining would require milling dry or using a flood coolant system.

“There is no reason a machine couldn’t be converted and then used for conventional milling,” says Kerscher. “But if a company is going to convert a machine to cryogenics, chances are they have a high demand for machining exotic metals, tough nickelbased alloys, and would want to dedicate that machine to the process.”

Johnston agrees that cryogenics has a specific niche today.

“Manufacturers are very excited about this process, but not every milling application can actually benefit from it,” he says. “It will work very well for shops that machine the tough materials.”

This article first appeared in the December 2016 issue of Canadian Metalworking. www.canadianmetalworking.com

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104

Forum LAW

Getting the terms of trade right

Many clients trade with customers on credit. When doing so, there is a risk that customers might be unable to pay, as explained by Ian Rosenfeld and Emma Simpson.

Sometimes we find that businesses are not doing everything they can to ensure they are paid for the goods or services they provide, and sometimes they do not involve solicitors until it is already too late to correct the mistakes. There are, however, some basic steps a business can take to afford itself some protection from its customer’s financial issues.

1: Confirm which entity you are to be dealing with In some cases, what may appear to be a single business could in fact be made up of several different entities or it may be a partnership of individuals. If the customer falls behind on payments, it can be difficult to take action for recovery of any outstanding amounts if it is not clear which entity you were trading with.

2: Ensure your customer signs a credit application It should include terms and conditions which clearly state what the terms of the engagement are and which are tailor made to fit your business. When a party defaults on the terms, it should be clear based on the terms that they have done so. Where parties proceed on terms that are either not in writing or are poorly written and unclear it can complicate the recovery process. If there are no terms of trade, for example, then it will be unclear when the customer is in default. It may also be in dispute who is responsible for certain charges, for example freight and storage charges and interest.

3: Consider asking for further protection for payment Examples include: a direct debit arrangement; a charging clause which will allow you to lodge a caveat over any real estate the customer may own; a personal guarantee from one or more of the directors. In some cases it will not be possible to have your customers agree to these. Nonetheless, where it is possible, taking these simple steps can encourage customers to pay on time and increases the likelihood of recovery in the long term.

4: Register you security interest on the Personal Property Security Register (PPSR) If you sell goods to customers on a retention of title basis (meaning that the goods remain your property until the customer has paid for the goods in full), it is also critical that you register your security interest in these goods PPSR. Generally, registration must occur prior to the goods being supplied to your customer. If your customer becomes insolvent or bankrupt and you have not registered your security interest in the required timeframes or at all, you will have no claim to the goods you have supplied to your customer which are unpaid. The fact that you ‘own’ the goods will not protect you.

If you register your security interest in the required timeframe, you will have a stronger claim for return of the goods or the sale proceeds in respect of the goods in the event of insolvency or bankruptcy of your customer. You do not need to register every time you supply goods to a customer. A single registration in respect of each customer is sufficient if you are routinely supplying goods under a single set of terms and conditions.

Does your organisation have a registrable security interest?

• If your organisation has a registrable security interest, you must register the security interest on the Personal Property Securities Register (PPSR) within the appropriate timeframe for your security interest to be enforceable.

AMT Jun/Jul 2017

• Failure to register can have severe consequences for your organisation if your customer becomes insolvent. Title or ownership of the goods may not offer sufficient protection.

• Generally speaking, security interests must be registered within 20 business days of the creation of the security interest (i.e., the earlier of when the agreement is signed and your customer taking possession of the property).

• However, some security interests must be registered before your customer takes possession of the relevant property.

• We recommend registering security interests immediately before the relevant agreement giving rise to the security interest is signed (or immediately before your customer obtains possession of the personal property, if this date is earlier).

Supplying goods on Retention of Title (ROT) terms Does your organisation provide goods to customers on the basis that payment is due after delivery, and title to the goods does not pass until payment? If yes, your organisation may have a registrable security interest in the goods which must be registered on the PPSR. Supplying goods on consignment Does your organisation deliver goods to customers on consignment - meaning that you or your finance company retain title until the goods are sold by your customer dealer? If yes, your organisation may have a registrable security interest in the goods which must be registered on the PPSR. Leasing equipment to customers (including by way of hire purchase) Do you provide goods to customers pursuant to a lease or hire purchase arrangement?. If yes, your organisation may have a registrable security interest in the goods which must be registered on the PPSR. Storing Goods on third party premises Does your organisation (or a customer) store goods or inventory on premises owned or leased by a third party? If yes, your organisation may have a registrable security interest in the goods which must be registered on the PPSR. Export Arrangements Does your organisation lease or supply goods on ROT or consignment terms to customers incorporated overseas or over assets located overseas? If yes, your organisation may need to register its security interest in Australia and in the jurisdiction of that foreign company.

PPSR registration remains the safest and most reliable way to perfect all of your security interests, even where you may have possession of the secured property or a right to possess the secured property in the future. For the vast majority of secured parties, registration on the PPSR is an inexpensive way to ensure their security has the strongest possible protection.

Rigby Cooke can assist with bringing your terms of trade up to date to ensure adequate protection and also assist businesses involved in disputes over unpaid debts. For more information, please contact Rigby Cooke on 03 9321 7888 or: Ian Rosenfeld, Partner: irosenfeld@rigbycooke.com.au Emma Simpson, Associate: esimpson@rigbycooke.com.au www.rigbycooke.com.au

Forum

Heading

Export

Protecting your IP when exporting

Exporting can be challenging – particularly the IP aspects. Here, Andrew Watson discusses some IP strategies that will help put you on the path to export success.

Working with small and medium business (SME) exporters on a daily basis, we get a lot of feedback on some of the key challenges they face when entering new overseas markets. From understanding cultural differences to what currency to trade in, the challenges of exporting can seem daunting, even to an established business.

One issue that continually comes up in our conversations with SME exporters is Intellectual Property (IP). Protecting your IP in the domestic market can seem confusing, open that up to multiple overseas markets and the task can appear overwhelming.

While one approach might be easy to file IP registrations in every market, it’s an approach that is neither practical nor cost-effective for most SME exporters. Coming up with an IP strategy is an excellent way to maximise your IP protection while minimising costs.

We’ve teamed up with IP Australia to develop the Protecting your IP overseas specialist paper. Here are five steps we’ve addressed to help you develop a robust IP strategy for your export business that will help put you on the right path for export success:

Consider your export strategy Be as clear as possible about which markets offer the best potential for your product– your IP strategy will be driven by your export strategy. The markets you target may depend on macroeconomic factors, like population size, demographics or disposable income, or it may come down to the markets with the best cultural fit for your product.

For Scott Boocock, inventor of Hegs Pegs, it was a combination of factors that helped him decide which countries he should export his innovative ‘peg with a hook’ to. “Our strategy for export was to choose countries with over 20 million people, and which had a level of GDP where people would go to the supermarket and actually spend money to buy Hegs Pegs.”

Being clear about which markets you want to target will make it easier when you start looking into the IP arrangements that apply to each jurisdiction.

Another option is to sell the rights to your IP to a third party, allowing them to manufacture and sell your product in particular markets, rather than exporting yourself.

Do your research When exporting to a new country, along with focusing on protecting your own IP, you’ll also need to ensure that you’re not breaching another company’s IP in the process. While your brand and product range may be unique in Australia, doing some research can help to prevent your company from expensive legal challenges from potential overseas competitors. Engaging an IP attorney to complete a thorough search on your behalf is a great idea, however doing some research yourself at first instance when putting together your export strategy will also help to ensure that there are no nasty surprises. You should also confirm that your brand and/or product name, and any images that you use, are not considered unlucky or offensive in other languages and cultures.

Choose your solutions You may be surprised to learn that your product may have more than one patentable element. Given that there are costs involved, this means that you may need to decide which element (or elements) of your product to cover with IP protection.

The answer isn’t always straightforward, something that Scott Boocock from Hegs discovered.

When he first came up with the design for the Hegs peg, Scott protected the hook feature with a patent, as this was an inventive element. But he soon realised that his IP extended much further than that. “When we did a novelty check on the Heg peg,” says Boocock, “we discovered that it had six patentable elements.

We’ve got a patent on the hook, but also on the design, which means people can’t make a peg with bigger or smaller hooks – the whole system is protected.”

A good approach is to prioritise the IP elements of your product, and think about how you might like to use each one in the future.

This will help you to decide on the most valuable element(s), which will make it easier to choose the correct IP solution to protect it.

Understand the costs While every market is different, protecting all of your IP across multiple markets could prove to be an expensive exercise, especially if more than one element needs protection. That’s why you may need to balance the costs involved with the potential costs to your business, should someone copy and sell your product.

Monique File, co-owner of b.box baby goods, says that deciding where to protect your IP is essentially a commercial decision.

“For a new business starting out with limited funds,” she says, “it becomes a question of ‘what do you invest in - protecting your IP or developing your products?’ While b.box invests a lot in IP protection, commercially it didn’t make sense for it to register trade marks in every single market around the world.

Hegs Pegs founder, Boocock, agrees that the costs of the right IP protection are well worth it. “The money is not just lost – it’s an actual asset on the balance sheet that you can sell,” he said.“Every time I go back to the valuation of the company, it’s all based around that patent becoming stronger and stronger, and more valuable as the business grows.”

Andrew Watson is Executive Director, Export Finance, Efic (Export Finance and Insurance Corporation). Efic is a specialist financier that delivers simple and creative solutions for Australian small and medium businesses - to enable them to win business, grow internationally and achieve export success.

Through its loans, guarantees and bonds, Efic has helped many Australian exporters and subcontractors take advantage of new contract opportunities that may otherwise have been out of reach. info@efic.gov.au ph: 1800 093 724 www.efic.gov.au

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Forum OHS

ISO 45001: OH&S Management Systems

With the release of the new ISO 9001: Quality Management Systems and ISO 14001: Environmental Management Systems in September 2015, the long-awaited ISO 45001: OH&S Management Systems is expected to be released in 2018. Here, Jo Kitney provides an update on ISO 45001 and how businesses can prepare for the introduction of this new Management System Standard.

ISO Standards The ISO (International Organisation for Standardisation) is the world’s largest developer of voluntary International Standards with many organisations referring to ISO standards in their business operations and to gain certification.

ISO standards are technically reviewed every 10 years and with the release of these latest standards, the ISO has taken the opportunity to create a high level structure common across their family of Management System Standards (MSS).

Standards already under the common framework include ISO 9001: Quality, ISO 14001: Environment, ISO 22000: Food Safety and ISO 50001: Energy Management. Although delayed in its release, the new ISO 45001 (OH&S) is due to be released in February (possibly June or July) 2018.

ISO 45001 The introduction of ISO 45001: OH&S Management Systems responds to the need to harmonise WHS/OHS management systems through a common international standard and shared best practices. Currently, the international standard is OHSAS 18001: 2007, with AS/NZ 4801: 2004 more commonly used in Australia and New Zealand. ISO 45001 will have the same high level structure (HLS) as other ISO management system standards whilst addressing OHS management practices.

Developing a new ISO standard and for an area as important and complex as health and safety is no easy feat. The standard is being developed by a committee of OHS experts, and follows other generic management system approaches such as ISO 9001 and ISO 14001. It also takes into account other international standards in this area such as OHSAS 18001, the International Labour Organisation’s ILO-OSH Guidelines and input from multiple countries, including Australia.

Benefits of the Standard There are multiple benefits for organisations which choose to adopt and implement ISO 45001. Along with enabling compliance with WHS legal obligations, reducing work-related incidents, injury and ill health and eliminating or managing health and safety risks, the Standard provides the opportunity to bring OHS into the heart of an organisation and align its strategic direction and business processes with OHS management.

Similar to other MSS, ISO 45001 should enable improvements to performance and effectiveness, demonstrate corporate responsibility, meet customer and supply chain requirements, protect brand reputation and motivate and engage personnel through leadership, participation and consultation.

High Level Structure The common framework in the HLS provides organisations with the opportunity to integrate management systems and business practices and contains 10 elements: 1. Scope 3. Terms and definitions 5. Leadership

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2. Normative references 4. Context of the organization 6. Planning

7. Support 9. Performance Evaluation

8. Operation 10. Improvement

Common text and terminology is introduced across the standards.

Elements that continue from previous ISO MSS include policy, leadership and management commitment, management of risk, training and information, operational controls, performance monitoring, non-conformances, management review and continuous improvement.

There is more focus on the context of the organisation to ensure the management system reflects its size, location/s, structure and industry type, on meeting legal and other obligations (incl. customer or client requirements), planning and resourcing, outsourcing, procurement and contractor management. New elements include actions to address risks and opportunity, ‘documented information’ (to reflect ways data may be held by an organization) and management of change.

ISO 45001 and WHS Duties The combination of the elements contained in ISO 45001 are well positioned to enable an organisation to address WHS duties for the four duty holders in WHS legislation; Officers, Person Conducting the Business or Undertaking (PCBU), Workers and Others.

By methodically working through each element of ISO/DIS 45001, an organisation can cross-check their system against the obligations laid down in WHS legislation to ensure duties are met.

Business Action Whilst ISO 45001 has been delayed in its release, organisations can still develop or update their OHSMS with reference to the HLS, enabling them to be better prepared for migration to ISO 45001 when it is released. As a consultancy practice which designs and implements WHS/OHS management systems for organisations, we have based the systems we develop on the new HLS for the past few years.

Organisations going through transitions to ISO 9001: 2015 and ISO 14001: 2015 will also find it significantly easier to implement ISO 45001 or any other ISO MSS based on the HLS in the future.

Draft International Standard The second Draft International Standard (DIS) of ISO 45001 was published on 19 May 2017, with ballot period for comments ending on 13 July 2017. Whilst some changes may occur to the Standard following this discussion and feedback period, businesses would be well placed to obtain a copy of the ISO/DIS 45001 when released. The document will be a useful reference for anticipating the forthcoming Standard and commencing updates to their WHS/ OHS management system.

For further information go to www.iso.org. Subscribe to receive their free e-Newsletter and notification of the release of the ISO/DIS 45001. Jo Kitney is the Managing Director and Principle Consultant with Kitney Occupational Health and Safety. Kitney is a Brisbane-based consultancy practice specialising in due diligence, governance, strategy, management systems, audits and risk management. www.kitney.com

Forum

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IP

The rise of the machine – drone delivery and autonomous vehicles in transport & logistics

Remotely piloted aircraft (aerial drones) were traditionally limited to military applications and the like, but are increasingly being developed for commercial applications including point-to-point delivery of goods. Graig Gleghorn explains.

Amazon has been at the forefront of experimentation and development of delivery services using drones. This is reflected in the number of drone-related patent applications filed in the US by Amazon.

Innovative concepts described in Amazon patent filings include:

inputs in real time, potentially paving the way for drones to be safely flown beyond visual range. Telstra is reportedly now working with CASA to demonstrate the ability to safely operate drones beyond visual range utilising its mobile network and sensors (1).

Although drone technology will no doubt improve with time, parcel size and weight constraints will likely always limit drone delivery to small, relatively lightweight packages. For larger and heavier items, automated delivery cars and trucks, which are able to sense their environment, avoid collisions, make decisions and navigate without any human input, may eventually become a common sight on our roads.

• Using a blimp as an airborne distribution centre from which drones are deployed to transport goods to users (US 9,305,280).

• Drone landing platforms on top of buildings, street light poles, phone towers, etc to enable drones to recharge/ refuel, collect and drop off packages (US 9,387,928) and • Delivery drones which can land in-flight on consenting transport vehicles such as trucks and buses and recharge using the airflow generated by the vehicle in motion (US 2016/0257401).

X - a Google-affiliated company - has also been actively working on drone development.

In recently granted US 9,580,173, Google described a payload delivery system suspended from a drone.

The system includes thrusters to compensate for cross winds during descent from the drone. Other companies actively seeking to patent their drone-based delivery innovations in the US include IBM, Walmart and Qualcomm.

With so many companies investing big dollars in the development of drones and autonomous vehicles, it will be fascinating to observe the impact this disruptive technology will eventually undoubtly have over the next 10 to 20 years in transport and logistics.

More locally, Australia Post conducted closed-field drone trials in April last year in a collaboration with ARI Labs, a Melbourne robotics company. The trials sought to investigate the feasibility and safety of drones for small parcel delivery. Australia Post reported late last year they were seeking permission from the Civil Aviation Safety Authority (CASA), the governing body of drone operation in Australia, to conduct further trials to test improvements in technology. In this respect, special approval is required to operate outside of the regulations, which notably requires operators to at all times maintain sight of the drone during flight, and operate only one drone at a time. The rules governing drones in Australia were most recently amended in September 2016 with the removal of the need for an operator’s certificate or a remote pilot licence for commercial use of drones under 2kg. However, the requirement for drone pilots to maintain line of sight remains a major obstacle to drone-based commercial delivery services. The safety of drones is a key concern and proven technology solutions will be needed before government bodies can even contemplate approving beyond light of sight drone flight, particularly over densely populated areas.

In a Senate inquiry early this year on the regulatory requirements of drones, Telstra submitted that its mobile network infrastructure could be harnessed to allow drones equipped with sensors to reliably communicate on-board sensory data and receive control

California is a focal point for the development of self-driving technology with traditional car companies competing with technology giants such as Google, Apple and Uber, and artificial intelligence startups like Drive.ai to dominate the market. Founded in 2015, Drive.ai is taking a slightly different approach to other companies by focusing on creating artificial intelligence software for autonomous vehicles using deep learning to create a system that can learn behaviour and recognise patterns and then make appropriate decisions to driving scenarios not encountered previously.

It may not be well known, but IBM is also actively involved in autonomous vehicle development and has recently been granted various patents in the US - namely US 9,361,409 and US 9,566,986 - in which cognitive computing strategies are employed to model human behaviour and help autonomous vehicles to better anticipate the actions of other road vehicles driven by humans. IBM was granted over 8000 US patents in 2016 and has top the list of patent recipients for the past 24 years.

With so many companies investing big dollars in the development of drones and autonomous vehicles, it will be fascinating to observe the impact this disruptive technology will eventually undoubtedly have over the next 10 to 20 years in transport and logistics.

Graig Gleghorn is an Associate with Watermark. Australianowned Watermark has a proud 157-year history in Intellectual Asset Management. Services include: Patents and Designs, Trade Marks, IP Legal, IP Advisory and Competitive Business Intelligence. Watermark has offices in VIC, NSW and WA and the international presence is strengthened with a global network of Associates in over 50 countries, giving access to local support in the United Kingdom, United States, Europe, Asia and the sub-continent.

Email:c.gleghorn@watermark.com.au. Ph: 03 9810 1437 www.watermark.com.au

(1) https://www.itnews.com.au/news/telstra-pushes-to-fly-drones-beyondline-of-sight-460249

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108 Manufacturing matters in Australia.

Our manufacturers lead the world in numerous products and industries.

Australia’s manufacturing industry is a major contributor to our economy each year, and our manufacturers employ large numbers of people, offering them challenging, rewarding work, and providing the basis for stable, diverse communities.

Welcome to the Manufacturers’ Pavilion, the section of AMT Magazine dedicated to celebrating some of the best, most dynamic, most innovative manufacturing companies working in Australia today.

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The Manufacturers’ Pavilion highlights the capabilities of Australia’s precision engineering and advanced manufacturing industry. Over the following pages, we will look at companies delivering products and services across a variety of industrial sectors, and employing a diverse array of processes.

It builds on the successful Manufacturers’ Pavilion exhibition area within the Austech trade show and is sure to enhance the profile of the leading edge manufacturers in our sector.

If you feel your company should be featured in a future edition of the Manufacturers’ Pavilion, please contact AMTIL Sales Manager Anne Samuelsson, on 03 9800 3666, or by emailing asamuelsson@amtil.com.au

Manufacturers Heading Pavilion

Capral Aluminium – Industrial solutions Established in 1936, Capral Aluminium is dedicated to bringing world-class aluminium solutions with quick turn-around.

Recently celebrating 80 years in business, Capral is now Australia’s largest manufacturer, stockholder and distributor of rolled and extruded aluminium and other semi-finished, non-ferrous products. As a specialist supplier to the defence, transport, marine, building industry, signage and general engineering industries, to name just a few, Capral Industrial Solutions is dedicated to delivering aluminium solutions to its customers.

Capral’s manufacturing footprint includes the largest extrusion facility in Australia, situated in Bundamba (Qld). In addition, are located in Vic., which houses a 12” 44MN industrial press, NSW, SA and WA – all supplying world-class products with efficient turn-around times. Capral offers a complete range of fabrication solutions, including a new state-of-the-art sevenaxis robotic machining centre, router plate cutting solutions, knurling, precision cutting, anodising, powder coating, slotting, punching and CNC machining. These are just some of the many added-value services offered to customers.

All extrusions manufactured by Capral are produced to the chemical composition,

mechanical property and dimensional tolerances in AS/NZS 1866:1997. In addition Capral is accredited to AS/NZS ISO 9001:2008 Quality Management Systems, AS/NZS ISO 14001:2004 Environmental Management Systems, ISO/IEC 17025 NATA Accredited Mechanical Testing Laboratory and AS/NZ 4801:2001 OHS Management Systems Accreditation, and by all major international marine classification societies including DNV (Det Norske Veritas) and Lloyds Register.

Capral has developed its new 24/7 online Capral E-Store, allowing customers to shop for the core range of industrial rolled and extruded aluminium products, with no minimum order requirements. Customers can complete an entire purchase and usually receive a next-day delivery, provided orders are placed by 2pm, to metropolitan areas.

Capral’s commitment to maintaining a significant investment in R&D, including a committed team of professionals in its Technology Solutions Group. Coupled with a vast national distribution network, this ensures Capral delivers on its promise to be the customer’s first choice supplier of aluminium products and solutions.

Capral Aluminium 151 Barry Road Campbellfield, Vic 3061 T: 1800 ALUMINIUM (258 646) W: www.capral.com.au E: mill.enquiries@capral.com.au Brad Ryan National Business Development Manager T: 0404 818 146 E: Brad.Ryan@capral.com.au Capral is Australia’s largest manufacturer and distributor of aluminium extrusion profiles. Its theme of “Shaping the Future” is fuelled by its world-class aluminium extrusion plants with 8 operating presses, an extensive distribution network, comprehensive range of products and logistics capabilities and innovative R&D. Its value-added services have resulted in Capral becoming the market leader in supply to major customers, fabricators and distributors.

TRANSFORM YOUR MANUFACTURING LINE INTO AN ASSEMBLY LINE.

Capral Aluminium is committed to helping customers create their own extruded aluminium profiles with a range of complimenting value add services, including our state-of- the-art 7-axis robotic machining centre.

Delivering semi-fabricated to fully finished aluminium product solutions throughout Australia.

To find out how we can help you, contact Capral Aluminium on 1800 ALUMINIUM (258 646) or visit www.capral.com.au.

PLATE, SHEET AND COIL • ALUMINIUM EXTRUSIONS • VALUE ADD SERVICES

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Manufacturers Pavilion

Innovative industrial design and engineering Overcoming complex design challenges through unique and innovative industrial product design and engineering has provided Integra Systems’ clients with improved productivity and sales both locally and globally.

Since 1991, Integra Systems has worked with hundreds of Australian businesses and helped them enjoy prosperity in both local and export markets with product designs that blow their competition out of contention. Integra Systems is proud to be a 100% Australian-owned family business, supporting customers globally.

With innovation as the cornerstone of Integra’s culture, Integra empowers clients in key areas of industrial design, product design engineering and mechanical engineering through highly efficient in-house advanced manufacturing systems and project management expertise.

The company focuses on working collaboratively with clients so they may secure new market opportunities and overcome complex design challenges in a highly diverse range of industries. Offering a unique design process – no matter what the industry – is what distinguishes Integra, and provides you with the ultimate solution.

Empowering you to ‘Make Your Vision Real’ is what drives Integra Systems.

Breakthrough product and engineering design, followed by world-class execution, is the method. Industry recognition for this is supported by the many awards Integra has received.

Integra TransForm – Innovating for Performance Integra Systems has created a new division – Integra TransForm – which specialises in product design and manufacturing of proprietary products owned and commercialised by Integra, right here in Australia. Global research and usercentric design inform the innovation of Integra TransForm products that have been conceived with the primary purpose of improving business, productivity, sales, service and personal performance.

AeroSMART & BioSMART

BioSMART cleverly converts your office furniture to sit–stand Delivers one–touch electronic simplicity Elegant design, built for strength A quality investment that will last All Australian made

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Paul Hughes Managing Director T: 03 9359 3133 E: paul@integrasystems.com.au For over 25 years, Integra has empowered clients to achieve their aspirations through integrated solutions – innovative, creative and break-through product design engineering and advanced manufacturing from ideation to delivery.

THE WORKSMART COLLECTION

Enquire about our BioSMART 30 day free trial *conditions apply

Integra is proudly a multi-award winning enterprise

197 Northcorp Blvd Broadmeadows, Vic, 3047 T: 03 9359 3133 F: 03 9359 3166 W: www.integrasystems.com.au E: enquiries@integrasystems.com.au

Ultimately, Integra’s business relationships are centred around its ability to ‘Make your Vision Real’.

Boost your workplace performance with beautiful sit–stand solutions that deliver health and productivity improvement results.

The strong and sturdy WorkSmart Collection uses world–class electronic technology and user–centric designs to deliver elegant sit–stand solutions to the highest quality, right here in Australia.

Your workplace will directly benefit from Integra’s drive to provide elegant ergonomics that deliver results.

A division of Integra Systems Pty Ltd Telephone +61 3 9359 3133 Facsimile +61 3 9359 3166 Email sales@integratransform.com.au www.integratransform.com.au

Integra Systems

Integra BioSMART

Integra AeroSMART

Manufacturers Heading Pavilion

High-quality supplier and re-grinder of machine knives and precision grinding services Davis & Jenkins offers a unique ability to handle large workpieces – including grinding – with extreme precision and at precise bevel angles on any kind of steel, plus a reputable refurbishment service for companies Australia-wide.

Recently, Davis & Jenkins acquired a new precision surface grinding machine, which substantially increased the company’s capacity. With that new machine, it is possible to handle work pieces with dimensions as large as 3,000mm x 1,000mm x 1,040mm, and weighing as much as 3,000kg. The ability to process such large workpieces, with a height up to 1,040mm, is rare in Australia. It allows the grinding of large workpieces including machine beds, bases, fixtures, jigs and large steel plates, with extreme precision. Davis & Jenkins has four more machines with a swivellable magnetic chuck capacity, which is also very large at 5,500mm x 300mm x 250mm, enabling the grinding of precise bevel angles on any kind of steel to a length of 5,500mm. This machine has also been utilised to provide a refurbishment service for press brake tooling, in particular, MultiVee Block Dies, helping other companies to save much money by not needing a new replacement tool. Various industries use machine knives in varying qualities in

paper or metal cutting guillotines, paper or metal slitters, newspaper presses and wood chippers, just to name a few. Davis & Jenkins is a manufacturer, supplier, and re-grinder of industrial machine knives for the printing, paper, wood, plastics, and metal industries.

A core service provided by the company is precision surface grinding with very largecapacity magnetic tables. Davis & Jenkins also supplies spare parts, accessories, and consumables for the printing industry.

The company originated as engineering arm of Alex Cowan & Sons (later known as Spicers Paper) in the late 1800s. Cowan sold that arm to Messers Davis & Jenkins in 1927, who remained a partnership until being incorporated in 1955. Currently, the company has eight employees in Melbourne providing supply and grinding services for companies throughout Australia. As the Australian agent for the German TKM Group (formerly IKS Klingelnberg), Davis & Jenkins has achieved an excellent reputation as a high-quality supplier and re-grinder of machine knives and for precision grinding services.

Davis & Jenkins Pty Ltd 198 Christmas Street Fairfield Victoria 3078 T: 03 9499 2858 F: 03 9497 1992 W: davisandjenkins.com.au E: info@davisandjenkins.com.au Patrick Vlahos Production Manager T: 03 9499 2858 E: info@davisandjenkins.com.au Currently, Davis & Jenkins has eight employees in Melbourne providing supply and grinding services for companies throughout Australia. Being the Australian agent for the German TKM Group (formerly IKS Klingelnberg), Davis & Jenkins has achieved an excellent reputation as a high quality supplier and re-grinder of machine knives and precision grinding services.

Quality+precision = reputation.

Davis & Jenkins – high quality supplier anD re-grinDer of machine knives anD precision grinDing services.

• Workpieces up to 3000 x 1000 x 1040mm, with a weight of 3000kg • Swivel-able magnetic chuck capacity is 5500 x 300 x 250mm, enabling precise bevel angles on any kind of steel to a length of 5500mm.

davisandjenkins.com.au 198 Christmas Street • Fairfield VICTORIA 3078 • Tel: 03 9499 2858 • Fax: 03 9497 1992 AMT Jun/Jul 2017

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Amtil Inside

Bringing value to our members As we head to the finish of another financial year I felt it would be worthwhile to recap some of AMTIL’s activities over the past year and thank our members for their support during that time.

Over the last 12 months, Australian manufacturing has been enjoying its most positive outlook in some time. The Australian Performance of Manufacturing Index (PMI) has seen a year of near-continuous expansion, with strong growth in the PMI’s machinery and equipment sub-index providing a significant indicator of an industry that is investing and building for the future. This spirit of renewed confidence has been equally evident in conversations we’ve had with our members and contacts throughout the industry.

The year has also been a busy one for AMTIL. In May, Austech 2017 was a resounding success, with 11,500 visitors to the exhibition – the strongest attendance in years.

In addition, our Events program included site tours of five leading manufacturing facilities, 24 networking and social events, and more than 20 educational seminars on business critical subjects.

AMT Magazine has continued to go from strength to strength, consolidating its position as the leading publication on advanced manufacturing and manufacturing technology in Australia. Our digital services such as the AMTIL News and Hotspots e-mail newsletters will continue to bring to you the inside edge on the latest developments and opportunities across the industry.

As a partner in the Federal Government’s Entrepreneurs’ Programme, AMTIL’s team of expert advisers have conducted reviews of 128 businesses’ manufacturing and management processes, as well as 210 technology reviews. In addition, AMTIL has continued its work as an advocate for our industry, through continuous liaison with Federal and State Governments, as well as participation in bodies such as the Innovative Manufacturing CRC, the Advanced Manufacturing Growth Centre, and the Victorian Manufacturing Skills Taskforce.

At AMTIL we believe the greatest value we can bring is through the creation and promotion of a community of shared interest, with the common goal of advancing our industry. However, some of the financial benefits AMTIL members have received in the last year include discounts on exhibitor fees and advertising space. Overall, AMTIL has returned more than $345,000 of savings to our members through our various discount programs and service partnerships.

The next 12 months will see AMTIL continue to engage with its members, through business conferences, networking sessions and social events, as well as its flagship activities, AMT Magazine and the Entrepreneurs’ Programme. Our Member Liaison will regularly touch base with you and will be your go-to person for any questions regarding AMTIL and its activities.

Our membership fees have not increased since 2012 and the AMTIL Board of Directors has again elected to keep our membership fees unchanged for the coming year. For Manufacturing Technology Supplier members, the membership fee remains at $880 including GST, and for Manufacturing Technology User members the membership fee remains at $550 including GST. Our Associate member fee also remains unchanged at $165 including GST. I would like to thank all our members for being a valued part of our community over the past 12 months and for allowing AMTIL to continue to support the interests of the advanced manufacturing sector in Australia. If you have any questions regarding your AMTIL membership, please contact us on 03 9800 3666.

Yours sincerely,

Shane Infanti CEO, AMTIL

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Amtil Heading Inside

EIF – Special offer for AMTIL members AMTIL Service Partner EIF International Freight took a stand at Austech 2017 in May, and following a successful week exhibiting at the show, they’ve announced a very special offer for all AMTIL members, with FREE customs clearance for all new orders through until the end of June.

“This has been a great exhibition here in Melbourne, and the first for EIF in attendance,” said Suzanne Agnello, EIF’s Australian Trade Lane Manager. “The entire EIF Team are extremely delighted to be part of AMTIL Network and the want to sincerely thank the Amtil team for such a very well-run event and look forward to the next one.”

EIF are the AMTIL exclusive Service Partner for international freight forwarding for your import and export needs, both air freight and sea freight as well as Australian customs and quarantine requirements. EIF are a privately owned International freight forwarder who is a third-party logistics (3PL) provider that can offer you a comprehensive range of transportation solutions for air freight and ocean freight, both domestically and globally. EIF’s services will maintain efficiencies within your supply chain, enabling goods to be delivered where they are needed in the speed, accuracy and reliability you require.

What makes EIF International different to normal freight forwarders?

EIF’s point of difference lies in its ability to provide each client with a dedicated account manager to ensure the clear communications that are essential to a smooth transaction of cargo. Your EIF account manager will be a hands-on operator who will handle all your shipments, from order placement, through track-and-trace, arrival and customs clearance – to delivery.

EIF’s team boasts a wealth of experience that enables them to provide a comprehensive range of solutions to suit your needs at a cost-effective price. EIF International believes ‘It’s People that Deliver.’

To take advantage of EIF’s special offer for AMTIL members or to discuss any other aspect of your freight and logistics needs, call +61 3 8676 5693 or email suzanne@eifint.com.au. For more information about AMTIL’s Service Partnerships, please contact our Corporate Services Manager Greg Chalker on 03 9800 3666 or by emailing gchalker@amtil.com.au. www.eifint.com.au

At your service.

AMTIL supports its members through its select range of AMTIL Service Partners.

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www.amtil.com.au/Membership/Service-Partners

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Amtil Inside

Paralympics hero meets the CEOs CEOs from Victorian fabrication companies enjoyed an evening of food, drink and networking on 21 April at Fedeles Restaurant in Melbourne, and they were joined by a very special guest: Aussie Paralympics hero Tim Disken.

Tim – or ‘Disko’ as he’s known to his mates – was born at just 24 weeks with cerebral palsy, and has had to contend with a number of ongoing health issues. In his early years he was hospitalised regularly, and was fed via a gastrostomy tube until the age of 17. Tim’s brain and his body movements have also been affected, with increased fatigue and stiffness as well as issues with brain/body communication.

However, those setbacks have not deterred Tim from living life to the full. He completed secondary school and produces his own music.

AMTIL FOOTY TIPPING 2017

Most importantly, he began learning to swim at the age of four, and began swimming competitively when he was 10. Numerous contests and medals followed, culminating in his selection for the Australian Paralympics team and the chance to represent his country at the Rio games last year. Tim came away with three medals, including gold in the 100m S9 freestyle. He’s also the current world record holder in the SB8 50m breaststroke short course.

Still only 20 years old, Tim is showing no sign of resting on his laurels. He’s already looking forward to representing Australia on home turf at the Commonwealth Games in Gold Coast next year, and beyond that the 2020 Paralympics in Tokyo. Outside his competitive endeavours, his ambition is to give back to the organisations that helped him, with hopes to work in education support with children with special needs after his swimming career. His ultimate dream is work at Glenallen Special School in Glen Waverley, which had helped him so much in becoming who he is today – and which has now named its swimming pool the Tim Disken Pool.

The CEOs gathered at Fedeles heard Tim tell his story and discuss his plans for the future. They then agreed to sponsor Tim’s

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swimming career going forward as he prepares to defend his title in Tokyo.

The event was one of a series of CEO gatherings that AMTIL has been organising, where the heads of manufacturing businesses can meet up and discuss the issues affecting their businesses, opportunities going forward, and simply to catch up with old friends. It’s also a chance for them to give feedback to AMTIL and say what they want from their association.

“We’ve run a number of these events in Victoria and New South Wales now, and I think everyone involved has really appreciated it,” says Greg Chalker, AMTIL’s Corporate Services Manager. “We intend to roll them out nationwide going forward, with similar get-togethers happening in the other states over the coming months.”

Boy-O-Boy!! What a season we’re having. This year’s winner will be the tipster who can get a read on which team will be consistent.

The big guns have gone missing with the Swans finally getting into drive, while the interstaters out west appear to get stage fright once they leave the warm, dry air.

I guess the inconsistency of teams keeps it interesting. I can’t go past the predictable fall from grace from those Tiggies… Hardwick is proud of their effort, so was my mum when I received 3rd prize for my drawing at the Dandenong Show back in 1975! Buckley keeps dodging the axe, but for how long?

Till next time. Sanchez ROUND 09 1 raxo 2 Vineet 3 StringyBark 4 Brendan 5 Brigitte 6 Murf56 7 Swannies 8 Frank C 9 Seco 10 Lou

53 (224 53 (235) 52 (199) 52 (220) 52 (234) 52 (254) 51 (160) 51 (199) 51 (280) 50 (190)

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Industry Calendar

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event

INTERNATIONAL M-Tech Japan, Tokyo 21-23 June 2017 Mechanical components & materials technology expo. www.mtech-tokyo.jp/en

EMO Germany, Hannover 18-23 September 2017 The world’s premier trade fair for the metalworking sector. www.emo-hannover.de/home

METALCON USA, LA 18-20 October 2017 International metalworking trade show for the construction industry. www.metalcon.com/metalcon17

METEF Italy, Verona 21-24 June 2017 Raw materials, processing, machining, technologies, machinery. Co-located with the Aluminium ICEB World Congress. www.metef.com

Metal Osaka Japan, Osaka 20-22 September 2017 Metalworking trade show. Includes press/die cast, sheet metal processing machines. www.metal-kansai.jp/en

Manufacturing Myanmar Myanmar, Yangon 20-22 October 2017 Intl. industrial manufacturing exhibition.

Colocated with Tools & Hardware Myanmar.

Intermach Myanmar, Subcon Myanmar, Metal Myanmar, and MYANPLAS (Plastic and Rubber exhibition). www.manufacturingmyanmar.com

AI Expo Japan, Tokyo 28-30 June 2017 Artificial Intelligence Exhibition & Conference. www.ai-expo.jp/en China International Plate Metal Expo China, Guangzhou 28-30 June 2017 Steel smelting technology, plate, strip and steel band, wire rod machinery for metal processing. www.julang.com.cn/english MTA VIETNAMVietnam, Ho Chi Minh City 4 -7 July 2017 Precision engineering, machine tools and metalworking exhibition & conference. http://mtavietnam.com Manufacturing Surabaya Indonesia, Surabaya, 19-22 July 2017 Machine tool, metalworking and allied industries exhibition. http://manufacturingsurabaya.com Aluminium China China, Shanghai 19-21 July 2017 Asia’s leading trade fair for the aluminium industry. www.aluminiumchina.com/en PDMEX Philippines, Manila 23-26 August 2017 Die & mould, machineries and equipment exhibition. http://pdmex.weebly.com CIEME China, Shenyang 1-5 September 2017 International manufacturing equipment exhibition. Includes machine tools, accessories. http://english.cieme.org.cn IMEX India, Mumbai 8-10 September 2017 International Machine Tools Expo. www.imexonline.com WESTEC USA, LA 12-14 September 2017 Features metalworking equipment, metrology, digital, software, engineering. www.westeconline.com

AMT Jun/Jul 2017

Russian Industrialist Forum Russia, St. Petersburg 20-22 September 2017 Includes automation, robotics, manufacturing technology, production engineering, engineering. http://promexpo.expoforum.ru/en/main CMTS Canadian Manufacturing Technology Show Canada, Mississauga 25-28 September 2017 Includes machine tools, metal forming/cutting/ shaping/tools and accessories, Q&I. Colocated with Industrial Automation Canada, CeMAT and Motion, Drive & Automation. https://industrialtechnology.ca Materials Week Germany, Dresden 27-29 September 2017 Includes advanced materials, composites, automotive parts, aerospace, industrial design, electronics, it, machine tools, Q&I. www.werkstoffwoche.de/home Northern Manufacturing & Electronics UK, Manchester 27-28 September 2017 Includes machine tools, automation, handling, design & rapid prototyping, Q&I,, electronics, fastenings, mouldings. www.industrynorth.co.uk Toolex Poland 3-5 October 2017 International Machine Tools expo. www.exposilesia.pl/toolex/uk ZEPS Intermetal Bosnia-Hercegovina, Zenica 3-7 October 2017 Includes metallurgical machines for metal processing, engineering. www.zeps.com/site/en MTA Vietnam, Hanoi 11-13 October 2017 International precision engineering, machine tools and metalworking exhibition. http://mtahanoi.com Metalex Vietnam Vietnam, Saigon 12-14 October 2017 Intl. machine tools exhibition. Colocated with Electronics Assembly and Industrial Components & Subcontracting Vietnam. http://metalexvietnam.com

Mashex Moscow Russia, Moscow 24-26 October 2017 International exhibition for sheet metal working, pipe bending technologies, machine tools. www.mashex.ru/en-GB Euromold Germany, Munich 24-26 October 2017 International exhibition for mould and pattern making, tooling, design, additive manufacturing and application development. http://euromold.com/en Korea Metal Week South Korea, Goyang 24-27 October 2017 International metal technology exhibition.

Includes automation, robotics, manufacturing technology, production engineering, engineering, machine tools. Co-located with Tool Tech and Korea Metal Week. www.korea-metal.com/en MSE Singapore 25-27 October 2017 Manufacturing Solutions Expo. Showcasing emerging technologies and solutions.

Includes digital factory, industrial automation, sustainable environment and supply chains. www.ms-expo.com Fabtech USA, Chicago 6-9 November 2017 Claimed to be North America’s largest metal forming, fabricating, welding and finishing event. www.fabtechexpo.com MWCS China, Shanghai 7-11 November 2017 Metalworking and CNC Machine Tool Show. www.metalworkingchina.com/en Formnext Germany, Frankfurt 14-17 November 2017 International exhibition on next-generation manufacturing technologies. Includes additive manufacturing, industrial tooling, design. Q&I. www.mesago.de/en/formnext/home.htm

Industry Calendar Heading local Australian Energy Storage Sydney, International Convention Centre 14-15 June 2017 Sydney’s only dedicated energy storage exhibition. This year’s theme ‘Investing in Australia’s Energy Storage Future’. www.australianenergystorage.com.au Adelaide Boat Show Adelaide Event & Exhibition Centre 30 June – 3 July 2017 Leading recreational boating event. www.adelaideboatshow.com.au Foodpro Sydney, Darling Harbour 16-19 July 2017 Showcases the latest technology and innovations in food processing, packaging, science and technology. http://foodproexh.com Sydney Boat Show Sydney International Convention Centre, 3-7 August 2017 Largest recreational marine event in the southern hemisphere. www.sydneyboatshow.com.au AWRE expo Melbourne Convention Centre 23-24 August 2017.

Dedicated to the Australasian waste & recycling marketplace. Includes latest innovations and seminars and workshops. www.awre.com.au AIMEX Sydney Showground 29-31 August 2017 Asia Pacific’s inernational mining exhibition.

Future of Mining and live demonstrations of new mining processes and technologies. www.aimex.com.au/home Safety in Action Melbourne Convention & Exhibition Centre 5-7 September 2017 www.safetyinaction.net.au/melbourne Pacific 2017 Sydney 3-5 October 2017 Exhibition of the latest maritime and naval defence technologies for the Indo- Asia Pacific region for industry, government and defence professionals. www.pacific2017.com.au

All-Energy Australia 2017 Melbourne Convention & Exhibition Centre 11-12 October 2017 Australia’s most comprehensive clean & renewable energy event. www.all-energy.com.au Ausbiotech 2017 Adelaide Convention Centre 25-26 October 2017 Areas of bio-therapeutics, medical technology (devices and diagnostics), food technology, industrial and agricultural. www.ausbiotechnc.org International Mining & Resources Conference Melbourne Convention & Exhibition Centre 30 Oct - 2 Nov 2017 Australia’s largest mining conference. Latest innovations, technology and services for the mining industry. http://imarcmelbourne.com/ Corrosion & Prevention Sydney, Intl. Convention Centre 12-15 November 2017 Event on corrosion mitigation. Corrosion control products, nano technology, cleaning equipment, air solutions, engineering, technology etc. in the Industrial industry. https://conference.corrosion.com.au AusRAIL PLUS 2017 Brisbane Convention & Exhibition Centre 21-23 November 2017 Exhibition for Australia’s rail sector. Largest rail event in Australasia. This year’s theme: ‘Rail’s Digital Revolution’. www.ausrail.com Asia-Pacific International Conference on Additive Manufacturing Melbourne, RMIT 4-6 December 2017 This APICAM is the first conference of its kind to be held in the Asia-Pacific region.

The conference has been created to provide an opportunity for industry professionals and thinkers to come together, share knowledge and engage in the type of networking that is vital to the furthering of the additive manufacturing industry. Early-Bird Registrations will close 31 August 2017. www.apicam2017.com.au

Advertiser Index 3D Systems (USA) 79 Alfex CNC 20 Alfex CNC 21 Applied Machinery 11 Avian Machinery Pty Ltd 59 Bolts & Industrial Supplies 61 Bystronic P/L 6 Bystronic 7 Complete Machine Tools 17 Compresssed Air Australia 19 Dimac 55 ECI Solutions 27 EIF Australia 87 EMO 23 Emona Instruments 83 Hare & Forbes 4 Hare & Forbes 5 Headland OBC IMTS Laser P/L 39 Industrial Laser 53 Iscar 2 Iscar 3 John Hart 25 Machinery Forum 119 Machines 4U 41 MTI Qualos 49 NORD 95 Okuma 9 Precision Specialty Tooling 47 QMI Solutions 29 Renishaw Oceania 85 Robert Bosch Australia 93 Sandvik 43 Seco Tools 15 SEW Eurodrive 97 Sheetmetal Tooling 99 Sutton Tools 1 Sutton Tools 13 Thyssenkrupp 57 Capral Ltd. Man Pav 109 Davis & Jenkins Man Pav 110 Integra Systems Man Pav 111 Your Industry. Your Magazine.

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AMT Jun/Jul 2017

117

118

history

Big wheels & little wheels – the story of Sir Laurence John Hartnett (1898 – 1986)

Beholden to Holden: An industry is born

Part 19

UK-born Sir Laurence Hartnett arrived in Australia in 1934. The visionary Sir Laurence became known as Australia’s ‘Father of the Holden’ – and much more. Before we continue our story of the success achieved by Sir Laurence with the GM and Holden’s merger, we digress in order to answer a question often posed to him.

W

henever I’m asked who founded the Australian motor-body-building industry I have no hesitation in nominating Sydney Albert Cheney, the head of S.A.Cheney Pty. Ltd., the Vauxhall distributors in Melbourne.

Cheney was a distributor of Dodge cars in Adelaide during the First World War, and was one of the pioneers of the car-retailing industry in Australia. In those days the horse-andbuggy era was still very much alive, and cars were regarded as a novelty, with reluctance to admit that cars would ever supersede the horse.

Soon after the war started in 1914, there was a move by the Federal Government to ban car imports. Shipping space was scarce and all luxury imports should be stopped, the critics said. The motor traders, with Cheney at their head in South Australia, vigorously opposed a ban. They argued that it would bring hardship to farmers, who needed the cars to help overcome the shortage of farm labour caused by mass enlistment of workers. And a ban on imports would put every car-selling company out of business. They argued that a quota of shipping space should be allotted to the car industry. The Government took no action until after America’s entry into the war in 1917. Then, on 10 August 1917, the Government announced its decision: it banned the import of completed’ cars, but allowed unrestricted import of car chassis.

Now there was a quandary: hardly any motor-body-building facilities existed in Australia at the time – and those few were being made only by slow and costly methods. Cheney had seen mass-production of bodies in America and he felt sure that mass-production could be developed in Australia. This decision threw the responsibility on to Australia to create a new industry - an industry that could become one of the biggest employers of labour in the country. That morning Cheney went into action. He decided that if the Government would agree to allow the bonnet, scuttle, dash, mudguards, running-board and valences to come in as part of the chassis, the rest of the body would be reasonably simple to make. But where should the bodies be made? And by whom? Adelaide had virtually no industries in 1917, except a soap factory, a couple of jam factories, a company which made furniture, and an enterprising firm of saddlery makers, Holden and Frost.

The furniture-maker was the obvious man to make car bodies, thought Cheney. He rang him at 6.30 a.m.. But the furniture-maker was not interested - emphatically not. He hung up on Cheney, and possibly, went back to bed. And turned his back on a chance to become a millionaire. The next choice was the saddler, H.J. Holden.

Cheney spoke to Holden’s son, Edward Holden, asking him to come with his father to Cheney’s office at 8.30 a.m. to discuss a matter of great importance. Young Holden agreed. Cheney knew of the Holden family’s reputation for business acumen from an incident

Left: Circa 1914. Sydney Albert Cheney (18831968). Born in South Australia, Cheney was South Australia’s first car salesman and in 1922, he set up Australia’s first car-assembly line. It was Cheney who conceived the idea of Australia building car bodies during the 1917 car-import embargo – an idea which was met with derision at the time but which was successfully adopted

by Holden.

during the Boer War in South Africa, when the firm secured the bulk of the contracts for the supply of harness for the Australian cavalry contingents.

Father and son arrived promptly at 8.30.

Cheney, enthusiastic, spoke to them of the chance the Government decision presented to Australia to start a completely new industry.

The Holdens hadn’t even read the announcement, and they didn’t know the first thing about building car bodies, but they were quick to appreciate the possibilities in the situation. Within minutes, Cheney had them as enthusiastic as himself. Holden said he’d need capital to get started, and left immediately to see his banker. In a little while he returned with the news that the Bank of Adelaide would let him have £50,000. The Holdens and Cheney agreed that a Dodge body should be built, and a price reached, so that the design, specification and price could be put to dealers.

Cheney called a conference of dealers in Sydney. The first body was built in Adelaide at a coach works which Holden had acquired by a share take-over, and the complete car with local body was taken by train to Sydney. It was put on a Dodge chassis, and rolled in to the meeting. It was well made, comfortably upholstered, and it had a quality appearance. Cheney and the Holdens staggered the dealers when they announced that it was an Australian-made body and would sell for £57/10/- (the only other Australian-made body, the Ford, was £125 higher.) The dealers cheered. The Cheney plan was approved. Dealers placed orders immediately, and the Holdens went back to Adelaide to procure plant and staff for their new industry. The results were to be momentous for Australia.

To be continued…

Circa 1905: Bringing suspicious and isolated South Australian farmers on-board was no mean feat. A tough test was demanded for the new-fangled motor car and it involved all of Cheney’s marketing skills, patience and ingenuity.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT Jun/Jul 2017

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