Industrial Machinery Digest - April 2023

IndustrialMachineryDigest.com | April 2023

North America’s Manufacturing Resource for Industry Professionals Since 1986

IMD Industry X Blueprinting Workshop: Create Your Journey Schuler and the Smart Press Shop: Digitalization with Digital Suite Deloitte and The Smart Factory@Wichita The Laser: Our Modern Lightsaber Using Robots with Toxins Lasers and Surface Pre-Treatment Introducing EFC-02 — Suhner's Electric Force Compliance System Industry News #Interoperability #Lasers #DigitalTwin #IoT #Robotics #AdditiveManufacturing #AdvancedFuelCells

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Table of Contents

APRIL 2023 6 10

EDITORIAL DIRECTIONS

20

BUSINESS 4.0

22

TALKING SHOP

26

SAFETY & MAINTENANCE

28

INDUSTRIAL AUTOMATION

32

WORKFORCE DEVELOPMENT

36

PROCESS

40

INDUSTRY INSIGHT

41

NEW TECHNOLOGY

INDUSTRY NEWS #Interoperability #Lasers #DigitalTwin #IoT #Robotics #AdditiveManufacturing #AdvancedFuelCells IMD Industry X Blueprinting Workshop Schuler Makes Digitalization a Realization with Digital Suite New Guidelines for Hexavalent Chromium and How Robots Can Help Clean Technology Lasers: The New Tool in Surface Pre-Treatment Deloitte and The Smart Factory@Wichita: Building the Future The Laser: Our Moder Lightsaber

22

Siemens Creates New Vertical Market Dedicated to Intralogistics in the US Introducing EFC-02 — Suhner's Electric Force Compliance System Active compliance for robotic material removal

42 4749 50

20

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PRODUCT SHOWCASE CLASSIFIEDS ADVERTISER INDEX

ON THE COVER Cover Sponsor: HYDMECH Canada Corp.

Photo: Courtesy iStock Photos.

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William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

Trey Bell, Editor-in-Chief trey@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Brian Self, Associate Editor assoc.editor@indmacdig.com

Shane Bell, Creative Director sbell@indmacdig.com

SALES

Lisa Hanschu, Sr. Account Executive lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199

William C. Strickland III, National Sales 205-903-9178 | fax 866-826-5918

Adrienne Gallender, Media Adviser agallender@indmacdig.com 888-407-7737

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INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers.

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Editorial Direction

Trey Bell – Editor in Chief trey@indmacdig.com

Q1 just wrapped up, and by the time you are reading this we will be well beyond the starting line for Q2.

The shininess from the new year has probably become a bit less reflective. Now is the time though to double down and refocus on leveraging your assets - in terms of people and technology and knowledge. We hope to provide you with some insight that will get you rolling again.

Our 1Q23 Quarterly issue focused on Robotics has hit the digital racks, and we are accelerating toward more Industry 4.0 insight with this edition for April.

In Business 4.0 this month we discuss our Industrial Machinery Digest Industry X Blueprinting Workshop. These Workshops enable IMD to bring to your location our perspectives on the Industry 4.0 evolution, trends in advanced manufacturing and machinery, access to our network of experts, facilitated examination of current state of operations, and next generation visioning for change in the form of a Workshop intended to yield actionable strategies for a digital operations transformation program.

Talking Shop is a bit different in format this month. We highlight a Digitalization and Modernization Workshop in Michigan conducted by Executives from Schuler Group and Schuler North America in which they take a deep dive into their Smart Press Shop. From VDP to lasers this is a working example of Industry 4.0 in action. The backplane is Schuler’s Digital Suite for what they coin Forming Technology 4.0.

In Safety and Maintenance, our guest contributor Chris Kolb is Vice-President of Sales for Aerobotix, an innovative leader in robotic solutions for the aerospace and defense industries headquartered in Huntsville, AL. Chris looks at how robots can be used for handling toxic materials such as hexavalent chromium.

We feature some of the advances being made by Siemens in our News and Industry Insight sections. These include the new Intralogistics vertical, as well as the Siemens Xcelerator platform.

Lasers are seemingly underutilized, but expanding rapidly due to their lower maintenance costs and high effectiveness in areas like cutting, marking, welding, and for instance cleaning. In our Schuler overview, lasers play a role. However, we also feature a contributed piece on how lasers can be used to clean surfaces in our Industrial Automation section this month. We take a deeper dive on laser technology - how lasers work, a timeline on discoveries and the differences between fiber lasers and CO2 lasers, and some ideas on capabilities in our article from Process called “The Laser - our Modern Lightsaber.”

Our Workforce Development section features The Smart Factory @ Wichita, in which industry leaders such as Deloitte, Amazon Web Services, Infor, SAP, Dragos, Siemens, and Wichita State University have come together to build a working factory that features operating Industry 4.0 use cases. This isn’t an idea on a wipe board, but rather a brick and mortar (well, really a metal and concrete and wind power and solar power and glass and digital and robotic and advanced net zero emissions) masterpiece. The factory provides among other things, a place for Wichita State students to experience first hand the impact of Industry 4.0 on manufacturing.

Other industry news and several product showcases that have been curated by our staff will round out this edition. Hope you made it to ProMat 2023 - ping me (trey@indmacdig.com) with your Workshop questions.

Keep building.

8 | IMD April 2023

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies.

WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

#Interoperability Siemens to showcase TIA Portal v18 The new version of TIA Portal boosts engineering efficiency with optimized functionalities for multi-user engineering, allowing users to work in teams and parallel on projects and build and manage shared libraries. In addition, access rights can be assigned individually or by group, making collaboration more flexible.

Siemens is expanding the TIA Portal, an all-in-one engineering ecosystem with IT-oriented workflows, by integrating Simatic Automation Xpansion (Simatic AX).

This integration provides IT professionals with a familiar development environment based on Visual Studio Code and version control via GitLab. Object-oriented libraries

www.IndustrialMachineryDigest.com 10 | IMD April 2023

can be created in Structured Text and integrated. OT and IT users can use the engineering platform without reskilling.

This development is a decisive step towards IT/OT integration and counters the growing need for more skilled workers in the OT world. Simatic AX is available as a cloudbased service, allowing projects to be easily downloaded and updated at any time and place.

Version 18 of TIA Portal also offers simple and holistic engineering of 5D/6D kinematics, enabling motion control functions across six interpolating axes.

This flexibility allows companies to expand, convert, or modify production facilities - without interfering with running systems. The scope for TIA Portal and Simatic controllers has also been further extended, with the Simatic S7-1500 and the Simatic ET 200SP providing higher computing and communication performance and

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

supporting R1 redundancy. This functionality ensures the maximum availability of applications and helps solve future automation challenges.

In addition, the R1 redundancy can be quickly and flexibly integrated into existing networks with no programming effort, making it one of the most straightforward solutions on the market that can be used in various applications - factory automation, logistics, or infrastructure. The new hardware also supports the latest security standards, with the Version 18 release focusing on state-of-the-art security improvements.

In short, TIA Portal version 18 offers even more efficient and flexible automation engineering thanks to enhanced team-collaboration functionalities, IT/OT integration, the advanced engineering of kinematics, and maximum availability through R1 redundancy. As a result, it's a tool well-suited for industrial companies looking for efficient automation engineering that can be quickly modified to meet new requirements, shorten time-tomarket, counterbalance the lack of skilled workers, and most importantly, always remain competitive.

helped create approximately thirty other Smart Factory projects for large OEMs and smaller manufacturers across the United States. In 2022, more than 2,000 people visited TRUMPF in Connecticut for technology demonstrations or training, and more are expected to visit once the new Smart Factory is complete.

The privately held global TRUMPF Group, which celebrates its 100th anniversary this year, opened the North American subsidiary in 1969 and began manufacturing in Connecticut in 1974. Dedicated to meeting customer demand for proximity, TRUMPF Inc. also maintains additional offices in California, Illinois and Michigan.

Find out more about TRUMPF at www.trumpf.com

#DigitalTwin

#Lasers TRUMPF Inc. Breaks Ground on New Smart Factory Production Expansion Groundbreaking ceremony in Farmington, Connecticut marks the beginning of construction // Expansion will house sheet metal production and Smart Factory to manufacture TRUMPF Inc. laser cutting, bending and welding machinery TRUMPF Inc. has begun work on expanding its local manufacture and sheet metal assembly of fabricating machine tools in Farmington, Connecticut. The North American subsidiary of the high-tech TRUMPF Group will add 55,800 square feet to its production building for the manufacture of laser cutting, bending and welding machinery. The project is part of ongoing recovery efforts related to damage sustained after a plane crashed into the production building in September of 2021. TRUMPF will invest an estimated $40 million into the project which will include a Smart Factory that demonstrates advanced automated and connected precision sheet metal production.

Construction on the project has begun and is expected to be completed by May of 2024. The building was designed by renowned architectural firms Barkow Leibinger and Tecton Architects. More than 620 of TRUMPF’s approximately 1,500 North American employees work in Connecticut.

The Connecticut Smart Factory project will become TRUMPF’s fourth Smart Factory worldwide and second in the United States. TRUMPF Inc. opened its first U.S. Smart Factory just outside Chicago in 2017. In the past five years, more than 8,000 manufacturers have visited the working model of connected manufacturing and TRUMPF has

Siemens presents software for Real-Time Locating System (RTLS) “Location Intelligence” software expands SIMATIC RTLS location platform to include the Digital Twin of performance and warehouse Siemens “Location Intelligence” software expands the SIMATIC RTLS (Real-Time Locating System) locating platform to include the digital twin of performance and warehouse. The web-based software analyzes and visualizes dynamic data, processes events, and can be addressed directly from local ERP (Enterprise Resource Planning) or MES (Manufacturing Execution System) systems. The intelligence acquired based on position data provides the user with a comprehensive overview of material flow, order information or possible problem areas.

The transponder ID is linked to the existing order data. Depending upon the process step and order status, order information can then be displayed on the SIMATIC RTLS ePaper transponders, providing a paperless solution.

Location Intelligence also offers users the opportunity to track individual workpieces or the entire order in real time.

When the order ID is entered, the real-time positions of linked transponders are shown on the customer’s digital card.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 11

Location Intelligence will also provide manufacturers with a digital twin of warehouse logistics. Warehouse content can be easily visualized with real-time maps or a custom-built dashboard to implement and support FIFO or LIFO concepts. It can even enable a “pick by light process” by using signal lights or LEDs of the transponder that trigger a visual notification if a work order remains immobile and needs to be moved to the next production step.

With a real-time locating technology, warehouse space can be utilized efficiently, the correct goods in the right amount at the right time will be made accessible for manufacturing, shipping and distribution while increasing delivery accuracy and processes quality.

In addition, the combination of location and business information leads to transparent processes: searches are reduced to a minimum because the positions of all relevant objects on various terminals are visualized in real time.

Bottlenecks or deviations from the production schedule can be avoided, workflow anomalies identified, paperless order information retrieved, and material flow and order status assessed. At the same time, previously untapped potential for optimization in the factory can be identified through real-time analyses and rapid decision-making.

#IoT Accelerating the digital transformation of the machine tool industry with Siemens Xcelerator » » »

»

Siemens Xcelerator includes selected portfolio of IoT-enabled hardware, software and digital offerings for the machine tool industry Software applications for cloud, edge and customer servers with numerous innovations for the machine tool business First partner applications based upon Industrial Edge for Machine Tools, the open ecosystem for IoT

Siemens demonstrates how the enormous potential for optimizing machine tools can be utilized, thanks to the continuous analysis of production data. With the open digital business platform Siemens Xcelerator, IoT-enabled hardware and software, the company demonstrates how the physical world can be connected to the digital world.

Such a portfolio accelerates digital transformation and enables flexible and sustainable action both in the building of machine tools and in use.

Apps for the machine tool business with Siemens Xcelerator Siemens recently launched an open, digital business platform called Xcelerator. By doing so, the company seeks to enable customers of all sizes in the fields of industry, buildings, power generation, public utilities and mobility to accelerate their digital transformation and increase

12 | IMD April 2023

value creation. The business platform makes digital transformation easier, faster and scalable. It comprises three cornerstones — a curated portfolio of internet of things (IoT) enabled hardware, software and digital services from across Siemens and certified third-parties; a growing ecosystem of partners; and an evolving marketplace to facilitate interactions and transactions between customers, partners, and developers.

With applications such as Manage MyResources / Tools, Manage MyResources /Programs, Analyze MyPerformance /OEE, Manage MyMachines, Manage MyMachines /Remote and Analyze MyMachine /Condition, as well as the Industrial Edge for Machine Tools platform, Siemens also provides offerings for machine tools via Siemens Xcelerator, both for the machine builder and CNC machine users.

Numerous innovations for machine tool apps In the area of work preparation, Siemens is presenting several innovations at IMTS in Chicago this year for the applications Manage MyResources /Tools, Manage MyResources /Programs and Analyze MyPerformance /OEE. The apps provide intelligent resource management that allows production orders to be prepared smoothly by providing the right tools and NC programs. A central solution at the manufacturing level manages real instances of tools, tool locations and programs for parts production, using the data from the CNC. Workflows in machining environments are optimized, tool circulation and tool inventory are efficiently organized.

The utilization of production capacities can be improved by analyzing overall equipment effectiveness (OEE). All three applications offer innovations, for example, with broader connectivity even for CNC machines that are not equipped with Siemens SINUMERIK CNC, a significant development. This means nothing stands in the way of a shopfloor-wide connection of machines to resource management. In addition, Manage MyResources /Tools can now provide further valuable insights into tool usage, such as the duration of the different life phases for certain tool types.

Also new is the possibility of more efficient tool planning with reservation of tools for a machine or production order or as a standard tool. With the help of unloading lists for balancing, the planning of tool requirements will become even more efficient in the future.

For Manage MyResources /Programs, additional use cases can now be covered by the possibility to add additional file types such as drawings to NC packages.

In Analyze MyPerformance /OEE, machine status can now be configured individually. In addition, the app provides detailed insights into workpiece statistics and production progress.

For the monitoring of CNC machines during operation, Siemens is also presenting innovations for

the already available apps Manage MyMachines, Manage MyMachines / Remote and Analyze MyMachine / Condition at IMTS. These apps analyze the data generated during workpiece machining, which can then be used to improve maintenance planning. Unexpected changes, for example, in machining performance or vibration, indicate disturbed processes.

In the new version of Manage MyMachines, it is now possible to examine reports of technical faults even more closely. Also new is the now seamless transition between the two apps Manage MyMachines and Manage MyMachines /Remote, which further improves the user-friendliness and efficiency of service calls.

Manage MyMachines is now also available with broader connectivity, which supports machine controllers from other manufacturers.

Open Siemens Industrial Edge for the Machine Tool ecosystem Siemens openness to partners is demonstrated by the Industrial Edge for Machine Tools ecosystem.

Based upon the Siemens Edge Platform, Schunk, the global manufacturer of gripping systems and clamping technology, developed its iTendo Service. By combining sensor data from the tool tip and data from the NC, Schunk wants to help machine tool operators improve the machining process and prevent tool breakage.

Siemens will accelerate digitalization for a sustainable tomorrow by demonstrating how the enormous potential for machine tool optimization can be utilized, thanks to the continuous analysis of production data.

Newly expanded, highly automated facility will create new jobs in the state of Michigan Expansion featuring the latest in automated and advanced manufacturing processes to open November 2023 Today, ABB strengthened its commitment to one of its largest customer markets – the US – with construction starting on the expansion of its existing North American robotics headquarters and manufacturing facility in Auburn Hills, Michigan. The project is expected to be completed in November 2023 and represents an investment of $20 million. The expansion will create 72 highly skilled new jobs in the area and is supported by a $450,000 Michigan Business Development Program performance-based grant.

Adding to the $14 billion ABB has already invested in the US since 2010, the latest investment in its Robotics headquarters and factory will benefit customers in the Americas, particularly those in growth sectors including electric vehicles, healthcare, packaging and logistics.

With the expansion set to significantly increase the factory’s production capacity, it responds to the increased demand for automation from 70 percent of US businesses looking to bring production closer to home, as revealed by ABB Robotics’ survey of 1,610 executives in the US and

Europe in June 2022.

ABB Robotics moved into the 538,000-square-foot building in 1993 and opened the manufacturing plant in 2015, becoming the first global industrial robotics company to fully commit to a North American robotics production footprint. The expansion and increased use of automation in the factory will create new jobs, supporting the ABB Robotics Packaging & Logistics Headquarters in Atlanta, Georgia and the Robotics Lifesciences and Healthcare Hub located at the Texas Medical Center in Houston, Texas. ABB already has a workforce of approximately 350 employees at Auburn Hills.

ABB’s footprint in the US is more than 20,000 employees over more than 40 sites nationally.

“The expanded facility will feature the most advanced technology available, with AI-enabled robots and smart digital manufacturing systems supporting the production and manufacture of state-of-the-art customer solutions,” said John Bubnikovich, ABB United States Robotics Division President. “Almost

#Robotics ABB to expand Robotics factory in US Investment of $20 million will increase production at its existing Auburn Hills facility and strengthen ABB’s US leadership INDUSTRIAL MACHINERY DIGEST.COM

IMD | 13

every aspect of the site will be upgraded to enrich our efforts to attract, retain and nurture the best automation talent, while creating a US manufacturing hub and headquarters befitting of a global leader in automation.”

This investment will see the latest digital and automation technologies implemented to manufacture next-generation robots in the US, for the Americas, streamlining the delivery process and reducing lead times.

Close to 90 percent of robots delivered to customers in the US, Canada, Mexico and South America will soon be made in Auburn Hills. The plant will utilize flexible, modular production cells that are digitally connected and networked, and served by intelligent autonomous mobile robots. AI-powered robotic systems will take on tasks such as screw driving, assembling and material handling, relieving people from these tasks and enabling more rewarding work.

ABB is a technology leader in electrification and automation, enabling a more sustainable and resourceefficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated.

Building on more than 130 years of excellence, ABB’s ~105,000 employees are committed to driving innovations that accelerate industrial transformation. www.abb.com

Hypertherm Associates announces Sofos Robotics Co. as new authorized partner for Robotmaster offline programming software Hypertherm Associates, a U.S.-based manufacturer of industrial cutting systems and software, today announced a new partnership for its Robotmaster ® offline programming software for robots. As an authorized partner, Sofos Robotics Co. will include Robotmaster as part of the robotic systems they offer when end users require an easy-to-use and powerful robot programming solution.

“Sofos Robotics is a great partner. Not only are they experts and power users of the Robotmaster offline programming software, but they also have years of experience in robotic system sales and integration,” said Cory A. John, Robotmaster software sales manager.

“Finding someone who can marry the two worlds together the way Sofos Robotics can is like hitting the jackpot. I have heard nothing but great things from the customers who get the pleasure to work with the team at Sofos Robotics.”

Sofos Robotics uses Robotmaster to perform robotic system engineering including cell design, reach and feasibility studies, as well as for their programming services.

“Robotmaster is a game-changer for our clients who are looking for a programming solution that is easy to use and allows them to program complex tasks with ease,” said John Huster, Sofos Robotics president. “By using Robotmaster, our clients drastically reduce programming time and costs, especially in small batch production

14 | IMD April 2023

runs. Ultimately, by pairing Robotmaster with our robotic systems, we are able to deliver a complete solution for our clients.”

Sofos Robotics was founded by Mark Walstrom and John Huster in January 2019. Located in Ham Lake, Minnesota, they provide automation and robotic integration services to help their customers maximize efficiency in their production processes.

Robotmaster, a Hypertherm Associates brand, is an offline programming software for robots that helps manufacturers maximize productivity on production runs of all sizes. Robotmaster makes programming parts of any complexity quick and easy as a result of its integrated CAD/ CAM functionality. This intuitive and powerful solution is designed with process experts in mind reducing the need for programming and robotic expertise. Learn more at www.robotmaster.com.

Hypertherm Associates is a U.S.-based manufacturer of industrial cutting products and software. Its products, including Hypertherm plasma and OMAX waterjet systems, are used by companies around the world to build ships, airplanes, and railcars; construct steel buildings, fabricate heavy equipment, erect wind turbines, and more. In addition to cutting systems, the company creates CNCs, and software trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. Founded in 1968,

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FIRST® Robotics Competition, is an important part of SprutCAM Tech's strategy.

#AdditiveManufacturing

Scott Wisotzke Joins New Scale Robotics as Director of Sales

Velo3D Announces the 2023 “Proof is in the Printing” Roadshow Tour Across Eight U.S. Cities

New Scale Technologies has appointed Scott Wisotzke as Director of Sales for its New Scale Robotics division, expanding the division’s sales team to capture opportunities in the fast-growing market for automated metrology in high-mix, small batch manufacturing.

Scott has more than 25 years of experience in sales, sales leadership, and business development in the manufacturing and machining industries. Over 13 years with Transcat, a distributor of test, measurement, and calibration equipment and services, he held positions of increasing responsibility including Director of Field Sales for North America. He was most recently with NYMAT Machine Tool Corp. and has additional experience with tool distributor Alltite, Fluke Process Instruments, ElectriCom, and Newark Electronics. He has served in the US Marine Corps active duty and reserves. He has a Bachelor’s Degree in Management from St. John Fisher College.

The series of events highlights how engineers can achieve repeatable outcomes in real-world environments and qualify parts for production Velo3D, Inc. (NYSE: VLD), a leading metal additive manufacturing technology company for mission-critical parts, today announced its 2023 roadshow, the Proof is in the Printing Additive Manufacturing Tour, which will visit eight cities across the U.S. The tour builds on Velo3D’s previous roadshow series that brought together more than 400 engineers around the U.S. to learn about how metal additive manufacturing can help them transform their businesses.

Velo3D piloted its roadshow program in 2021.

Each roadshow is a half-day event that includes presentations from Velo3D leadership team members, partners, and customers.

By attending, engineers can hear how their peers are utilizing metal additive manufacturing to produce parts and qualify them for use by utilizing the Velo3D fully integrated additive manufacturing solution.

Presentations will also discuss how to optimize the additive manufacturing process to produce more performant parts and increase throughput.

Tour dates have been scheduled for the following cities: » Phoenix, AZ: March 29, 2023 » Denver, CO: April 27, 2023 » Houston, TX: May 17, 2023 » Jupiter, FL: June 15, 2023 » Long Beach, CA: August 17, 2023 » Detroit, MI: September 20, 2023 » Fremont, CA: October 19, 2023 » Cincinnati, OH: November 2023

SprutCAM Tech announces support for FIRST® Robotics Competition teams worldwide FRC teams from different countries that have mastered SprutCAM X are already participating in this robotics competition.

FIRST® Robotics Competition (FRC), organized by the global robotics community FIRST (For Inspiration and Recognition of Science and Technology), combines the excitement of sports with the rigor of science and technology. FRC teams (ages 14-18) design, program, and build a robot using a standard set of parts and a common set of rules to compete in a themed head-to-head challenge.

The main vector of SprutCAM X software development is to become the world's #1 solution by implementing the Offline Programming of Industrial Robots (OLP) technology in the product. OLP makes it possible to run a new machining program on a robot in just a few hours, whereas the same task takes several days with traditional online programming. The development of its global educational program, including support for initiatives such as the

Dates will be announced for roadshow events in Europe and Asia. Velo3D’s distribution partner GoEngineer will also host a roadshow in Albuquerque, NM. "If you have struggled to go into production with high- quality, additively manufactured metal parts, this roadshow lays down the groundwork to speed up and simplify the process," said Josh Brown, GoEngineer Director of Metal AM. “Attendees will leave with a clear understanding of how to utilize metal additive manufacturing for their mission-critical parts and qualify them for production use.”

Engineers interested in attending one of the shows on the tour can visit velo3d.com/roadshows to register or email info@velo3d.com.

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HII Receives Additive Manufacturing Approval from Naval Sea Systems Command Global all-domain defense partner HII (NYSE: HII) announced today that its Newport News Shipbuilding division recently received approval as a vendor to provide some additive manufacturing components to Naval Sea Systems (NAVSEA) platforms.

The certification enables NNS to use additive manufacturing, or 3D printing, to fabricate pipefittings or other potential components for use on aircraft carriers, submarines and other NAVSEA platforms.

“Innovation is driving our business transformation at Newport News Shipbuilding,” NNS Vice President of Engineering and Design Dave Bolcar said. “Our continued advances in additive manufacturing are revolutionizing naval engineering and shipbuilding. This will continue to propel our progress in efficiency, safety and affordability as we remain steadfast in our mission to deliver the critical ships our Navy needs to protect peace around the world.”

In 2018, NAVSEA approved the technical standards for 3D printing after extensive collaboration with HII and industry partners that involved the rigorous printing of test parts and materials, extensive development of an engineered test program and publishing of the results.

The first 3D-printed metal part, a piping assembly, was delivered to the U.S. Navy for installation on the NNS-built USS Harry S. Truman (CVN 75) in January 2019. Since then, NNS has received approval for several other metal 3D-printed parts on U.S. Navy ships of varying criticality.

This most recent certification is for stainless steel (316/316L grade) additively manufactured pipefittings. NNS is also pursuing approvals that will enable broader

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use and implementation of additive manufacturing across the naval enterprise. The highly digitized process could lead to cost savings and reduced production schedules for naval ships.

NNS is the only builder and refueler of nuclear-powered U.S. Navy aircraft carriers and one of just two shipyards building nuclearpowered submarines for the Navy.

Desktop Metal Qualifies Copper Alloy C18150 on the Production System™ with Sandvik Additive Manufacturing and Top Five Global Automaker »

Additive Manufacturing Users Group Awards Two Scholarships Dr. Les Kalman and Brent Griffith to be recognized at the 2023 AMUG Conference The Additive Manufacturing Users Group (AMUG) today announced the recipients of its scholarships.

Dr. Les Kalman, Assistant Professor in restorative dentistry at Western University (London, Ontario, Canada), has been awarded the Randy Stevens Scholarship for educators in additive manufacturing. Brent Griffith, P.E., is pursuing a Master of Engineering in Additive Manufacturing and Design through Penn State University (State College, Pennsylvania) and has been awarded the Guy E. Bourdeau Scholarship for students in additive manufacturing.

Online at www.amug.com.

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Also known as chromium zirconium copper, C18150 is a high-strength, high-conductivity copper alloy commonly used in thermal transfer applications, such as electrical connectors, welding electrodes, as well as other electrical and electronic components A global automaker is now testing a unique 3D printed part design, which is being developed for a future production application, in C18150 using Sandvik’s Osprey® metal powder Desktop Metal and Sandvik Additive Manufacturing will discuss details of this joint automotive project during a presentation at AMUG 2023, held March 19-23 in Chicago With the addition of C18150, Desktop Metal now offers a world-leading 23 metal materials on its binder jet 3D printing systems, which includes the Shop System™, Production System™, and X-Series platforms

Desktop Metal, Inc. (NYSE: DM), a global leader in additive manufacturing technologies for mass production, in collaboration with Sandvik Additive Manufacturing, a world-leading producer of gas atomized metal powders, and a top five global automotive manufacturer, today announced that copper alloy C18150 has been DM Qualified for binder jet 3D printing on the Production System™.

Sandvik Osprey developed and provided C18150 powder that routinely delivered as-sintered densities of 98-99% when printed on the P-1, allowing the automaker to deliver a unique component design that is targeted for high-volume production on the Production System™ P-50 after additional development.

Chromium zirconium copper offers a combination of strength, conductivity, and corrosion resistance that makes it suitable for a wide range of industrial and commercial applications. It’s also able to withstand service temperatures up to 500°C, making it ideal for certain applications in the automotive industry.

Learn more about Desktop Metal and our #TeamDM brands at www.desktopmetal.com.

the P-1, for research and development of binder jetting projects for serial production, and the P-50, the world’s fastest metal binder jet system, offering the lowest cost per part, with SPJ technology.

TriTech Titanium Parts LLC, which is ISO 9001:2015 certified, uses metal injection molding (MIM), investment casting, and now, binder jet 3D printing on the Desktop Metal Production System P-1 to produce titanium parts.

The company is a spin-off of AmeriTi Manufacturing Co., which was founded in 1984 and sold last year to Kymera International.

Production System users interested in working with titanium should consult their Desktop Metal sales representative on hardware and binder requirements.

Learn more at desktopmetal.com/materials.

SFM Technology Create the First Helicopter Main Rotor Blade Restraint Cradle With 3D Printing Technology Urgently requested to provide cradles for helicopters, SFM Technology turned directly to the BigRep PRO For the aerospace and defense giant Leonardo - tasked by the Ministry of Defence to provide AgustaWestland AW101s for the Royal Navy - they found that their pre-existing main rotor blade restraint cradles were not living up to their standard. Leonardo turned to SFM Technology and their AeroAdditive section to provide a solution. The result was the first main rotor blade restraint cradle – measuring 900 x 230 x 160mm - created with 3D printing.

3D PRINTING PROVIDES THE SOLUTION

Desktop Metal and TriTech Titanium Parts Qualify Titanium Alloy Ti64 for Binder Jet 3D Printing on the Production System™ »

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Detroit-based TriTech is an experienced manufacturer of titanium parts for the commercial and industrial markets, including aerospace, marine, and automotive Ti64 is a popular material because of its excellent strength-to-weight ratio, corrosion resistance, and biocompatibility Binder jetting of Ti64 simplifies production of complex titanium parts, which can be challenging and expensive to fabricate using traditional manufacturing methods

As a solution had to be found very quickly, SFM turned immediately to the possibilities of additive manufacturing.

As Mr. Wilson says, "This is quite a long process, so we had a look at many aspects of 3D printing. We must look at cost, efficiency, and of course, the size, which pushed us to BigRep. Eventually, we looked at the BigRep PRO as we had to look at a production 3D printer, which I believe the BigRep PRO can provide. The machine is used as a production machine, so every rotor blade restraint cradle will be going to the end customer."

3D PRINTING MORE VERSATILE THAN TRADITIONAL METHODS In the aerospace industry, lightweight yet strong parts are essential. SFM Technology found through stress-testing

Desktop Metal, Inc. (NYSE: DM), a global leader in additive manufacturing technologies for mass production, in collaboration with Detroit-based TriTech Titanium Parts LLC, today announced that Ti64 has been customer-qualified for binder jet 3D printing on the Production System™.

The Production System platform features high-speed Single Pass Jetting (SPJ) technology on two models: INDUSTRIAL MACHINERY DIGEST.COM

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that their 3D-printed printed parts performed better than original, non-printed parts. By using Hi-Temp CF – a carbon fiber reinforced material with versatile, high-strength properties – the blades have a powerful resistance to wear and tear as well as any external pressure.

SFM Technology are now looking to use the BigRep PRO as a batch 3D printer, able to sequence production and create improved results across the board. It is likely that more aerospace designers will see the benefits of 3D printing and look to adopt it in due course.

industries including healthcare, automotive, aerospace, defense and more.

Find more information at: www.sfmtechnology.org. uk/ Find out more at www.bigrep.com

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Visionary keynote speakers and topics include: »

Sintavia to Develop Additive Manufacturing Facility for the U.S. Navy Partnership with Bechtel Plant Machinery, Inc. will enhance adoption of additive technology across multiple nuclear platforms Sintavia, LLC, a designer and additive manufacturer of complex mechanical systems and components for the Aerospace & Defense industry, announced today that it had been awarded a contract from Bechtel Plant Machinery, Inc. (“BPMI”) to develop a dedicated additive manufacturing facility in support of the United States Naval Nuclear Propulsion Program. The new, vertically integrated facility will develop and additively manufacture advanced nuclear propulsion systems for both in-production and in-development submarine programs of the United States Navy, including the next generation nuclear-powered attack submarine.

The new facility, located in Hollywood, Florida, is expected to come online in the second quarter of 2023.

For more information visit http://www.sintavia.com.

From Spaceflight to Industry Insight: Additive Manufacturing Keynote Speakers Announced for RAPID + TCT 2023 Daily keynote presentations and 170 technical presentations highlight impact, innovation and more as the largest AM event in North America returns May 2 - 4 in Chicago The most accredited leaders and experts in additive manufacturing (AM) will gather to educate and innovate at RAPID + TCT 2023, North America’s largest and most influential AM event in North America as it returns to Chicago’s McCormick Place, May 2 - 4. Each day will kick off with a keynote speaker presentation featuring leading authorities and iconic innovators in AM covering topics like AM applications in space, scaling digital manufacturing spaces, and a panel discussion taking a pulse on AM’s challenges and what the future holds.

The three-day event, produced by SME and Rapid News Publications, owner of the TCT Group, will bring together thousands of AM experts and students from around the world, feature hundreds of exhibitors, as well as two thought-leadership panels across a swath of

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Building and Scaling an Industrial Digital Manufacturing System: Tuesday, May 2Kevin Czinger founder, lead inventor and CEO of Divergent Technologies will discuss the architecture and elements of the Divergent Adaptive System (DAPS™), its benefits and the business model for localizing sustainable manufacturing on a global scale.

Additive Manufacture for Space: Past, Present, Future: Wednesday, May 3Omar Mireles, PhD, Additive Manufacturing R&D engineer at NASA Marshall Space Flight Center, will discuss how AM enables tech, decreases the cost of rocket engine manufacturing, increases design flexibility, provides access to new materials and more.

AM Industry Outlook: Opportunities and Challenges: Thursday, May 4 Terry Wohlers, head of Advisory Services and Market Intelligence, ASTM International Robert ‘Bob’ Willig, executive director & CEO of SME Chris Ciuca, vice president of Programs at SAE International Wohlers, Willig and Ciuca will join the winner of the AM Industry Achievement Award, which will be announced during the event, for a panel discussion discussing challenges and opportunities in AM.

In addition to keynote presentations, RAPID + TCT 2023 will feature almost 170 technical presentations, evaluated and selected by a team of world-class experts, covering AM trends across industries including healthcare, aerospace, defense, automotive, design for additive manufacturing, economics, R&D, supply chains, metrology and more. Topics range from tips on getting started with large-format 3D printing in consumer-goods industries to the impact of micro 3D printing on prototyping and designs in healthcare.

Registration is now open to attend the premier destination for technology providers and industry leaders worldwide.

To learn more about what RAPID + TCT 2023 has to offer, visit www.rapid3devent.com and keep up to date with all things AM by following us @RAPID_Event on Twitter and LinkedIn.

#AdvancedFuelCells Advent Technologies Announces Opening of R&D and Manufacturing Facility in Charlestown, MA Advent Technologies Holdings, Inc. (NASDAQ: ADN) (“Advent” or the “Company”), an innovation-driven leader in the fuel cell and hydrogen technology sectors, is pleased to announce the opening of its new state-of-the-art

research and development and manufacturing facility at Hood Park in Charlestown, MA. The new facility represents a significant investment in Advent's future growth and will enable the Company to accelerate its efforts to scale-up and deliver on the increasing global demand for electrochemical components in the clean energy sector.

Advent's Hood Park facility is situated in the center of Boston's thriving innovation and R&D community and boasts a total area of approximately twenty one thousand square feet. The new facility brings together Advent's corporate office staff, who were previously based at 200 Clarendon Street in downtown Boston, and the Company's research and development team, which was based at Greentown Labs in Somerville, Massachusetts. By integrating these two teams under one roof, Advent aims to streamline its operations and foster a more collaborative and innovative work environment.

Advent's newly opened site offers an array of state-ofthe-art equipment and facilities, including: » modern coating machines to support the seamless transition from prototypes to initial production runs for advanced membranes and electrodes for both fuel cells and low-cost hydrogen production; » a fully analytical facility dedicated to quality control, failure analysis, and improving product lifetime; » fuel cell and electrolyzer test stations for statistical process control and development of next-generation membrane electrode assembly (MEA) materials, and, » a mechanical engineering lab for developing automated assembly processes for MEAs and stacks.

Advent's Hood Park facility will be producing a range of innovative products, including the ion-pair Advent MEA, which is currently under development as part of the Company's joint development program with the U.S. Department of Energy's Los Alamos National Laboratory, Brookhaven National Laboratory, and National Renewable Energy Laboratory.

With the ion-pair MEA technology, Advent is looking to revolutionize the global MEA market by producing fuel cells that can last at least three times longer and deliver double the power density of its previous systems. These next-generation PEM-based fuel cells would be capable of consistently operating at more than 100°C for over 20,000 hours, making them an ideal choice for heavy-duty mobility applications. The move to the Hood Park facility will enable Advent to significantly expand the production capacity of

the ion-pair Advent MEA in-line with its growth plan.

Dr. Vasilis Gregoriou, Chairman and Chief Executive Officer of Advent Technologies, stated, "Today is a significant achievement for the entire Advent team worldwide. Undoubtedly, 2022 was a year of tremendous progress in the clean energy sector, leading to an unprecedented surge in interest in fuel cell products and electrochemistry components. Over the past two years, we have been dedicated to completing our new state-of-the-art R&D and manufacturing facility. The move to Hood Park is perfectly timed and marks a major step forward for Advent's goal of becoming a leader in the hydrogen industry. We are excited about expanding our production capacity and growing our team to meet the increasing global demand for our innovative products.”

Dr. Emory De Castro, Chief Technology Officer of Advent Technologies, added: "Advent's new facility at the Hood Park campus is a major milestone in the Company’s quest to accelerate the global transition to a net-zero carbon future. By providing clean and sustainable power from hydrogen fuels, Advent is helping to replace polluting diesel generators and combustion engines with environmentally friendly alternatives. In addition to supporting Advent's growth in the U.S. market, the new facility is also expected to create numerous job opportunities for young professionals, including material scientists and fuel cell engineers based in Massachusetts.

The proximity of Hood Park to top research universities will enable Advent to tap into a rich pool of intellectual talent and further enhance its innovative efforts, solidifying its position as a leader in the electrochemistry components industry.”

For more information, visit www.advent.energy.

INDUSTRIAL MACHINERY DIGEST.COM

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Business 4.0

IMD Industry X Blueprinting Workshop

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e live in a world of now. Consumers can purchase just about anything, on their own schedule, for delivery when they wish, to an address they specify. And the item might be personalized very specifically to their requirements. It is a marketof-one environment for retail where the largest internet footprint has a dominating position for convenience. This is of course Amazon, which as a virtual bookstore sold its first book in 1995. The transformational impact on how consumers experience retail was swift - changing habits, changing marketing plans, driving new models. Behind this incredible transformation has been the expanding role of computers and digitalization.

Digitalization in the industrial machining and manufacturing segments has been similarly impacted and is undergoing generational transformation. Increasing speed of delivery to win orders, rapidly changing requirements that are configured to each order, wildly moving schedules, and different working models characterize today’s B2B environments. The changing requirements landscape is blended with step function changes in how items are produced today - the options are quite broad, and quite different from as recent as 10 years ago. Many today call this digital industrial revolution

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the move to Industry 4.0. However, there is mention now of Industry 5.0, and more evolved capabilities on the way. It’s difficult to stay hinged to a temporal point of view so we prefer to call this transformation the move to Industry X. Drawing on our experiences, our industry viewpoints and insight, and our relationships with various subject matter experts, Industrial Machinery Digest is pleased to announce our Industry X Blueprinting Workshop program, through which clients can engage with IMD experts for half day or full day on-site (your site) sessions.

The objective of the Workshop is to develop companyspecific actionable Industry X capability blueprints, which can become the strategic foundation for a digital transformation program.

As a preliminary activity and informal opportunity for connecting, there will be an icebreaker dinner the night before each Workshop. This dinner will be sponsored

by IMD and one of our industry partners. Workshop participants and the IMD team will use this event to build rapport that underpins the dialog for the Workshop session the next day - and to build rapport between attendees that may be from different functional areas within the company that has engaged IMD for the Workshop.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

IMD is uniquely positioned to bring a viewpoint of the trends in industrial manufacturing, with this discussion framing the opening topic for a typical workshop. Capability segments such as robotic automation, additive manufacturing, data science and analytics, IIoT, RFID and related sensor technologies, relevant software advances, and new business-as-aservice models such as cloud computing or warehouse AMRs are just a few planned to be part of the trend overview, as well as an evolutionary history that has led to our current industrial operating state. How digital impacts the current environment will be one of the anchors for the discussion. Within each capability segment, we will also take a look at the various degrees of and approaches to adoption and operationalization within an industrial setting.

Following the Industry X trends discussion and a structured Q&A session, a previously arranged video conference with a topic expert will be part of the Workshop as well, as we aim to connect a broad set of relevant external deeply experienced SMEs on topics. In a preparation call, the various options for these on-demand SME video conferences will be defined and selected.

An SME video conference will be a real-time video conference with interactive dialog, based on a content area with relevance to the engaging company operations environment or manufacturing environment.

The first two sessions set the foundation for direction of Industry. After those sessions, a 30-45 minute facility “walk” will provide a quick view of the current state of operations. During the “walk” a designated tour guide from the engaging company should take the Workshop team through the key manufacturing work centers or areas in the facility. Some of this data will have been discussed

in a prep call with the Workshop Presenters from IMD. We will reconvene from the “walk” in the Workshop area for a brief break.

Following the break, a facilitated group discussion will yield the high priority challenges from the “walk” that need addressing in a near-term, mid-term, and longer-term horizon. An important outcome of this discussion is an introspective view from the Workshop team of the current situation and its needs and complications, as viewed from a broad lens (a recommended makeup of the Workshop team will be provided in the Workshop Prep Kit, which is provided to all engaging companies several weeks before the Workshop). A facilitated activity will be used to prioritize the needs and complications.

We will leverage our consulting backgrounds and provide the tools and guidance needed to break out into small groups and create the blueprints (actions and broad schedules) to address the needs and complications previously identified so that real benefits can be achieved.

In addition, our tools will push the Workshop team to think more broadly on how to change the game and create step function improvements.

IMD Industry X Blueprinting Workshops can be set up for half-day or 8-hr day sessions, each with specific pricing.

To get pricing information and more details about these Workshops which are conducted onsite at your facility, email our Chief Editor at trey@indmacdig.com.

INDUSTRIAL MACHINERY DIGEST.COM

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Talking Shop

Schuler Group makes Digitalization a Realization with Digital Suite Workshop Debrief From Michigan

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he mark of a leader is making bold, directionally correct statements that define industry transforming goals - then delivering on those goals. From now on, we can designate Schuler as a Digital Leader. They have delivered on their 2018 commitment with Porsche to create not just a joint venture for car parts, but a Smart Press Shop which has completely leveraged and incorporated Industry 4.0 capabilities.

Executives from Schuler talked in Michigan about this Press Shop of the Future earlier this year, coined Forming Technology 4.0. Participants and topic presenters in the Workshopstyled event were Dominico Iacovelli (CEO Schuler Group), Kevin MacAllister (President, Schuler North America), Tiago Vasconcellos (Sales Director, Schuler North America), Andreas Gebele (Product Manager Digital Automotive Solutions), Samuel Czyzewski (Service and Digitalization Engineer), Flavio Rudiger (Lead Digitalization Engineer, Schuler North America), Andy Osborn (Director of Modernizations, Schuler North America), Kim Spencer (Customer Service Manager, Schuler North America), and Rodrigo Branco (Engineering Group Lead, Schuler North America). Let’s take a look at a timeline that provides context and overview for this realization.

History of the Future In 2018 the two companies issued a joint press release entitled Schuler and Porsche Establish Joint Venture For Car Body Parts. Specifically quoted from this press release in 2018, “The purpose of the joint venture between Schuler and Porsche is to build a Smart Press Shop. The intention is for the new, highly flexible press shop to produce complex body parts using pioneering technologies; the focus will be on aluminium outer skin panels, as well as the production of smaller batch sizes. ‘With this joint venture, Porsche is making important decisions regarding the sports car

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production of the future. We took the first step back in 2015 with the acquisition of the Porsche Werkzeugbau subsidiary, and the joint venture with Schuler AG represents a logical progression’, says Albrecht Reimold, Member of the Executive Board for Production and Logistics at Porsche AG. ‘The aim of this undertaking is to use future technologies and innovations to make processes more efficient. The significant interplay between design, development, body planning, tool manufacturing and production within the Porsche Group will have a considerable effect on the quality of our sports cars.’ ” The 2018 release highlighted improved production efficiency, machine connectivity, and end-to-end process data acquisition, touting a press shop that set new standards. “Process expertise in the field of metal forming is subject to ongoing development through the end-to-end networking of production data and the use of machine learning, for example. Porsche and Schuler are setting new standards in areas including predictive maintenance and intelligent production control.” Together with a stated commitment to add 100 jobs with this new factory, the tone and direction for transformational capabilities was set.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

In 2019 the formation of a reality was crystallized further with the selection of Halle an der Saale, Germany, as the location for their new joint press shop. Construction was slated to begin in 2019 and opening for production scheduled for 2021. Domenico Iacovelli, CEO of Schuler AG, explained: “Our main focus is the cooperation with Porsche – an important premium customer for us with very exacting standards. At the same time, however, we regard the joint construction and operation of the Smart Press Shop as a project which will enable us to raise production efficiency and the digitalization of important process steps in car manufacturing to a new level for forming technology.

Ultimately, other customers of Schuler will also benefit from this project.”

In January of 2021, a press release indicated that the plant in Germany had received many of the members (machinery) of its initial production line. “The first major members of Smart Press Shop GmbH have arrived at the Star Park industrial area in Halle (Saxony-Anhalt). These are the components for a ServoLine 20, induction press and laser blanking line, which is to be put into operation in 2021 in the state-of-the-art press shop of the joint venture between Porsche and Schuler. In this newly emerging press shop, the body parts of the Porsche Macan II are pressed, followed by assembly at the body shop in the Porsche plant in Leipzig.

The press line with an output of up to 20 strokes per minute (for example 40 doors, 80 fenders) has numerous intelligent functions from the Industry 4.0 kit by Schuler.”

Then in August of 2021, Schuler took another huge step in their Digital Suite strategy by announcing a partnership with a cloud-based IoT company. In the press release,

Schuler says, “German Edge Cloud (GEC), which specialises in edge and cloud systems, is cooperating with Schuler, a machine and plant building company. In this context, Schuler is offering a track-and-trace solution for press plants within the Digital Suite, based on technology from German Edge Cloud. The Schuler Digital Suite with the “track-and-trace application powered by GEC” is being used, among other things, in the Smart Press Shop, a joint venture between Schuler and Porsche.” The press release goes on to outline that the GEC solution would enable cloud integration with other OEMs on a global basis, as well as integrations to hybrid clouds such as the Schuler private cloud. This was one of the defining moments in the journey to the Industry 4.0 offerings found in the digital suite, in my opinion. Schuler not only created an IoT backplane, but it did so in a way that provided access to a massive set of trend and analytics data. Analysis of issues encountered during press shop production, or even during support of units, could eventually be referenced to a broader universe of information for trend analysis and decision support.

With a press release that was entitled Schuler Presents the Press Shop of the Future, which was in itself seemingly a bold comment, Schuler North America would unveil digitalization and modernization best practices with an industry workshop and grand opening of a new facility. The media event would serve as the grand opening of Schuler’s Michigan Ave Service Facility. The facility is 32,000 sq. ft. and is equipped with a 50-ton crane, in-house press pit for rebuilds and assembly, specialized equipment, and full-time field service and engineering support hub.

“The Digitalization Modernization Workshop is an opportunity to inform the market about Schuler’s Digital INDUSTRIAL MACHINERY DIGEST.COM

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Suite solutions and how manufacturers can create a fully networked press shop. Concurrently, our new facility exemplifies Schuler’s capabilities to the local market,” explained Kevin McAllister, President of Schuler North America. “The Michigan Ave Service Facility enables reduced turnaround time for repairs, press rebuilds, and modernization projects. We created a convenient space for customer shipments, follow-ups, reviews, and buy-offs.”

Workshop Setup As the Workshop began in February, Schuler provided an overview of locations and capabilities. Schuler has over 300 employees in North America with a location in Querétaro, Mexico and one in Austin, TX., and four facilities in Michigan (two hydroforming capability locations in Canton, the Modernization and Service Center on display in Canton, and a spare parts location in Hastings). The Schuler digitalization message has traction, as Schuler identified an order footprint in the US across several industries, that included hydraulic presses, visual die protection (VDP), EHF technology for energy savings, robots for automated stacking, ServoLine Max press orders, and Digital Suite components, as well as Laser Blanking Line (LBL) items.

During the setup, Tiago Vasconcellos, from Schuler North America, recapped the genesis of the Smart Press Shop JV with Porsche. Of particular interest is that the Smart Press Shop is 1) optimized for small batch production, 2) focused on steel and aluminum materials, 3) driven with equipment parameters that are compatible with major OEMs, and 4) has sub-assembly capabilities. These are strategic intentions that mean the facility can do quick change overs in an automated fashion and evaluate production performance against industry wide baselines.

After the overview, the Workshop began with Schuler’s Digital Suite offering overview - with video examples of each of the offerings being tied back to the joint venture with Porsche. Real-world video examples of Industry 4.0 in action was the result! The offering overview communicated the intention well: target measurable improvements in Operating Equipment Efficiency, or OEE. Impact areas that would be measured in the Forming Technology 4.0 space (coined by Schuler) included performance impacts, quality impacts, and high availability impacts. Specific key performance indicators were assessed for each area. Performance impacts are measured through Schuler’s Performance Monitor and DigiSim capabilities. Quality impacts are measured through their Visual Quality Inspection capability. Track & Trace keeps the data relationships between Quality Impacts and Performance Impacts.

Measuring the High Availability impacts are Cooling Analytics, Lubrication Analytics, Drive Analytics, and an externally accessible Schuler Connect module that leverages wearable technology (yes, the smart glasses made it to the party finally) and the cloud connection. Additional impact measures are from the Press Force Monitor, Visual Die Protection which is a great application of image

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comparisons using a reference image, Cyber Security Check leveraging cloud, and Service Portal for information and manuals related to equipment.

Factory Getting it Done The videos reflected a super clean environment, with equipment synchronization, video displays, tablet-based interactions and large screens with easy to read HMI (human machine interface) options that indicated the smooth and precise orchestration of a symphony rather than the overbearing muscle of a typical press shop. The Kuka robotic arms were impressively coordinated both in timing and in function.

Some of the key technologies in use on the Laser Blanking Line included an efficient automated coil loading process, automated material threading and cropping of the first outside winding that saves on waste and improves quality, integrated Track & Trace measures which were viewable on a Digital Suite display, visual inspection technology to assess material thickness, roughness, and oil thickness. The first cropped cut was on the main line but dropped to a lower level via a chute - before the next production guide was lowered. Laser cut blanks were cleaned and stacked at the end of the line in an automated fashion after a Dynamic Flow Technology fiber laser cutting process was used.

We also were educated on how the small lot production capability has been created. 2 gripper cranes work in parallel to provide the ability to stage dies for changeovers. A moving bolster allows for automatic clamping and connecting of all dies. A tooling cart with RFID is used for tooling verification of all feeders and robots. Changeover target times are managed to a maximum of 3 minutes, and that is part-to-part. Everything is underpinned by the latest measuring equipment, digital support & maintenance, and digitized logistics.

Dies are inspected using the Visual Die Protection capability which takes a video image from two different perspectives (that can be configured by customer) and compares it with two reference images, identifying and alerting if there are impingements or impairments being created by objects or alignment. VDP is an excellent use of the advances in image processing and comparison, and could be the single biggest money-saving deployment option as you consider the cost of die replacements or production line downs due to die issues. Imaging is also used for weld seam recognition and draw edge monitoring.

The Machine Monitoring System is organized around data capture, data preparation, data storage, data analysis, data visualization, and reaction to results. Data preparation is organized around creating normalized sets of data that can be compared in the cloud, allowing broad analysis either at a machine level, at a facility level, at a regional level, a customer level, a Schuler private cloud level, or even theoretically at an anonymous global or multi-OEM level. Reaction to results is an advanced approach that is

based on workflow that is instantiated depending on results. Very heady stuff which is in the sweet spot of Industry 4.0, and it feels very differentiating in this Forming Technology 4.0 view.

The overview also included a laser cutting analysis comparative for edge cuts made by Schuler’s fiber laser on the Laser Blanking Line. Under microscope the edges were smoother with no dross, minimal HAZ, and no evidence of striations or micro fractures. Compared to the reference, a truly remarkable quality improvement.

The setup and optimization of the laser cutting uses the LBL Studio, which is part of the Digital Suite. The LBL Studio enables simulation and optimization of the cutting contour, while the planned DigiSim 2.0 provides simulation, optimization, and generation of parameters for the upload to the line. All of the access is tracked through User ID authentication and authorization.

This was a fantastic capabilities overview - and we only scratched the surface on some of the use cases

which are not only imagined by Schuler, but are brought to life by their digital strategy deployed in Digital Suite.

We don’t have the space to really dive into the Preventive Diagnostics and Maintenance use cases built into the Digital Suite offerings, or even the Tryout Press and the press processing - but they are powerful. Schuler has delivered on their commitment and their Digital Suite, integrated with a host of equipment, is worth consideration for every press shop looking to move to Forming Tech 4.0.

Porsche has driven yet another victory with a precisionfocused partner.

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Safety & Maintenance

New Guidelines for Cancer-Causing Chemical Hexavalent Chromium — And How Robots Can Help

R

ecently, the EPA released the findings for its study on the human health impact of hexavalent chromium.

The dangers of this chemical, also known as Cr(VI) and usually produced by an industrial process, are widely known in the workplace and proven to cause many illnesses in humans, including cancer. The EPA will likely use its study, released in October 2022, to eventually set expansive new regulatory standards for the chemical.

Theatergoers might remember that it was this same chemical that provided a key plot point in the Julia Roberts movie “Erin Brockovich.” In the film, the title character fights for citizens of a California town to receive legal monetary damages from a company exposing nearby residents to ailments caused by hexavalent chromium.

The illnesses in “Erin Brockovich” are caused by contaminated groundwater, but humans are often just as vulnerable to Cr(VI) exposure from unsafe conditions in the workplace. Keep reading to learn how industrial robots can help remove human workers from hazardous environments, but first, let’s take a deeper look at Cr(VI).

Hexavalent chromium at work Human exposure to hexavalent chromium is widespread in various industrial processes, including: » Electroplating: Cr(VI) is produced during the electroplating process when a current is passed through a solution containing chromium ions. The process produces a hard, durable and corrosionresistant coating on metal objects. » Welding and cutting: Cr(VI) is generated during welding and cutting processes involving stainless steel and other alloys containing chromium. » Painting and coating: Cr(VI) is used in pigments and dyes for paints and coatings. During the painting process, hexavalent chromium can be released into the air as a fine mist. » Woodworking: Cr(VI) is used as a wood preservative and as a wood stain. During the wood treatment process, hexavalent chromium can be released into the air and water. » Chemical manufacturing: Cr(VI) is used as a catalyst in various chemical reactions. During these reactions, hexavalent chromium can be released into the air and water.

26 | IMD April 2023

As documented by the Occupational Safety and Health Administration (OSHA), in all of these industries, vulnerability to respiratory problems caused by inhalation of Cr(VI) is significant, due to potential damage to the lungs and airways. But harmful exposure can also occur due to ingestion or contact with the skin.

The health risks There have been many studies on the potential health risks associated with working around hexavalent chromium.

As previously mentioned, one of the most serious is the potential for respiratory and lung cancer linked to inhalation of the chemical.

But there are also a variety of other serious health effects that have been connected to Cr(VI) exposure: » Respiratory problems: Inhalation of Cr(VI) can cause irritation of the nose, throat and lungs, leading to respiratory problems such as asthma and bronchitis. » Skin irritation and dermatitis: Cr(VI) exposure can cause skin irritation, redness and dermatitis. » Eye irritation: Exposure to Cr(VI) can cause eye irritation, conjunctivitis and damage to the cornea. » Kidney damage: Long-term exposure to Cr(VI) has been associated with kidney damage and increased risk of kidney cancer. » Gastrointestinal problems: Ingestion of Cr(VI) can cause gastrointestinal problems such as abdominal pain, vomiting and diarrhea.

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» Reproductive problems: Exposure to Cr(VI) can affect fertility and may increase the risk of birth defects in children.

The severity of these health effects can vary depending on the duration and intensity of the exposure, as well as other individual factors such as age, health status and genetic susceptibility.

The EPA’s study Among the findings of the EPA’s study are that humans risk exposure to hexavalent chromium in many different industries and in several different ways. The study states that: Occupational exposures to Cr(VI) occur primarily via inhalation or dermal contact and typically exceed those of non-occupational exposures. Workers can potentially inhale Cr(VI) during its processing or manufacture and when working with mixtures containing the chemical or chemical precursors. Dermal exposures may potentially result from the splashing or spilling of chromium-containing materials that contact the skin or from contact with construction materials containing Portland cement (due to a Cr(VI) impurity). Portal-of-entry sites may be exposed via hand-tomouth contact and hand-to-nose contact and the extent of these transfers depends on the industry, exposure matrix, and workplace hygiene practices. Industries that may have workers who are in contact with Cr(VI)-containing materials include stainless-steel welding, painting, electroplating, steel mill, iron and steel foundries, wood preserving, and occupations that produce paints, coatings, inks, plastic colorants, chromium catalyst, and other chemicals (such as chromium dioxide and chromium sulfate) Other industries with limited potential exposures to Cr(VI) compounds include textile dyeing, glass production, printing, leather tanning, brick production, woodworking, solid waste incineration, oil and gas well drilling, construction and Portland cement production.

A further finding of the study relates to the EPA’s concern about community exposure to Cr(VI) in even trace amounts, including in municipal water supplies. This underscores the importance of minimizing or eliminating human exposure to larger amounts of the chemical in industrial workplaces.

How robots can help As described above, humans face significant health risks from working with hexavalent chromium. But robots do not, and automated solutions can keep humans from needing to work directly with Cr(VI) and other hazardous chemicals.

Certainly, one of the strongest arguments for robots is their ability to protect humans by safeguarding them from working in the types of dangerous occupations that often threaten worker safety.

For example, in the aerospace industry, recoating the inlets of F-22 fighter jets was once a manual process that required extensive manual labor and significant human

exposure to the coating material. But now, the installation of turnkey robots can eliminate the need for humans to work in the confined spaces of aircraft inlets.

A 2022 study by the National Library of Medicine found that the use of robots for repetitive site work can reduce unsafe, monotonous tasks by 25-90%, lowering human exposure to hazardous situations by an average of 72%.

But it’s important to work with a robotic integrator affiliated with the Robotic Industry Association (RIA). To minimize human exposure to danger while also gaining the benefit of robotic solutions’ potential cost-savings, it’s critical to install the right robot and with the correct implementation. Moreover, any robotic set-up should have a risk assessment performed to ensure that RIA standards are met.

Measures that a compliant robotic integrator might recommend meeting those standards include: » Extra sensors » Emergency stop buttons » Scanners that detect human presence in unsafe areas » Fencing off robot work areas » A safer workplace Creating a safe workplace in manufacturing industries that protects humans from the effects of hexavalent chromium, and other occupational dangers, is easier to implement with the right safety solutions in place. These include robot workers, which can never get cancer, respiratory ailments, injuries or skin irritation from contact with chemicals.

The dangers for humans from working with and around Cr(VI) are apparent, obvious and proven. Robots are among the best solutions for keeping humans who work in manufacturing industries safer and healthier.

Chris Kolb is vice president of sales at Aerobotix, an innovative leader in robotic solutions for the aerospace and defense industries. Headquartered in Huntsville, Alabama, the company specializes in the creation of cutting-edge automated robotic solutions for high-value, high-precision components, aircraft and vehicles.

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Industrial Automation

Clean Technology Lasers: The New Tool in Surface Pre-Treatment for Superior Coating Adhesion Laser systems remove corrosion, grease, residue, and existing coatings from metal surfaces quickly, with less preparation and mess than traditional techniques

M

ost manufacturers understand the value of pretreating metal surfaces of parts to remove corrosion, grease, residue, old coatings, or to roughen the surface of metals prior to coating.

By ensuring the items are cleaned down to bare metal, manufacturers can avoid costly warranty issues that result when coatings peel, flake, bubble, or otherwise fail prematurely.

Unfortunately, the traditional techniques used for this purpose – such as sandblasting, dry ice blasting, and chemical stripping – are messy and require expensive consumables, as well as substantial time for preparation and cleanup.

These methods are also drawing scrutiny from regulators like the EPA and OSHA since they can pose risks to the environment and applicators.

Today, a more effective alternative is utilizing industrial-grade, precision laser-based systems that can remove paint, contaminants, rust, and residues with a high-energy laser beam that leaves the substrate unaffected. Preparation and cleanup time are minimal, and the low-maintenance equipment can last decades.

According to Vincent Galiardi, owner of Galiardi Laser Clean, a surface cleaning operator based in St. Charles County, Missouri, many people are surprised to learn that clean technology lasers are the most cost-effective, efficient, and safest method of industrial surface preparation.

“Many people are unfamiliar with the use of lasers to pretreat metal surfaces,” says Galiardi. “When I do a demonstration, at first the people in attendance are skeptical. But after I use the laser to treat a small area, everyone starts talking and getting excited. By the end, when I let them try the equipment, everyone is having a good time and saying how great the laser works.”

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Given its effectiveness pretreating metal surfaces, industrial laser systems are increasingly being used in manufacturing facilities. The systems can be integrated into automated inline processing lines, or technicians can use mobile handheld units. With significant advantages in safety and efficiency, laser cleaning is poised to disrupt the surface pre-treatment market across more sectors.

Resolving Conventional Cleaning Limitations There are many applications in manufacturing that require pre-treatment of metal surfaces prior to coating. To improve coating adhesion, residue, oil, or grease must be removed before coating application. In some cases, a manufacturer may seek to further enhance coating adhesion by roughening the surface.

When defective metal parts are produced, instead of discarding the product, manufacturers can strip the paint and re-coat the component.

To refurbish existing metal parts or recoat industrial infrastructure, removing the previous coating along with any corrosion is usually required to facilitate the new coating’s adhesion to the surface.

To pretreat metal surfaces, sandblasting, dry ice blasting, or chemical stripping are traditionally used as industrial cleaning processes.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

Sand Blasting Abrasive sandblasting involves forcefully projecting a stream of abrasive particles onto a surface, usually with compressed air or steam. The silica sand used in abrasive blasting typically fractures into fine particles and becomes airborne, which can cause serious or fatal respiratory disease.

When workers inhale crystalline silica, the lung tissue reacts by developing fibrotic nodules and scarring around the trapped silica particles, causing a fibrotic lung condition called silicosis. Estimates indicate that more than 1 million U.S. workers are at risk of developing silicosis and that more than 100,000 of these workers are employed as sandblasters.

In addition, particles are generated during abrasive blasting that further contribute to respiratory problems and other harmful health effects.

“When sand or any other media is used to knock off particles from a substrate, there is always a byproduct that has the potential to become airborne and inhaled,” says Galiardi. “Besides the sand, this could be the particles you’re removing – the coatings, plating, anodizing, corrosion, and even lead paint.”

“Industry has needed a cleaner, safer surface pre-treatment solution for a very long time,” adds Galiardi.

“Sandblasting is inherently unsafe for operators. The silica glass used in sandblasting is toxic. An operator must wear a full HEPA suit when sandblasting to avoid breathing in particulates.”

Sandblasting also is time-consuming to clean up since the sand essentially scatters everywhere, even though it is usually considered a “fast” cleaning method.

Dry Ice Blasting With dry ice blasting, dry ice pellets are used as the abrasive. The challenge is that dry ice blasting is often not abrasive enough to sufficiently remove paint or corrosion from the surface of metals. Since dry ice is an expensive consumable, the costs can escalate when cleaning metal surfaces in higher volumes.

Chemical Stripping With chemical stripping, harsh, even toxic chemicals are used to strip metal-based objects of paint, rust, and other contaminants to bare metal. However, for operators, exposure to corrosive acids and noxious chemical fumes is inherently dangerous. The process can also be time-consuming to prepare the proper chemical bath, achieve the required level of cleaning, and dispose of the waste. In addition, disposing of toxic chemicals is costly and closely regulated by agencies like OSHA and the EPA.

Safe, Effective Laser Cleaning Laser-based systems have significant advantages over these traditional methods, including ease of use in which an operator simply points and clicks a high-energy laser

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beam at the surface. The substrate is not affected by the laser, and the systems do not create any mess or byproducts. The approach is eco-friendly, energy-efficient, and completes the job in half the time of traditional methods when preparation and cleanup are considered.

“In our experience, laser cleaning is as fast at removing rust or old coatings as other methods, but without the same amount of cleanup,” said Galiardi. “When we treat a surface with lasers, any fumes or dislodged particulate is extracted into a HEPA filter and the job is done. There is no media [sand, dry ice, chemicals] to replenish or clean up.”

Galiardi Laser Clean uses laser systems made by Orlando, Florida-based Laser Photonics, a leading provider of patented industrial grade CleanTech® laser systems for cleaning and surface conditioning. The American-made systems function either as mobile standalone units or can be integrated into production lines.

The laser systems are available in portable and stationary models ranging from 50 to 3,000-watts (a 4,000-watt version is in development) with chamber sizes from 3’ x 3’ in size to 6’ x 12’. The systems can also be installed in manufacturing lines in cabinets or operated by a robotic arm.

Galiardi says that laser pre-treatment of metal surfaces can be used to streamline various manufacturing processes. Corrosion, for example, can begin to accumulate within a very short time on new parts, depending on the material and environmental conditions, and should be removed prior to coating.

For one major auto manufacturer, Galiardi Laser Clean was asked to remove rust from conveying system components used to transport cars through the manufacturing process. The components were corroded due to being left outside during a 6-month delay in the project. When it was time to install the items, the provider wanted to first treat the surfaces and return the components to a “like new” appearance.

In another example, Galiardi was asked to remove rust from over 400 transmissions in a couple of days. The laser systems are particularly effective when reaching into tight spaces that are hard to reach by hand. By masking the area to protect vulnerable parts, the laser can be applied without affecting the rest of the assembled product.

“No other parts [of the transmission] had to be removed and nothing had to be cleaned afterwards,” he says.

Galiardi’s company also utilized the laser system to remove cleaning oils from truck chassis. “We used the laser to remove the oil right before painting so it was a bare metal object going with nothing on it that would affect the coating,” he says.

Industrial plants that need to recoat existing metal structures also need to remove rust before painting. According to Galiardi, he removed corrosion from a very large storage tank using the CleanTech laser system in about half the time of the alternative being considered, an abrasive disc grinder.

“Disc grinders basically just chip off [the rust] and it becomes airborne and makes a mess. Grinders can also be dangerous because sparks or debris can shoot off the wheel or catch an article of clothing,” he says.

With clean laser technology, there is now an environmentally friendly alternative to abrasive blasting and chemical stripping for surface pretreatment. The approach is safer for operators and highly adaptable to a wide range of manufacturing and industrial applications.

“As people become more aware of laser-based systems and compare them to traditional methods, they need to factor in prep and cleanup time, which can significantly impact project cost. When the improved operator safety, equipment longevity, and lower maintenance of laser systems are also considered, the clean laser technology has a much higher ROI,” says Galiardi.

The longevity of low-maintenance laser systems further adds to their value, increasing ROI, and making replacement unnecessary for decades.

“CleanTech laser systems can last for 50,000 to 100,000 hours. That’s many decades working eight-hour days. After purchase, there’s virtually no maintenance necessary,” concludes Galiardi.

For more information on laser cleaning solutions for surface preparation, contact Laser Photonics at (407) 804-1000 or visit www.laserphotonics.com.

30 | IMD April 2023

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Workforce Development

Deloitte and The Smart Factory@Wichita: Building the Future

W

e talk about this in every edition of IMD. The change is dramatic in today’s manufacturing environments - as the delivery of smaller lots and more customized products in B2B and B2C environments increases, the propagation of Industry 4.0 digital operations accelerate. So when several industry titans joined together to create a showcase where a person could walk the floor and see smart automation, digital twins, analytics, and interoperability in action, expectations could have outpaced delivery. When these industry titans joined together to create The Smart Factory@Wichita and a partner ecosystem thought, the expectations were outpaced by the delivery.

Advanced Capabilities and Partner Ecosystem The Smart Factory@Wichita is a collaborative effort of Deloitte and a global ecosystem of technology providers that have a history of delivering smart factory capabilities.

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Here is a list of the Founding Sponsors for The Smart Factory@Wichita, and some of the areas where they deliver capabilities to smart factories: » Deloitte provides experts in smart manufacturing, digital transformation, and Industry 4.0 who are working with the Smart Factory's ecosystem of partners to help organizations explore what's possible with smart factory applications and help them move closer to creating sustainable smart manufacturing investments.

Transforming a factory requires collaboration between manufacturing, supply chain, and IT business functions.

It also requires new technologies and a commitment to becoming an insight-driven organization. Deloitte has a proven approach to helping clients navigate this transition and a proprietary smart manufacturing solution that can help clients increase throughput and profitability.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

» Amazon Web Services provides more than 200 fully featured advanced manufacturing services support virtually any cloud workload, including compute, storage, databases, networking, analytics, ML (Machine Learning) and AI, Internet of Things (IoT), mobile, security, hybrid, virtual reality (VR) and augmented reality (AR), media, and application development, deployment, and management supported and delivered through a global infrastructure. AWS also offers a Digital Twin building platform, TwinMaker. » Dragos provides industrial cybersecurity solutions that can help protect smart factories from cyberattacks. The Dragos Platform utilizes deep packet inspection to give operators a holistic picture of connected OT equipment and network communications. » Infor provides cloud analytics software that can be used to manage the operations of a smart factory. Infor provides manufacturers with end-to-end CloudSuites, featuring highly flexible architecture, advanced technologies, and AI-driven analytics for valuable data insights. Infor software connects data, people, and processes for a complete digital transformation that will help you align with customers, manage complexities, and seize growth opportunities. » SAP provides cloud based enterprise resource planning (ERP) software that can be used to manage the relationships between a smart factory and its customers. At the core of The Smart Factory@Wichita is SAP S/4HANA, the intelligent enterprise cloud solution that runs mission-critical operations with integrated supply chain solutions for manufacturing and asset management. These and other digital solutions enable the physical production line on the shop floor. » Siemens provides automation and control systems, and a digital software suite that can be used to control the operations of a smart factory. Siemens

Digital Industries Software is driving transformation to enable a digital enterprise where today’s engineering, manufacturing, and electronics design meets tomorrow. The Xcelerator portfolio helps companies of all sizes create and leverage digital twins, providing new insights, opportunities, and levels of automation to drive innovation. » Wichita State University provides academic research and support to the Smart Factory@Wichita.

These providers offer a wide range of solutions and services that can help organizations accelerate innovation and make Industry 4.0 a reality. Some of the specific technologies that are featured in the Smart Factory include: » The Internet of Things (IoT) » Cloud computing » Artificial intelligence (AI) » Computer vision » Robotics These technologies can be used to improve efficiency, productivity, and sustainability across the greater enterprise. The Smart Factory@Wichita provides a hands-on environment where organizations can explore the possibilities of smart factory applications and learn how to make them work for their business. And as an added bonus, The Smart Factory@Wichita operates sustainably at net-zero energy consumption and is outfitted with wind trees, solar assets, and smart lighting.

Simulation and Digital Twin One name that is seen fairly often in this magazine, because of the breadth of offerings in the manufacturing space, is founding member of The Smart Factory@Wichita along with Deloitte and other ecosystem members, Siemens. Siemens developed the eXplore Live space at The Smart Factory as INDUSTRIAL MACHINERY DIGEST.COM

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a 3,000 square-foot area dedicated to hands-on learning opportunities for companies looking to modernize, reshore, localize, or regionalize their operations in North America.

The eXplore Live space will enable Siemens to expand customer engagements at The Smart Factory@Wichita with a showcase focused on design and optimization using a closed loop digital twin. It will also enable exploration of industry digital threads and provide space for innovation workshops, co-creation, and help empower the next generation of engineers. The Smart Factory@Wichita’s Siemens eXplore Live space joins Siemens’ global eXplore Center network, best-in-class customer experience centers that, combined with a proven innovation methodology, help companies discover what’s possible for a digital tomorrow, help define a vision for their organization and design a roadmap for making it real.

“Our alliance with Deloitte has been bringing together mutual customers to explore the future of manufacturing and industry 4.0 for over a decade,” said Bob Jones, EVP, Global Sales; Customer Success, Siemens Digital Industries Software. “The opening of Siemens eXplore Live space at The Smart Factory@Wichita is the next progression of this relationship; bringing to life the concepts, ideas and practicalities of The Smart Factory, and enabling customers in multiple industries to accelerate digital transformation and solve complex manufacturing challenges.”

“As an industry leader in digitalization and advanced simulation, Siemens is helping manufacturers quickly adopt state-of-the-art Industry 4.0 technologies through its end-to-end suite of solutions,” said Stephen Laaper, principal and Smart Manufacturing leader, Deloitte

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Consulting LLP. “At the new Siemens eXplore Live space at The Smart Factory@Wichita, visitors can easily experience the power of Deloitte’s and Siemens’ combined industry and digital transformation expertise to help accelerate the implementation of smart manufacturing solutions, solve complex challenges and engineer advantage.”

The Student Experience What does all of this mean to students and to further workforce development in advanced manufacturing?

Leaders with impressive digital experience are coming forward and putting real hard dollar investments behind their comments. The beneficiaries are the current students in engineering or those considering engineering or manufacturing technology learning. The Smart Factory@ Wichita is a world-class facility that provides students with hands-on experience in advanced manufacturing technologies. The facility is home to a variety of equipment, including robots, 3D printers, and CNC machines. Students can use these tools to design and build products, or to learn how to operate and maintain them.

The Smart Factory also offers a variety of educational programs, including workshops, lectures, and internships.

These programs allow students to learn about the latest trends in manufacturing and to gain the skills they need to succeed in the workforce. The Smart Factory@Wichita is a valuable resource for students who are interested in pursuing a career in manufacturing. The facility provides students with the opportunity to learn about the latest technologies and to gain the skills they need to succeed in the workforce.

For example, an engineering student could be given the opportunity to work at the Smart Factory@ Wichita. In this opportunity he would be tasked with designing and building a 3D printed model of a new product. He would work with a team of other students and mentors to complete a project. Upon completion of a successful project, he would gain practical insight into 3D printing techniques and product design. This scenario is unfolding every day at The Smart Factory and students claim that experience as being invaluable to their learning process. » Students will develop the skills they need to be successful in the manufacturing industry. » Students will learn about the latest technologies in manufacturing. » Students will have the opportunity to network with industry professionals. » Students will have the opportunity to gain hands-on experience in the world of smart manufacturing.

A news release from SAP’s website regarding The Smart Factory@Wichita impact on Wichita State University students says, “The Smart Factory@Wichita also serves Wichita State University students as an applied learning environment for smart manufacturing and its impact on sustainability outcomes. The need is critical, according to a report from Deloitte: “The manufacturing industry is facing a skills and

talent gap that will leave 2 million of nearly 3.5 million manufacturing jobs unfilled.”

“We’re building traction as an emerging leader in the field of digital transformation; and trailblazers — like Deloitte — are taking notice that Wichita State’s research and expertise give them a competitive edge,” said Dr. Rick Muma, president of Wichita State University. “And our students benefit from the applied learning opportunities that they’ll gain at The Smart Factory@Wichita. As Deloitte professionals educate the workforce of tomorrow, Shocker students train side-by-side with experts in the fields of smart manufacturing, artificial intelligence, Internet of Things, and robotics.”

However it isn’t just college students that are getting the benefits from The Smart Factory@Wichita. The factory itself produces a STEM kit that it sends to middle school students around the United States. In a partnership with Elenco Electronics, the factory cranks out Smart Rover Kits which are made from 100% recycled polyethylene terephthalate (rPET) taken from the local recycling stream.

The kits are intended to inspire STEM learning for students, and there is a goal to reach 800,000 students over a four year period. During the factory startup period, initial donations enabled reaching middle school students in Philadelphia, Metro Detroit, and Wichita.

For more information on The Smart Factory@Wichita, email info@thesmartfactory.io

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Process

The Laser — Our Modern Lightsaber

T

he visionary gadgets used in Gene Roddenberry’s creation Star Trek have had many fans suggest a foreshadowing of great technology advances – one such advance being the original cell phone with a flip top, that uncannily resembled the “communicator” used by Captain Kirk and crew in almost every episode of Star Trek, as well as in the subsequent movies. Not to be outdone, the Star Wars franchise (yes Sheldon, I used both of them in a single paragraph), brought to life by the imagination of George Lucas also featured a recognizable technology element that was leveraged as the defensive weapon of the Jedi Knights. The keepers of the universe used lightsabers to do everything from deflecting lasers fired from blasters, to Force impacting hand to hand combat, to lighting pathways, to piercing metal “blaster doors.” The color of the lightsaber had meaning too, especially in the earliest releases, as the characters wielding red lightsabers were widely viewed as followers of the Dark Side, while our heroes and heroines that used blue lightsabers were representative of truth, integrity, hope, and all the good in The Force.

In Star Wars: Episode I – The Phantom Menace, Qui-Gon Jinn is dispatched to settle a Trade Dispute and in

36 | IMD April 2023

the early parts of the movie he uses his lightsaber to turn thick doors into molten metal – as the thickness of the metal is increased by different layers being added, Qui-Gon must slow down his rate of cutting and double the focus on his lightsaber capabilities. Audiences loved the special effects – and may not even realize that in today’s industrial manufacturing environment, the use of light energy to cut metal is a very widespread reality. This light energy is from lasers – which itself is an acronym that stands for Light Amplification by Stimulated Emission of Radiation.

First showing up on the cultural scene in a movie from the 1960s, as a weapon used against secret agent 007 James Bond by one of his adversaries in the movie Goldfinger, laser technology is being used today in automated cutting, engraving, measuring, and welding. And as amazing as it sounds, the color of the laser does indeed have meaning to the power that it yields and whether it can work with various metals. Most notably, improvements in blue laser technology are changing the game in welding capabilities for thin film highly reflective metals.

We went to www.explainthatstuff.com/lasers.html (Woodford, Chris. (2006/2019) Lasers. Retrieved from

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

https://www.explainthatstuff.com/lasers.html. [Accessed March 19, 2023]) to get some insight on the details of how lasers work. Before we discuss lasers and how they work, it's important to understand a bit about light and how photons can be created. Initially, atoms in a stable state consist of a nucleus orbited by one or many electrons. When an atom absorbs energy, one or several electrons shift further away from the nucleus into higher energy levels, and the atom is said to be in an “excited” state. This is known as absorption.

These electrons tend to move in an instant back to their original energy levels. When the electrons move back to their original energy orbits, they emit the excess energy in the form of a photon of energy, or packet of light.

Now, imagine if you will, firing a photon with just the right energy through several atoms to create this state, and ultimately causing one of the excited electrons to jump back down to its ground state, yielding both the photon we fired in and the photon produced by the electron's change of state. Because we're stimulating atoms to get radiation (not the harmful kind of radiation, but the light energy packets) out of them, this process is called stimulated emission. We get two photons out after putting one photon in, effectively doubling our light and amplifying it (increasing it). These two photons can stimulate other atoms to give off more photons, so, pretty soon, we get a cascade of photons—a chain reaction—throwing out a brilliant beam of pure, coherent laser light. What we've done here is amplify light

using stimulated emission of radiation—and that's how a laser gets its name.” (Woodford, Chris. (2006/2019) Lasers.

Retrieved from www.explainthatstuff.com/lasers.html.

[Accessed March 19, 2023]) A laser is a concentrated or coherent beam of light that is the same color. Each wave of light has the same length (wavelength) that has been amplified through the laser creation from the photons emitted. To make an electron jump from a lower to a higher level, you have to feed in a precise amount (quantum) of energy, equal to the difference between the two energy levels. When electrons flip back down from their excited state to their ground state, they give out the same, precise amount of energy, which takes the form of a photon of light of a particular color.

By guiding the light we can focus it down to very narrow beams. Stimulated emission in lasers makes electrons produce a cascade of identical photons—identical in energy, frequency, wavelength—and that's why laser light is monochromatic.

The photons produced are equivalent to waves of light whose peaks and troughs line up (in other words, they are "in phase")—and that's what makes laser light coherent.

Lasers can be created by stimulating the atoms in different forms of matter, including solids, liquids, or gasses. Generally crystalline ruby or other crystalline based solids are pumped with energy from high intensity light to generate a laser beam. For gasses, various compound gasses are generally used for a medium with the most

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common being CO2 excited by electricity. Liquid mediums can be tuned to emit specific wavelengths which can be important when seeking different colors and power. Two other forms of lasers are semiconductor diode lasers and fiber lasers. Fiber lasers use an optical fiber cable made of silica glass, that has been doped with ion impurities, to guide light. The resulting laser beam is more precise than with other types of lasers because it is straighter and smaller.

Within industrial manufacturing, CO2 lasers and fiber lasers tend to be the most widely used options. Crystal lasers are generally more expensive and more difficult to maintain than CO2 and fiber lasers. As the most recently invented, fiber lasers also tend to be the least expensive with a smaller footprint and generally are viewed as producing the highest power output for the power consumption required, yielding a more sustainable solution.

Metal cutting with lasers is a thermal separation process. The focused photon energy in the laser beam is absorbed in a thin surface layer of the metal. The absorbed energy is converted into heat that is intense enough to raise the temperature of the metal to its melting point or to a vaporization level. The molten “hole” is then moved through the metal cut – creating an area about the width of the laser called the kerf. A coaxial jet blast of assist gas is generally used to blow cut by-products through the hole. The underside of the cut is called the dross and this is where any remnants or burrs may occur. The intense kerf (cut) leaves behind an HAZ – or heat affected zone.

The primary factor for cutting speed and thickness is beam power or energy density. A faster rate of cutting though is also a compromise on the quality of the cut.

While only 7-8% of the energy in a focused beam is initially absorbed, nearly 50% is absorbed in the molten metal.

Coupled with pure oxygen or nitrogen as the assist gas, an

extremely intense exothermic reaction occurs in the laser spot diameter, ultimately melting through the thickness of metal. The gas pressure ejects the molten matter from the kerf. This approach requires more critical focus on control of gas pressure, shape of the gas stream, and positioning of the gas nozzle orifice above the metal surface.

Ultimately the absorptivity of the metal will determine how well the cut or weld will perform. In most cases, fiber lasers operate in a visible IR light range, as do CO2 lasers.

A fiber laser generates light in the 1,060 nm wavelength range, while CO2 operates in the 10,600 nm wavelength range. Whether a material can absorb light within the operating wavelength range is a large determinant for which type of laser to use. In general the smaller wavelength has more absorption across a broader set of metal materials and this can be seen in the advances in blue diode lasers with smaller wavelengths which are now enabling more effective cladding and welding with highly reflective metals such as aluminum and copper and gold alloy. The smaller wavelength can be more tightly focused as well, yielding higher power densities. On the Bystronic.com website, an analysis of the focused energy of a fiber laser vs a CO2 laser was dramatic. A 4400 watt CO2 laser could be focused down to a 2.2 MegaWatt/cm2 energy density, where a fiber laser could be focused to a 10 MegaWatt/cm2 energy density. When comparing It's easy to see if you are processing stainless, aluminum, brass or copper materials which are highly reflective (having a lower absorptivity), fiber laser technology is the fastest and most economical regardless of thickness.

Lasers are one of several options for fabricators – and one that is very precise, but there are also others such as plasma cutting, waterjet cutting, CNC milling, and abrasive cutting.

The choice of the most appropriate cutting method should be

History of Industrial Lasers » » » » » » » » » » » » » » » »

1917 – Albert Enstein developed the theory of stimulated emission of radiation 1951 – Charles Towns demonstrated the Maser - microwave amplification 1959 – Gordon Gould suggested that stimulated emission of radiation could also amplify light 1960 – Theodore Malman created the first ruby laser in a California laboratory.

1961 – Elias Snitzer invented the fiber laser 1962 – Robert W. Hellwarth and R.J. McClung demonstrated Q-switching (pulsed laser beams) 1963 – Snitzer demonstrated the use of fiber lasers 1964 – Bell Labs scientist Kumar Patel invented a gas laser thermal cutting process that used CO2 as a more effective solution over ruby laser.

1965 – Western Engineering Research Center in Buffalo, New York uses lasers to drill die holes for electrical wires 1966 – Development of the fluorescent dye laser, making the color of the laser light freely selectable 1969 – Boeing uses gas laser cutting in commercial processes to cut titanium, Hastelloy, and ceramic.

1970s – Aerospace industry adopts gas laser cutting machines 1979 – Prima Industrie of Collegno, Italy invents 3D laser cutting technique 1980s – Widespread use of gas laser cutting machines 1988 – First double-clad fiber laser is demonstrated by Snitzer (more efficient light guiding) 1990s – Widespread use of fiber laser technology

38 | IMD April 2023

based on the type of metal being used, the required precision of the cut, the thickness of the metal, and other factors.

The cost of lasers varies depending on several factors such as power output, wavelength, manufacturer, and the specific application for which the laser is being used. Here is a rough estimate of the cost ranges for four types of lasers: » Green disk lasers: These lasers typically have a power output in the range of 10W to 100W and a wavelength of around 532nm (nanometers are 10-9m). The cost for general green cutting lasers can range from $10,000 to $100,000 (generalized) and up. New advances have seen output (e.g. Trumpf TruDisk) with continuous wave power of 3kW and pulse power as high as 4kW. » Blue diode lasers: These lasers typically have a power output in the range of 100mW to 5W and a wavelength of around 445nm. The cost for general blue lasers can range from $500 to $10,000 (generalized). Laserline Blue Diode lasers have continuous wave output at power as high as 3kW. » CO2 lasers: These lasers typically have a power output in the range of 20W to 20kW and a wavelength of around 10.6 microns (microns are 10-6m). The cost for these lasers can range from $5,000 to $50,000 and up. » Fiber lasers: These lasers typically have a power output in the range of 10W to 6kW and a wavelength of around 1,064nm. The cost for these lasers can range from $20,000 to $100,000.

It's worth noting that these are very rough estimates, and the actual cost can vary widely depending on several factors. Recent advances have yielded a class of laser called Ultra High Power lasers, which are generally above 10kW in power output. Additionally, the cost of laser cutting or other laser-based fabrication services will depend on a variety of factors beyond just the cost of the laser itself, such as the complexity of the project, the materials being used, and the desired precision and speed of the cutting process.

As laser technology evolves, the power of light and the ingenuity of people will come together to create new solutions now and continue to innovate – maybe even getting to that lightsaber concept soon. Some companies and resources that will be helpful for you in your search for the perfect laser cutting equipment at your facility are: » Laserax » www.lasersystemseurope.com » Thunder Laser USA » Bystronic » Laserline » Trumpf SOME MATERIAL FROM Woodford, Chris. (2006/2019) Lasers. Retrieved from www.explainthatstuff.com/lasers.html. [Accessed March 19, 2023]

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IMD | 39

Industry Insight

Siemens creates new vertical market dedicated to Intralogistics in the U.S.

The Intralogistics segment will provide a holistic, systematic approach for materials handling

S

iemens recently announced the formation of the new Intralogistics vertical that brings best-in-class material handling thought leadership, hardware automation, software and service solutions to customers in the United States. Siemens is leveraging its broad technology to address the market needs for digital transformation, cybersecurity, safety and sustainability.

Joel Thomas is the head of the Intralogistics vertical.

Besides management of the group, Thomas will also work closely with trade associations who serve the intralogistics industry and will foster programs at Siemens to educate the next generation of engineers, programmers, software developers and plant operations personnel who will manage the warehouses of the future.

This new group will serve machine builders and end-customers alike. For example, using the Siemens TIA Portal, a warehouse facility or postal clearing house will be able to integrate all its motion control hardware, software systems and communications protocols, internal and external, as needed. From the Siemens software portfolio, customers will have access to a portfolio of end-to-end software and consulting solutions, including the Supply Chain Suite (SCS) for the data-driven analysis, simulation and optimization of logistical processes. Siemens software, hardware and services will allow a warehouse or manufacturing operation to test all the “what ifs” before taking action on a material handling challenge.

40 | IMD April 2023

Further, notes Joel Thomas, “The goal for all companies should be smart manufacturing and automated material flow, which is adaptable to changing market and technology conditions. This is especially challenging in older brownfield operations, where the legacy equipment might not handle the needs of the company, tomorrow or even today.”

Predictive analytics and predictive maintenance, powered by Siemens industry-leading IoT solutions, will also be among the key drivers for the Siemens Intralogistics business, as it strives to offer users the needed system components to maximize productivity and to gather the data needed to monitor and maintain the operation. The biggest challenge for this new group, according to Thomas, is to identify and bring the necessary skills and solutions to the resident knowledge base for each customer. He notes this varies considerably based upon each company’s size and onboard skill sets.

Thomas also comments how sustainability, which involves energy consumption and the ability to anticipate what equipment and software will be needed in the future to keep the plant running at maximum efficiency, will be a critical factor in the service package provided to customers.

Lastly, with use of this digital-to-real world technology, the Intralogistics business will help companies achieve a more productive eco-system and, with various Siemens solutions and services, a homogenous environment in the future-proofing of their operations.

New Technology

Introducing EFC-02 — Suhner's Electric Force Compliance System Active compliance for robotic material removal

W

ith today's supply chain and labor challenges, manufacturers of all types and sizes are looking for solutions to help them do more with fewer resources. That's what smart manufacturing is all about – and why Suhner is expanding its suite of robotic grinding accessories and tools with the fully electric EFC-02 active compliance system.

Smart Automation for High Surface Quality Results Exact contact force with the surface is the single most crucial factor in robotic grinding, sanding and deburring processes. It's also one of the biggest challenges, especially for hard-to-reach areas. Thoughtfully designed based on Suhner's decades of material removal process know-how – the EFC-02 helps overcome that challenge.

As with any end-of-arm tooling, the EFC-02 connects a grinding machine – angle grinders, orbital sanders, angle polishers, straight grinders and others – to the robot. What makes Suhner's system unique, however, is its compact design and fully electric operation.

The lightest and smallest in its category, the EFC-02 can be used for material removal or surface finishing even in tight or narrow spaces often found when processing stainless tanks and vessels for the food and pharma industries or fiberglass bathtubs and sinks. The all-electric technology also allows high-frequency measurements to monitor force and acceleration throughout the process.

An advanced control algorithm then dynamically adjusts force and automates grinding processes based on pre-programmed parameters.

The result? Constant contact force with each movement from start to finish for a consistent surface quality – regardless of the surface type, shape, size or orientation.

or Fieldbus communication.

This includes defining target force, payload and stroke values. » Advanced functionality that is in line with the vision behind Industry 4.0. For instance, a visual LED indicator on the EFC-02 tells users whether the grinding wheel is in contact with the surface or not and when the stroke is at 50% to ensure maximum compensation, among other critical operational information. The EFC-02 even lets users know when maintenance is needed.

One stop for a custom, end-to-end solution The end-of-arm EFC-02 active compliance system is fully compatible with Suhner's end effectors, including angle grinders, orbital sanders, angle polishers and straight grinders. Optional automatic changers for abrasives or belts, which integrate easily with the EFC-02, are also available.

By storing and dispensing new abrasives for pickup by a sander – these automatic changers effectively help speed processes and increase productivity.

Suhner also gives its customers access to one of the most comprehensive ranges of abrasives in the market from all the industry's leading manufacturers. Plus, Suhner's ABRACare customized, volume-based pay-as-you-go inventory management program ensures you always have the abrasives you need.

Working with Suhner means more than having access to industry-leading tools and abrasives – manufacturers also have access to a global network of seasoned abrasives and material removal experts ready to help you solve virtually any challenge.

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Robotic processes are no longer just for mass production.

As the technology has evolved, robotics have become easier to use and more flexible – making them ideal for both small- and medium-sized manufacturers looking to add efficiency, lower production costs or both.

Suhner engineered the EFC-02 with this in mind, giving users: » Simple robot programming for setting up even complex processes using an intuitive web-based interface

The EFC-02 combines over a century of Suhner's abrasives and material removal expertise with smart automation for the highest surface quality results. Its compact size, all-electric technology and simple programming make it possible to replicate and automate most grinding, polishing, sanding and deburring on a variety of surfaces. This gives manufacturers a cost-effective, low-maintenance solution for replacing many time-consuming and tedious manual processes – saving time and money.

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IMD | 41

Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

Suhner to Unveil New Robotic Electric Force Compliance System at AUTOMATE The new EFC-02 combines a century of Suhner's abrasives and material removal expertise with smart automation for the highest surface quality results.

Recognizing the role robotics plays in adding efficiency and lowering production costs for manufacturers of all types and sizes, Suhner continues to expand its robotics offering. The fully electric EFC-02 delivers precise, constant force throughout robotic grinding, sanding and deburring processes – resulting in superior, consistent surface quality.

The EFC-02 is the lightest and smallest in its category, making it a good solution for material removal and surface finishing in tight, narrow spaces that traditional robotics cannot reach. Simple robot programming and advanced functionality in line with smart manufacturing and Industry 4.0 make the EFC-02 a perfect solution for both large- and small-batch production.

For maximum efficiency, the EFC-02 is compatible

Authentise Releases RFQ Responder Standalone package of tried-and-tested features to enable faster, more accurate quotes for complex parts through automation, collaboration, and AI. Authentise (www.authentise.com), the leader in data-driven engineering & manufacturing workflow tools, has released RFQ Responder to help contract manufacturers respond to Requests For Quotes (RFQ) quickly and efficiently.

With RFQ Responder, teams can quickly gather full requirements through configurable interfaces for both customers and staff. It provides key design data

42 | IMD April 2023

with Suhner's angle grinders, orbital sanders, polishers and straight grinders. This is combined with Suhner's comprehensive abrasives offering from all the industry's leading manufacturers.

This newest addition to Suhner's robotics offering was thoughtfully designed based on decades of process know-how in material removal – matching the right tool to the right abrasive to achieve the quality surface finish necessary for a wide range of applications. The company will showcase the EFC-02 at Booth #1850 at AUTOMATE 2023, May 22-25, in Detroit, MI. Visit: www.robotic-grinding.suhner.com/efc02-us

and prices automatically as a baseline, which can then be adjusted based on templatized workflows and Authentise’s unique Guideline recommendation engine.

It is the additive industry’s only tool that can do so for assemblies. The baseline can be edited collaboratively by a team to identify the right technology and production process, communicating through chat and tracking tasks in the Pre-Production Workflow Manager. In doing so, they can build on historical experience through both the Build and Model Libraries. The resulting quotes are easily configurable to allow work items to be hidden, discounted, or excluded.

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not least the standards required in production. This can take weeks. With our recent release of Guidelines and the collaboration and quoting tools previously only available through Flows, we’re in the prime position to help make companies more reactive to incoming inquires. We’re delighted to bring this third spin-off product from Flows to market, next to Materials Management and the Digital Design Warehouse.”

API Brings Back Popular Radian Plus and vProbe/iScan3D Bundles at Special Pricing RFQ Responder builds on the experience and technology stack used for Authentise’s flagship workflow management tool, Flows. As such, it provides the same integrations into ERP and PLM systems, and high security environment, including on-premise deployment and ITAR hosting options. It also allows for deeper analytics thanks to no-code integrations with Microsoft Power Automate.

Connecting RFQ Responder to Flows allows for deep machine learning by comparing estimates against actuals over time and using the insights to improve the predicted production time and errors for future production runs.

“Responding to RFPs for complex parts requires collaboration between many stakeholders, especially if they’re moving towards production rate. They’re not quoted in instant online portals.” Says Andre Wegner, 2022 IMD AD final 11-21-2.pdf 1 11/22/22 12:16 AM CEO of Authentise. “Experts consider a range of factors,

Automated Precision, Inc. (API) is pleased to announce that the company is bringing back its popular bundles of Radian Plus and vProbe or iScan3D at their lowest prices ever. Now that supply chain issues have been resolved, API

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is passing production cost savings onto their customers.

The bundles, which offer a combination of API's advanced measurement solutions, will be available immediately.

Both bundles include API's Radian Plus Laser Tracker, which is known for its high accuracy and long-range measurement capabilities. Also available are API’s vProbe, a high-precision, non-contact measurement probe that is ideal for use in tight spaces and hard-to-reach areas or iScan3D, a high-speed handheld scanner with flexible probe locations for all part inspection or reverse engineering applications. Together, these products provide a complete measurement solution for a wide range of industrial and manufacturing applications.

"We are excited to offer these bundles again to our customers, as they provide a cost-effective way to access some of our most advanced measurement solutions," said Joe Bioty, President of API. "We understand the importance of accurate measurement in today's manufacturing environment and are committed to providing our customers with the best products and pricing possible."

Laser Trackers and tactile probes are used by many industries such as aerospace, automotive, and heavy machinery to ensure accurate measurements and improve the efficiency of their manufacturing processes. Radian Plus and vProbe have set the industry standard for high-speed shop-floor CMM measurements since 2013 as the first fully-wireless solution and have only improved in the last decade.

“API’s comprehensive support and services ensure that our customers have the tools they need to achieve success,” said Paul Nicholas, VP of North American Sales at API. “With the Radian Plus and vProbe bundle, we hope to help manufacturers meet tight deadlines without sacrificing accuracy.”

For more information about the Radian Plus and vProbe bundles, or any of API's other products, please visit www.apimetrology.com.

Bernard and Tregaskiss Release New Welding Guns & Consumables Catalog Bernard and Tregaskiss have announced the availability of a joint MIG Welding Guns & Consumables catalog.

The 46-page, full-color catalog includes a consumable comparison chart to compare contact tip, nozzle and diffuser types across the brands’ available consumables offerings, along with a consumables and MIG gun series compatibility chart to guide users in their selection.

The catalog offers easy-to-read key features and part numbers for its products and is organized by product category, first highlighting the brands’ exclusive AccuLock™ S and AccuLock R Consumables — both designed to reduce downtime and improve welding performance.

Also included in the catalog are product details

44 | IMD April 2023

and configurator overviews for customizing Bernard® Semi-Automatic MIG Guns, Tregaskiss® Robotic MIG Guns, Clean Air™ Guns and more. Tregaskiss Fixed Automatic MIG Guns for hard tooling applications are also featured.

Each page includes website quick links with URLs users can visit to learn more about a specific product, plus service and support contact numbers and directions to explore online resources, such as videos and product configurators.

The catalog can be downloaded as a PDF or ordered as a printed copy at Tregaskiss.com/literature.

CERATIZIT Fulfils Customer Demand with New In-Stock Products

To ensure customers receive the tooling they need as quickly and possible, CERATIZIT offers three advanced tooling solutions that are in-stock and ready for immediate delivery. Among the company’s latest UP2DATE product developments, these innovative solutions include enhancements to the popular EcoCut Series of indexable inserts, the new PolyClamp Verso universal part clamping system and new MaxiLock-N turning toolholders that incorporate the company’s DirectCooling technology.

Turn and drill ISO-P steels with ease To overcome the challenges of turning and drilling steels, CERATIZIT has updated its classic EcoCut to the new EcoCut-P, and extensive tests have shown that the new inserts achieve 15% greater performance than the predecessor models. With the company’s special DRAGONSKIN coating for ISO-P materials, the inserts increase tool life and reduce machining time - thanks to the coating’s optimised layer structure.

The coating’s mechanical post-treatment induces a unique state of residual stress in the layer surface, which in turn increases process security. The DRAGONSKIN grade CTCP425-P with advanced AL2O3-TiN CVD coating is particularly well suited for when uninterrupted cuts are required. It delivers excellent wear resistance even at increased cutting speeds.

When it comes to general steel machining with interrupted cutting, the AL2O3-TiN CVD DRAGONSKIN

grade CTCP435-P excels in poor machining conditions and in all applications where a high degree of toughness is required.

Flexible clamping for multi-axis machines Featuring universal multiple vices, the PolyClamp Verso from CERATIZIT is ideal for use in 3-, 4- or 5-axis machines, where it easily clamps all part variants. The system’s jaws are slimmed down for this purpose while allowing even more jaws to be clamped per base rail for clamping larger unmachined or finished parts.

A scale lasered onto the centric vice is a further benefit when it comes to handling. It allows the jaws to be positioned evenly and precisely on the rail, in accordance with requirements.

The PolyClamp Verso is equipped with a quick jaw change system as standard. Using just two screws, the fixed and adjustable jaws are released, removed upwards or repositioned. This significantly reduces setup times because each jaw is individually removable without having to dismantle the others.

Precision targeted coolant extends tool life Complementing CERATIZIT’s DirectCooling product range, the MaxiLock-N turning tool holders incorporate two internal coolant holes that aim coolant directly at the cutting edge to prevent wear and ensure stable processes.

Using these coolant holes, nozzles direct coolant to the clamping flat from above as well as from below to the flank. This additional flank cooling contributes to the tools ability to extend tool life by 60% compared those that cool only at the clamping flat.

To avoid interference with workpiece contours, the lengths of DirectCooling Series holders are ideally matched to one another and offer optimal stability and unlimited flexibility. This flexibility is further enhanced with an HSK-T universal standard interface for turning tools that ensures straightforward connection to multifunction machines such as turning/milling centers and milling/ turning centers.

For more information visit www.CuttingTools.CERATIZIT.com or call 1-800-783-2280.

A Truly Sustainable Future for Air Filtration The technology behind Air Cleaning BlowersTM (ACBs) constitutes a fundamental disruption in the air and gas filtering industry. With this technology available, there are thousands of applications where it no longer makes sense to capture debris that nobody wants. Our units do not require filter elements that can clog or need maintenance over time. As a result, they eliminate the need for buying, shipping, storing, cleaning, changing, and disposing of filter media.

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IMD | 45

For centuries people have cleaned the air by trapping the unwanted particles in something, from simple cloths or screens to highly sophisticated bags, panels, cartridges, and other materials. Our difference is that ACBs simply separate out the contaminants from the gas, fling the debris back into the atmosphere from which it came and then send the clean air towards where the users need it. Since a filter medium can only remove debris if air passes through it, ACBs eliminate the need for an additional propelling force to drive the air to its application, which makes the entire package simpler and unitary, hence easier to install, operate, and maintain.

Without the use of filter media, ACB units have nothing to clog and interfere with the flow of air. Eliminating the clogging of the filter elements makes designing systems to cool, heat, pressurize and ventilate easier by assuring: » Constant and Predictable Air Flow » Constant and Predictable Air Pressure » Constant and Predictable Air Quality » Constant and Predictable Energy Consumption Utilizing our multi-patented technology, Air Cleaning BlowersTM can facilitate the design and manufacture of products that require clean air to pressurize and/ or ventilate. Such uses include control buildings, air-compressor systems, and electrical equipment such as motor control centers (MCCs). ACBs can also serve clean rooms, classrooms, hospitals, apartments, and grain

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elevators. In military and emergency response situations, ejecting particles, such as pathogens and radio-active dusts, eliminates the dangers of handling, changing, and disposing of filter media that collect them.

Used in homes, mines, steel plants and military applications worldwide, ACBs have proven themselves under both simple and harsh conditions. Since they treat liquids essentially as they 2 do particles, they even keep out rain and snow, both of which hamper the functioning of filter media, especially if they trap water and freeze. Unlike other purportedly self-cleaning air filtration systems, ACBs truly do keep themselves clean. All filter media-based bags or cartridge systems that use shaking and/or compressed air to remove some of the accumulated material eventually require replacing the bags or cartridges, which costs money and labor. Some filter companies claim that they offer "sustainable" (green) filtration systems when they simply make the filter media deeper or otherwise capable of trapping more dirt to postpone the need for maintenance or replacement. However, in most cases doing that just prolongs the clogging period and spreads the energy and other costs of clogging over a longer period between changes; it does not reduce the consumption of energy in total. In contrast, by not clogging, the ACBs truly sustain the same air flow, air pressure, air quality, and energy consumption the life of the blower motor.

Filter-element manufacturers normally label their media as removing a certain size of particle and having a certain pressure drop when brand new. However, they generally do not actually attain that level of particlecapturing effectiveness (as many food processors have learned) until a certain number of debris has accumulated in them. Those manufacturers design the elements to need those collected contaminants to close the pores in the elements enough that they can block and capture those smaller particles. Therefore, those filter makers rate their products based on the airflows and pressure drops when new, not after they have clogged enough to remove what the label says. Again, in contrast, ACBs remove their rated sizes of particles predictably and maintain consistent air flow, pressure, and quality—and steady electrical consumption— throughout their lives.

Independent testing and success in the field have established the effectiveness of the ACBs. Their scalability from fewer than 50 CFM (85 M3 /hour) to many thousands allow them to solve problems in a wide range of applications. Without media they eliminate the neverending need to buy, transport, stock, clean, and replace and dispose of exhausted, and potentially hazardous, filter elements and bags. This short video shows ACBs working in a variety of tough applications.

Air Cleaning BlowersTM have just begun to disrupt the gas and air-filtration industries. As we continue to take leaps forward in reducing the sizes, complication, weights and costs of air-cleaning, Air Cleaning Blowers, LLC will play an increasing role in the world's air-filtration industry and in the lives of its users.

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Advertiser Index Actek Manufacturing and Engineering Inc. — www.actekmfg.com ........................................... 6 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ........................................ 3 Betenbender Manufacturing, Inc — www.betenbender.com ...................................................... 5 Clamprite — www.clamprite.com ....................................................................................................45 COLE TUVE — www.coletuve.com ..................................................................................................49

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Cosen Saws, USA — www.cosensaws.com ...................................................................................29 Denver Breaker & Supply — www.denverbreaker.com ............................................................... 47 Design-2-Part Shows — www.d2p.com .........................................................................................48 Dynabrade, Inc. — www.dynabrade.com ......................................................................................... 7 ENM Co — www.enmco.com ...........................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com .....................................................48 Formdrill USA Inc. — www.formdrill-usa.com ..............................................................................39 H&K Equipment, Inc. — www.hkequipment.com .........................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ........................................ 14 HYDMECH — www.hydmech.com ..................................................................................................FC Industrial Magnetics, Inc. — www.magnetics.com ....................................................................... 35 Kanetec USA Corp — www.kanetec.com ....................................................................................... 47 KHK Gears — www.khkgears.us ........................................................................................................ 37 L&L Special Furnace Co., Inc. — www.llfurnace.com ..................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ........................46 Morgan Manufacturing, Inc. — www.MorganMfg.com ...............................................................49 Northwest Machine Tool Expo — www.machinetoolexpos.com ........................................... IBC Pro-Line — www.1proline.com .........................................................................................................49 Radwell International, Inc. — www.Radwell.com ....................................................................... IFC Royal Products — www.mistcollectors.com ..................................................................................49 Schweiss Doors — www.schweissdoors.com ...............................................................................49 SME — www.mtseries.com ................................................................................................................ 31 Standard Direct — www.Standard-Direct.com ............................................................................. 47 Stor-Loc — www.storloc.com ............................................................................................................ 9 Suhner Industrial Products — www.suhner-machining.com..................................................... BC Tormach — www.tormach.com ....................................................................................................... 25 Trim-Lok — www.trimlok.com ..........................................................................................................43

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