Industrial Machinery Digest - November 2024

IndustrialMachineryDigest.com | November 2024

North America’s Manufacturing Resource for Industry Professionals Since 1986

Cosen Saws at Fabtech 2024: Showcasing Cutting-Edge Solutions for Precision and Productivity Recapping Fabtech 2024 and Cosen’s Innovations HYDMECH Shines at FABTECH 2024: Innovations and Industry Insights from VP Rick Arcaro As G7 Production Falters, will the BRICS Economies Capitalize on it?

Navigating OSHA Inspections: Your Guide to Safety and Compliance Success Taming the Complexity of Machine Vision AI: A Guide to Edge Hardware Solutions Machine Shops Profit from Near Net Shape Forgings Reduce Machine Time, Waste Chips, Cutting Fluids, Tool Wear and Delivery Time Transforming Resin Post-Processing: How Prototek Enhanced Production Efficiency with PostProcess Technologies

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Table of Contents

November 2024 8 10 16

EDITORIAL DIRECTION INDUSTRY NEWS BUSINESS 4.0 As G7 Production Falters, will the BRICS Economies Capitalize on it?

By Jack Loughney, Senior Research Analyst – Interact Analysis

18

TALKING SHOP Cosen Saws at Fabtech 2024: Showcasing Cutting-Edge Solutions for Precision and Productivity

18

Recapping Fabtech 2024 and Cosen’s Innovations

20

SAFETY & MAINTENANCE

22

MANUFACTURING SHOWCASE

28

INDUSTRIAL AUTOMATION

30

WORKFORCE DEVELOPMENT

Navigating OSHA Inspections: Your Guide to Safety and Compliance Success HYDMECH Shines at FABTECH 2024: Innovations and Industry Insights from VP Rick Arcaro Taming the Complexity of Machine Vision AI: A Guide to Edge Hardware Solutions Machine Shops Profit from Near Net Shape Forgings

20

Reduce Machine Time, Waste Chips, Cutting Fluids, Tool Wear and Delivery Time

32

NEW TECHNOLOGY

34

PROCESS

36

INDUSTRY INSIGHT

40 47 49 50

PRODUCT SHOWCASE

Transforming Resin Post-Processing: How Prototek Enhanced Production Efficiency with PostProcess Technologies

22

TRUMPF’s New TSC 200 Slat Cleaner: A Game-Changer in Laser Cutting Maintenance EMAG Introduces VST 50: Revolutionizing High-Speed, High-Precision Ball Pin Production

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As we close out another exciting year in manufacturing, it's clear that the industry is moving at a pace few could have imagined just a few years ago.

Between the buzz around automation at Fabtech 2024 and the ever-evolving demands of Industry 4.0, manufacturers are balancing tradition with a relentless push toward innovation. For many, it’s not just about keeping up—it’s about staying ahead in a field where efficiency and precision have become essential for survival.

This issue brings together insights from every corner of the manufacturing world. We dive into the challenges— and opportunities—that come with preparing for an OSHA inspection, offering a proactive guide to keeping the workforce safe and compliant. For those exploring the future of machine vision, we unpack how AI and edge hardware are simplifying complex vision tasks, giving manufacturers a clearer view of their operations (quite literally). And don’t miss our deep dive into near net shape forgings, where we reveal how shops can trim time, costs, and tool wear to boost their bottom line.

Our coverage of Fabtech 2024 offers a front-row seat to the latest in cutting technology, from Cosen’s precision saws to HYDMECH’s forward-thinking approach to fluid power. It’s a fascinating look at how these companies are leveraging new tools and strategies to tackle challenges, like labor shortages and high production demands. Speaking of production demands, we’re also excited to introduce EMAG’s VST 50, a machine that embodies the future of high-speed, high-precision manufacturing—a reminder that the manufacturing world is as competitive as ever, with constant pressure to optimize speed and quality.

In the face of global shifts in production power from the G7 to emerging economies, manufacturers worldwide are sharpening their strategies. Whether you're a small shop or a major industry player, embracing technology, improving efficiencies, and meeting rising standards aren’t just goals— they’re essential steps to thriving in today’s landscape.

Here’s to staying sharp, staying efficient, and—most importantly—staying ahead.

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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.

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Minnesota Farmer Likes His 40-Foot Hydraulic Door from Schweiss Doors Gary Seehusen, a thirdgeneration farmer from Danube, Minnesota, has enhanced his farm operations with a 40-foot hydraulic door from Schweiss Doors. Installed in a newly planned 72-foot by 144-foot machine shed by Country Wide Lumber, the door measures 40 feet by 17 feet, 5 inches and features photo eye sensors, a remote opener, and two large sliding windows. Gary chose a hydraulic door over a bifold option to maximize headroom, appreciating the door's quiet operation, excellent sealing, and durability, which he expects to last over 50 years. The sturdy construction, supported by additional bracing from Ebbers & Seidel Construction, ensures reliable performance despite the door's substantial size. Gary also commends the compact Schweiss hydraulic pump unit for its convenience and the responsive customer support from Schweiss Doors. His positive experience underscores the quality and reliability of Schweiss Doors' products, making them a recommended choice for durable agricultural solutions.

For More Information: www.schweissdoors.com

TAB Industries to Showcase Two Orbital Stretch Wrapper Models at FABTECH Booth #S-11128 TAB Industries, LLC, a leader in orbital stretch wrapping solutions, will present its patented TAB Wrapper Tornado machines at FABTECH Orlando from October 15-17, 2024.

Located at Booth #S-11128, TAB Industries will showcase

www.IndustrialMachineryDigest.com 10 | IMD November 2024

two models equipped with Smart Controls automation technology, featuring wireless remote operation and automated cut-and-wrap capabilities. These orbital stretch wrappers, available in 100-inch and 80-inch wrapping rings, include a new LED safety light tower and can securely wrap pallets in under 30 seconds without requiring forklift operators to leave their seats. Designed for metal shops involved in fabrication, stamping, powder coating, cutting, and welding, the TAB Wrapper Tornado ensures stable, unitized loads by applying stretch wrap 360 degrees around and under pallets. The machines eliminate the need for boxes, banding, and crates, reducing shifting during transit and storage. Manufactured in Reading, PA, the wrappers come with warranties and are compatible with a variety of stretch wrap materials. TAB Industries also offers a companion line of stretch wrap and additional models, including a 115-inch option and semi-automated versions.

Interested attendees can request a free brochure or schedule a demo by contacting TAB Industries directly.

For More Information: www.tabwrapper.com

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Two-Thirds of Manufacturers Surveyed Say Integrating Data and Applications Across the Product Digital Thread is Important or Critical A new report titled “Integrating Data and Processes Across the Product Digital Thread” highlights that two-thirds of global manufacturers consider the integration of data and applications across the product digital thread as important or critical for achieving business objectives.

Despite recognizing its significance, most manufacturers lack fully integrated ERP, PLM, or supply chain systems, according to responses from 138 global companies. The shift towards digitally-based systems for product design and production emphasizes the need for better data integration to enhance quality, efficiency, and decision-making. Jim Brown, founder of Tech-Clarity, and Eric Doubell, CEO of Razorleaf, stress that optimizing the digital enterprise is the next frontier in productivity. The report underscores the necessity for systems-agnostic integrators to automate the interconnection of various tools, facilitating seamless communication and faster decision-making across departments and suppliers. A recent webinar discussing the survey is available at www.razorleaf.com, and the full report can be downloaded for free at www.razorleaf.com.

For More Information: www.razorleaf.com

Yaskawa Motoman’s Versatile Compact Welding Workcells!

Yaskawa Motoman showcased its versatile compact welding workcells at FABTECH Orlando. At Booth #W4871, attendees experienced the ArcWorld® HC portable collaborative welding workcell, designed for humancollaborative interaction and suitable for fabricating small to medium-sized parts in high-mix, low-volume production environments. The ArcWorld® RS pre-engineered workcell, also featured, demonstrated quick deployment capabilities, enabling operations to begin within an afternoon. Ideal for welding small parts, material removal, or part inspection, these workcells address manufacturing challenges such as skilled worker shortages, complex weld outputs, and slow factory workflows. Yaskawa Motoman’s solutions offer reliable, efficient automation to streamline welding processes and boost factory productivity.

For More Information: www.yaskawa.com

TIG welder, tailored for precise EV motor repair, was also on display.

In addition to welding equipment, AMADA presented the WM-200A Networked Resistance Weld Monitor, an IIoT-ready device providing real-time waveform data for process monitoring and traceability. Other highlights included the MM-400B and MM-410B Resistance Weld Monitors for efficient monitoring of key welding variables, and the ES-1A Coil Processing Machine for EV motors, developed

by AMADA Press Systems, designed for high-speed, precise copper wire forming.

For More Information: www.amadaweldtech.com

Arnold Magnetic Technologies Expands with New Thailand Facility Arnold Magnetic Technologies has opened a new 26,250-square-foot facility in Amata City, Chonburi, Thailand, to enhance support for its growing global customer base. The facility focuses on producing permanent magnet assemblies, including rotors and stators, for diverse industries in the Asia Pacific, Europe, and North America. This expansion represents Arnold’s commitment to providing localized solutions to meet regional demands and strengthen its global footprint.

Operating within Thailand’s leading industrial zone, the facility began production in October 2024.

This strategic addition allows Arnold to respond more effectively to customer needs across critical sectors like automotive, aerospace, and medical technology. The company’s decision to establish a second facility in Asia aligns with its mission to support clients globally, improve logistical efficiency, and ensure rapid delivery of advanced magnetic solutions.

AMADA WELD TECH Showcases Advanced Equipment for Battery and EV Manufacturing

For More Information: www.arnoldmagnetics.com

AMADA WELD TECH recently showcased its latest equipment for battery and EV manufacturing at The Battery Show, held October 7-10, 2024, in Detroit, Michigan. At Booth 3011, attendees explored cutting-edge laser and resistance welding technology, including the WL-P300A Laser Processing Workstation, ideal for laser marking and welding battery tabs, and the UB-4000A Linear DC Welding Power Supply, offering programmable control for reliable battery pack assembly. The MAWA-300B Pulsed Micro

BIG DAISHOWA’s "Tools for Schools" Program Continues to Support Future Manufacturers Now in its third year, BIG DAISHOWA’s Tools for Schools program enables customers to support educational institutions by earning tooling certificates with qualifying purchases. Until December 30, 2024, customers purchasing $5,000 or more in BIG DAISHOWA products will receive a certificate valued at 20% of their order to donate to a school of their choice. Schools can redeem certificates for any INDUSTRIAL MACHINERY DIGEST.COM

IMD | 11

BIG DAISHOWA’s "Tools for Schools" Program Supports Future Manufacturers

Combilift CEO Martin McVicar on Winning Irish Exporter of the Year

BIG DAISHOWA products, from tool holders to advanced boring systems.

This program has issued nearly $50,000 in tooling certificates to high schools, colleges, and vocational training programs, supporting hands-on learning for future machinists and engineers. BIG DAISHOWA’s commitment to workforce development aligns with its mission to enhance manufacturing education and give students practical experience with industry-standard tools they will use in their careers.

set the company on a path of rapid expansion. Today, Combilift exports account for 97% of its business, with a product lineup that has broadened to include advanced logistical solutions.

Receiving the Irish Exporter of the Year award underscores Combilift’s dedication to sustainable, customer-focused growth and product innovation.

Combilift’s efficient designs and commitment to quality have built lasting customer relationships, solidifying its reputation in over 300 global markets. The award celebrates Combilift as a trailblazer in manufacturing and logistics solutions worldwide.

For More Information: www.us.bigdaishowa.com

CERATIZIT USA Welcomes New Technical Director Eric Gerringer

For More Information: www.combilift.com

CERATIZIT USA has appointed Eric Gerringer as its new Technical Director, bringing over 25 years of industry experience in engineering, applications, and strategic leadership. Gerringer’s expertise encompasses hands-on machining, CAD/CAM, and business development, which will enhance CERATIZIT’s commitment to delivering precise and high-performing cutting solutions. With a focus on innovation, he aims to identify and implement advanced metal-cutting technologies to meet evolving industry needs.

As Technical Director, Gerringer will lead the team in problem-solving initiatives that boost productivity and operational efficiency for CERATIZIT’s customers.

His addition strengthens CERATIZIT’s ability to deliver sustainable and effective tooling solutions to a wide array of industries, emphasizing practical solutions that benefit both the bottom line and customer satisfaction.

The Communications Group’s 2025 Industrial Marketing Trends Report Now Available

For More Information: www.cuttingtools.ceratizit.com

Combilift CEO Martin McVicar on Winning Irish Exporter of the Year Combilift CEO Martin McVicar reflects on the company’s growth since its founding in 1998, from a small team with a unique forklift concept to a global leader in material handling solutions. Combilift’s 4-ton C-Series multidirectional forklift, which moves both forward and sideways, revolutionized long-load handling and

12 | IMD November 2024

The Communications Group (ComGroup) has published its 2025 Industrial Marketing Trends report, aimed at helping industrial B2B leaders shape effective marketing strategies.

Drawing on more than 30 years of expertise, ComGroup’s report offers insights into upcoming trends, from data analytics to evolving consumer expectations. The report provides practical guidance for adapting to new technology, enhancing data-driven decision-making, and navigating changing market demands.

Industrial professionals can use the report’s findings to fine-tune their marketing and communication plans for the upcoming year. Additionally, ComGroup offers free resources, such as website audits, to support ongoing improvement in digital engagement and customer outreach. The 2025 report is part of ComGroup’s broader commitment to equipping industry leaders with the tools they need to remain competitive in an ever-evolving landscape.

For More Information: www.comgroup.com

Coxreels Introduces "Ship Ready" Program for Fast Delivery Coxreels has introduced its Ship Ready program to expedite order fulfillment and provide next-business-day shipping on

over 80 popular SKU items. With customer feedback driving this initiative, the program aims to deliver rapid access to Coxreels’ industry-leading hose, cord, and cable reels, which are renowned for their durability and performance.

Orders confirmed through the Ship Ready program will be dispatched the next business day, with same-day shipping available whenever possible.

Focused on customer satisfaction, the Ship Ready program allows up to 10 units per SKU per order, meeting demand for high-quality reels with faster lead times.

As a leader in reeling products, Coxreels continues to demonstrate its commitment to innovation and responsiveness in customer service. This program is set to enhance the company’s reputation for reliability and efficiency in delivering American-made reeling solutions.

For More Information: www.coxreels.com/shipready.html

Dorner Unveils C3 Belted Curve Conveyor at PACK EXPO 2024 At PACK EXPO 2024 in Chicago, Dorner introduced the C3 Belted Curve Conveyor, engineered to optimize

space and efficiency for sanitary applications. The C3 Conveyor, featuring FDA-approved fabric belting, is designed to manage both 90- and 180-degree turns, making it a significant innovation for industries that require streamlined product movement in confined spaces. Its stainless steel and food-safe construction aligns with strict BISSC standards, ideal for food, beverage, and confectionery production.

Dorner’s PACK EXPO display also showcased solutions like the AquaGard GT and FlexMove Helix conveyors, emphasizing versatility, rapid lead times, and

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enhanced productivity. The C3 Conveyor, alongside other Dorner systems, exemplifies how the company meets diverse industry needs with cutting-edge automation and efficiency. Dorner’s customer-centric approach continues to drive innovation in conveying systems, offering effective solutions for packaging and processing sectors.

For More Information: www.dornerconveyors.com

time and carbon emissions by 40%. The system aligns with Stellantis’ commitment to reducing environmental impact while enhancing vehicle production for electric and hybrid models.

This new plant, a collaborative project between Dürr and Stellantis, incorporates recycled robots from previous facilities, emphasizing sustainability. Additionally, Dürr’s patented RoDip® dip coating process saves water, chemicals, and energy, making it an ideal choice for the environmentally conscious automaker. Dürr’s innovative systems help Stellantis boost production capabilities while setting a new standard for sustainable practices in the automotive sector.

For More Information: www.durr.com

Alexander Steinacher Appointed CFO at EMCO GmbH Dürr’s EcoInCure Electric Oven Boosts Efficiency in Stellantis Paint Shop Dürr has implemented its EcoInCure electric oven at Stellantis’ new paint shop in Kenitra, Morocco, focusing on eco-friendly and energy-efficient vehicle coating processes.

The EcoInCure oven uses an internal airflow design to heat car bodies from the inside out, reducing heating

14 | IMD November 2024

Alexander Steinacher has joined EMCO GmbH as Chief Financial Officer, succeeding Horst Rettenbacher, who is retiring after a decade of transformative leadership at the Austrian machine tool manufacturer. Steinacher brings a background in finance and controlling, having held various management roles across industries such as automotive, engineering, and banking. His expertise includes market expansion, strategic financial planning, and international business development.

Steinacher’s extensive experience is expected to drive EMCO’s continued growth and financial stability, strengthening its global presence in machine tool manufacturing. Alongside CEO Dr. Markus Nolte and CSO Jörg Weinkogl, Steinacher joins the executive team with a focus on financial resilience and market innovation, positioning EMCO to meet future industry demands and foster sustainable growth.

For More Information: www.emco-world.com

PLASTICS Celebrates Manufacturing Day to Promote Career Opportunities The Plastics Industry Association (PLASTICS) is commemorating Manufacturing Day to spotlight career paths within the plastics industry. As the eighth largest manufacturing sector in the U.S., plastics play an integral role in producing essential, lightweight, and sustainable products. Manufacturing Day encourages students, job seekers, and the public to learn about modern manufacturing and explore diverse career options in fields like engineering, production, and materials science.

PLASTICS’ commitment to advancing industry skills is evident as it invests in new technologies and sustainabilityfocused innovations. PLASTICS President and CEO Matt Seaholm highlights the value of manufacturing careers, noting the industry’s impact on daily life and economic

growth. Through events and initiatives, PLASTICS aims to inspire the next generation of workers to join a sector that prioritizes innovation and environmental stewardship.

For More Information: www.plasticsindustry.org

Universal Robots Increases Payload Capacity for UR20 and UR30 Cobots Universal Robots has enhanced its UR20 and UR30 collaborative robots (cobots) with increased payload capacities of 25 kg and 35 kg, respectively. Achieved through a software update to PolyScope 5.19, this improvement allows users to perform more demanding tasks like palletizing without additional hardware costs. By providing this boost, Universal Robots demonstrates its commitment to enhancing customer productivity and offering cost-effective upgrades.

The increased payload capacity enables more versatile applications across industries, from logistics to heavy-duty manufacturing, enhancing the cobots’ functionality and value. Universal Robots showcased these upgraded models at the China International Industry Fair, where attendees observed the cobots’ expanded capabilities for real-world applications. The update reflects Universal Robots’ dedication to delivering continuous value through accessible technology upgrades.

For More Information: www.universal-robots.com

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IMD | 15

Business 4.0

As G7 Production Falters, will the BRICS Economies Capitalize on it?

By Jack Loughney, Senior Research Analyst – Interact Analysis

J

ack works as the primary data analyst across multiple research activities.

His expertise lies in data modelling, economic forecasting and streamlining processes to enhance product efficiency. Jack is responsible for the upkeep and enrichment of our MIO tracker.

The manufacturing economies of the G7 group of nations face growing competition from the rest of the world, as globalization connects countries’ economic fortunes more closely. Huge changes have taken place within manufacturing as companies - particularly within the industrialized nations - turn to automation to tackle growing problems with skills and labor shortages and rising input costs, coupled with demand for greater efficiency and throughput. In addition, world events resonate within industry and the impact of global conflicts on energy costs and supply chains are affecting production.

Meanwhile, many of the BRICS nations have improved production capacity and output growth, as domestic demand increases. In the current climate, opportunities may exist for the BRICS economies to capitalize on weaker projected growth for the G7 nations and expand their manufacturing industries due to costlier exports and already strong production capacity. This begs the question, can the BRICS nations take advantage of the current slump in manufacturing output in the G7, and will they choose to do so?

In existence since 1973, the G7 is a political and economic forum of industrialized nations (Canada, France, Germany, Italy, Japan, the United Kingdom, and the United States, with the European Union as a non-enumerated member). Formed much more recently, the BRICS geopolitical bloc comprises Brazil, Russia, India, China, South Africa, Iran, Egypt, Ethiopia, and the United Arab Emirates. As a whole, the BRICS nations have traditionally had lower production capacity than the G7 countries.

According to the latest data from Interact Analysis’ quarterly Manufacturing Output Tracker (MIO), 2024 will prove tough for manufacturing worldwide. Despite lower output being forecast for most nations, the dip for many will be relatively low. When China is excluded from the global data, production output is expected to drop to -0.9%. China, the ‘Factory of the World’ continues to prop up the figures, with the forecast at 0.6% when it is included in the data.

16 | IMD November 2024

Manufacturing conditions remain difficult for the G7 Germany’s manufacturing industry has been the worst hit of the G7 nations as it attempts to shift its reliance on Russian gas, experiences falling business from China, and is undercut by cheaper production elsewhere. The overly bureaucratic industrial and political system continues to hamper recovery. Taking the German car industry as an example, Volkswagen recently announced plans to close two of its production facilities in its home country.

And it is not the only major automotive company to do so, with others considering plant closures, including tyre giants Continental and Michelin. Ford has revealed it is cutting 3,500 jobs at a German plant, and Automotive Cells Company (ACC) has halted construction on battery manufacturing sites in both Germany and Italy.

Italy has seen minor effects of the global slowdown, but the severe problems in Germany have not manifested as acutely as feared, with machinery sales remaining robust. However, growth has flatlined and the current situation is wait and see. High production costs and production capacity in many large European economies mean they have struggled to increase production. Both Germany and Italy have witnessed companies moving factories to cheaper neighboring countries like Romania, Czechia, Hungary and Poland. The effect of this movement within the European Union benefits the wider G7 to some degree, but is to the detriment of individual G7 members.

We have yet to see any impact of France hosting the 2024 Olympic Games show within the manufacturing data, so it is unclear what effect, if any, the event will have on the nation’s economic fortune. Meanwhile, the UK continues to feel the aftershocks of Brexit, with import and export costs increasing. As the economy falters, it remains unclear whether a change of government will bring about

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

changes in relations with the rest of Europe and policies that affect manufacturing.

Japan is the third largest manufacturing economy in the world, but it continues to struggle as the accelerating decline of the yen places households under pressure.

As a net importer, the pressure on internal consumption is coupled with emerging southeast Asian economies undercutting it in some of its key manufacturing sectors.

Within the G7, the US is not experiencing economic pressures to the same extent and consumer demand has remained robust, despite rising prices. The Interact Analysis MIO Tracker is not currently forecasting a contraction for US output in 2024. Additionally, US industry has benefitted from government policies such as the CHIPS and Science Act. The US has invested heavily into the growing semiconductor industry to secure domestic production and reduce imports from China. This stimulus will likely continue to boost manufacturing in the US. With less proactive measures from the government, Canada’s manufacturing data is weaker, affected by a dip in global demand for metals. The latest drop has increased calls for action to boost production.

What does this mean for the BRICS economies?

With the current downturn largely affecting the Americas and Europe in particular, the BRICS economies have shown greater resilience. Despite China’s weak recovery in domestic demand, due to its fluctuating housing market, it is still expected to increase production output by +2.3% in 2024 as exports rebound. So far, the government has avoided large-scale economic stimuli, although reports now suggest that some form of stimulus is being planned.

The real estate market is expected to stabilize in 2025, while higher rates of growth are predicted for production output into 2026 and 2027.

India has been particularly resilient and is on a strong growth path. Its high population density and poor availability of raw materials mean it is unlikely to become the ‘next China’. However, Interact Analysis has raised India’s long term growth forecast to +5.4%.

India is capitalizing on weaknesses in the G7 through its manufacturing industry as it continues to trade widely with, for example, China, Russia and the US. A significant increase in investment is also being hailed as a key driver of growth. S&P Global has predicted it could rise to become the third largest economy in the world by 2030. It may well be that the Indian government’s ‘Make in India’ flagship program is starting to bear fruit. However, it is notable that India’s manufacturing industry is facing some challenges within certain sectors from smaller countries, particularly in areas such as semiconductor manufacturing from territories such as South Korea and Malaysia.

The overall picture is inconsistent across the manufacturing industries of all the BRICS nations. For example, according to the MIO, the Covid-19 pandemic affected Brazil more than any other large manufacturing economy and it is still regaining lost ground following a

particularly difficult 2023. Brazil is not expected to see manufacturing growth return until at least 2025 and it remains heavily reliant on exports to China and the US, both of which have dipped. However, it is anticipated that monetary policy changes will return its economy to growth and boost manufacturing.

Russia’s economy has generally held up, despite the war in Ukraine, and it has spent heavily on military production. But it is not clear how long this will last.

Additionally, some of the smaller BRICS economies, such as Ethiopia, South Africa and Egypt, have experienced a range of political and economic challenges that have affected manufacturing productivity. The UAE in contrast has seen diversification policies and increases in oil prices and production boost its output and economy.

So, can and will the BRICS economies capitalize on the current G7 manufacturing slump?

Any capital BRICS nations are going to make from the current downturn will need to be swift, as another manufacturing downturn is not forecast by Interact Analysis until 2029 or 2030. Looking at the MIO Tracker, the Americas is forecast to see a compound annual growth rate (CAGR) of 5.4% between 2024 and 2029, considerably higher than the 3.9% anticipated for Europe and Asia. Asia’s lower 5-year CAGR is mostly due to the sheer size of China’s manufacturing industry, as it is harder to achieve growth from a larger base. India’s manufacturing CAGR for the 5-year period is 6% and Asia as whole - excluding China - is 5.5%.

Growth trajectories are predicted for the 3 major manufacturing regions There is little time for the BRICS nations to capitalize on the widespread manufacturing struggles of many of the G7, so it is unlikely that much additional growth will be generated in the short term. The post-Covid nearshoring trend is continuing and government incentives to generate domestic investment (such as the CHIPS Act in the US and Make in India) may become more widespread. With the G7 undoubtedly facing increasing competition from the rest of the world, this may be a means by which wealthier countries attempt to protect their manufacturing industries and reduce over-reliance on Chinese imports. However, China is such a dominant force in global manufacturing, with all the benefits that rich natural resources and domestic consumption bring, that it is unlikely to see any significant impact in the near term.

The picture is also far more complicated than simply G7 vs BRICS nations. We have seen smaller, more agile nations such as Indonesia, Malaysia, Czechia and Poland grow their manufacturing industries and specialized industries as larger territories experience output struggles.

With such a wide range of variables in place and an imminent global recovery forecast, it appears that the BRICS nations are unlikely to make manufacturing capital out of the current downturn in many of the G7 economies.

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IMD | 17

Talking Shop

Cosen Saws at Fabtech 2024: Showcasing Cutting-Edge Solutions for Precision and Productivity Recapping Fabtech 2024 and Cosen’s Innovations

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t the recent Fabtech 2024 Expo, held October 15-17 in Orlando, Florida, Cosen Saws presented a lineup of advanced sawing solutions designed to meet the diverse needs of industries like automotive, aerospace, and structural fabrication. Cosen’s presence at booth S15011 drew considerable attention, particularly for its innovative approach to automation, efficiency, and precision in band sawing.

Visitors to Fabtech were especially captivated by Cosen's NC510MG, a fully automatic scissor-style mitering band saw. Marketed as an ideal choice for fabricators looking to elevate productivity, this model stands out for its combination of power and precision. Hayden Peterson, Cosen’s North American Marketing Manager, demonstrated the NC510MG’s robust capabilities, focusing on its user-friendly automation features. “This machine is designed for those fabricators who want to take production to the next level,” Peterson said. With a price point around $61,000, the NC510MG offers features that simplify complex cuts, setting a new benchmark for value in high-demand production environments.

The NC510MG includes a full-capacity top clamp, a standout feature enabling it to securely hold large or

18 | IMD November 2024

bundled materials for high-straightness cuts. For operators managing multiple projects, its fully programmable control system offers storage for up to 100 different jobs. The automated mitering function allows users to pre-program precise angles, minimizing manual adjustments. The ability to input specific degrees—like a 60-degree angle—means the machine handles adjustments independently, letting operators “set it and forget it.” This model exemplifies how Cosen has seamlessly integrated automation into its sawing solutions to meet the evolving demands of modern fabrication.

A Diverse Array of Sawing Solutions While the NC510MG was a crowd favorite, Cosen also showcased a diverse lineup of models, each catering to unique fabrication needs: » G320 Fully Automatic Dual Column Band Saw: This saw features a cutting capacity of 12.8" x 15", making it a top choice for high-volume production facilities. With its dual-column structure, the G320 maintains exceptional stability and precision during continuous operations, making it ideal for applications that require reliable performance over long shifts.

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» AV-2026NC Vertical Tilt-Frame Band Saw: Known for its versatility, this model is a fully automated vertical tilt-frame saw with a 20" x 26.3" cutting capacity.

It is designed for heavy-duty structural fabrication, particularly where angle adjustments are frequent. The AV-2026NC’s vertical tilt-frame provides ease in cutting large beams and I-beams, meeting the demands of both structural and general fabrication. » C-300MNC Fully Automatic Scissor-Style Mitering Band Saw: Another fully automated model, the C-300MNC is built for medium-capacity tasks with a cutting range of 9" x 11.5". Its scissor-style mitering design allows for easy angle adjustments, making it suitable for smaller but diverse production needs. » SH-1000F Semi-Automatic Dual Column Band Saw: With a substantial cutting capacity of 20.5" x 40", the SH-1000F is designed for cutting large billets. Its dual-column design ensures structural rigidity, making it highly effective for demanding applications like steel construction. Semi-automatic functionality in this model provides operational efficiency without the need for full automation, catering to users who want reliability with a measure of manual control. » SH-500M Semi-Automatic Scissor-Style Mitering Band Saw: Highly popular among fabricators, the SH-500M features a scissor-style design and miter capabilities up to 60 degrees in one direction, accommodating cuts for complex layouts. With a cutting capacity of 11" x 19.7", this model combines functionality with adaptability, handling tasks like flipping parts for opposing angles. » SC-350 Semi-Automatic Circular Cold Saw: This circular cold saw caters to smaller production operations, with the ability to cut both solid materials (up to 2.362") and tubing (up to 4.331"). The SC-350 is valued for its precision in making clean cuts on smaller stock, from tubing to metal bars, fitting seamlessly into shops with more specific cutting needs.

America—covers an array of band saw solutions tailored to both large-scale and specialty applications. Cosen has continually evolved to address the needs of key industries, such as automotive, aerospace, steel construction, and more, offering machines that bring durability, precision, and versatility to the shop floor. Recognized as a top sawing manufacturer in Metal Center News' Top-10 Equipment Brands survey, Cosen’s reputation for quality has made it a preferred choice among fabricators.

Cosen’s North American headquarters in Charlotte, NC, serves as the company’s central hub for product distribution, service, and support. Maintaining an extensive parts inventory and a team of skilled technicians, Cosen ensures prompt support to minimize downtime for customers.

The company’s motto, “Pinnacle of Cutting Performance,” reflects its commitment to helping customers find the right solutions to meet their production needs.

Expanding Cutting Capabilities for the Future Fabtech 2024 highlighted Cosen’s role as an industry leader in the development of band saw technology, bringing attention to solutions that address modern fabrication challenges. As industries like aerospace, automotive, and construction move toward automation and digital integration, Cosen’s machines are positioned to keep pace with evolving production requirements. The diversity of models on display at Fabtech demonstrated Cosen’s capacity to support applications ranging from simple cuts to complex angled layouts, ensuring precision in even the most demanding settings.

With a foundation of reliability, an expansive service network, and a portfolio that keeps expanding with innovative technology, Cosen remains dedicated to driving the future of cutting solutions. Their continued advancements in automation and user-focused design mean that customers can look forward to machines that don’t just cut but actively enhance production capabilities.

Emphasis on Automation and Operator Efficiency Cosen’s booth not only showcased individual saw models but also highlighted its advances in automation.

With new technologies focused on sawing automation integration, Cosen’s solutions improve operator efficiency and streamline production flow. The introduction of programmable mitering, enhanced clamp systems, and job storage across models exemplifies how Cosen meets market demand for higher productivity and minimized downtime. By automating repetitive tasks, Cosen’s machines enable operators to focus on overseeing complex projects rather than making constant manual adjustments, which has become essential in sectors requiring high production and accuracy.

For More Information For more details about Cosen’s extensive range of sawing solutions, visit www.cosensaws.com or reach out to the team at info@cosensaws.com or by calling 704-943-1030.

Commitment to Quality and Versatility Since its founding in 1976, Cosen Saws has been known for its dedication to quality and customer-focused service. The company’s expansive product line—now a staple in North INDUSTRIAL MACHINERY DIGEST.COM

IMD | 19

Safety & Maintenance

Navigating OSHA Inspections: Your Guide to Safety and Compliance Success

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reparing for an OSHA inspection may seem daunting, but a proactive approach can ensure smoother navigation of the process. Occupational Safety and Health Administration (OSHA) inspections are designed to ensure workplace safety and minimize hazards. While they can feel disruptive, these inspections also offer valuable insight into areas that need improvement. With the right preparation, employers can protect their workforce and avoid costly penalties. Here’s a comprehensive guide on the critical steps to manage an OSHA inspection effectively.

Why OSHA Inspections Matter OSHA is dedicated to maintaining safe workplaces, and inspections play a vital role in enforcing this mission.

Companies in high-risk industries, those with recent complaints, or workplaces where severe injuries have occurred are among those most likely to face an OSHA inspection. Beyond the immediate implications of an inspection, keeping workplaces in compliance with OSHA standards significantly reduces the likelihood of injuries, improves morale, and even enhances productivity.

Preparation Is Key: Laying the Groundwork for a Successful Inspection » Review and Organize Documentation A well-maintained record of safety documentation is the foundation of a strong inspection process. OSHA mandates that employers keep accurate records of workplace injuries and illnesses, including OSHA 300, 301, and 300A forms. Ensuring these documents are current, accurate, and easily accessible demonstrates a commitment to compliance and can make a positive impression on inspectors. » Ensure Training Compliance Safety training, especially on OSHA-regulated topics like hazard communication and personal protective equipment (PPE), is essential. Keep a log of training records that includes dates, employee names, and the content covered. OSHA inspectors will assess these records to verify that training is thorough and frequent enough to mitigate known risks effectively. » Conduct Routine Safety Audits Regular safety audits offer insights into potential hazards and ensure that corrective measures are taken before they escalate.

Forming a safety committee or assigning a safety officer

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to oversee these audits can foster a culture of proactive safety management. Documenting these audits and their findings is equally important, as OSHA inspectors may review these records as part of their evaluation. » Prepare for the Inspection with Mock Walkthroughs Conducting a mock OSHA inspection can identify areas for improvement and highlight any gaps in safety practices. This exercise not only ensures compliance but also familiarizes team members with the inspection process, minimizing stress when an actual inspection occurs.

Understanding the Inspection Process When an OSHA Compliance Safety and Health Officer (CSHO) arrives for an inspection, they will typically begin with an Opening Conference. In this phase, the CSHO explains the purpose of the visit, which may be scheduled or unannounced, depending on the circumstances.

For instance, inspections related to severe incidents or imminent dangers are often unscheduled to capture real-time practices. » Request Identification and Verify the Scope of the Inspection Politely ask the CSHO for identification and ensure their credentials are in order. Once identification is confirmed, clarify the inspection scope, as some inspections may focus on specific hazards, while others may be comprehensive. Designating a company representative to handle communications with the inspector helps maintain organization and control over the inspection process.

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» Define Internal Roles and Responsibilities Assigning specific roles—such as a point person to accompany the inspector and a record-keeper to document the inspection process—helps ensure that key aspects of the inspection are handled promptly and accurately.

requires additional documentation or corrective actions, confirm a timeline for follow-up. This request provides a clear path for remedying concerns and completing outstanding requirements.

Post-Inspection: Follow-Up and Record-Keeping The Walkaround: Ensuring Compliance in Real Time During the Walkaround Inspection, the CSHO will tour the facility, inspecting specific areas, equipment, and work practices. This stage is critical, as it provides the most direct insight into OSHA’s evaluation of your workplace. » Document the Inspector’s Movements and Observations During the walkaround, your designated company representative should take detailed notes on every area inspected, equipment observed, and any specific safety practices noted by the inspector. Photos can also be valuable for your records, particularly if the inspector highlights areas of concern. » Display Normal Working Conditions Ensure that work operations during the inspection reflect typical conditions rather than adjusting or halting activities. This approach demonstrates transparency and adherence to safety standards as they are practiced day-to-day, which can work to your advantage. » Limit Access to Confidential Areas OSHA allows employers to mark certain areas as confidential if they contain sensitive information or trade secrets. Discuss these designations in advance and inform the inspector of any restrictions, while still accommodating the needs of the inspection. » Handle Employee and Management Interviews with Care Inspectors often interview employees during the inspection process. To facilitate these interviews: » Educate Employees on Their Rights: Inform employees that they have the right to request a representative, refuse recording, and answer questions without speculation. These interviews offer employees a chance to share their experiences openly, and educating them about the process beforehand can promote a constructive atmosphere. » Debrief After Interviews: After the interviews, consider holding a brief meeting with employees to review topics discussed, which helps maintain alignment across safety practices.

Addressing Findings in the Closing Conference Following the walkaround, the inspection concludes with a Closing Conference. During this phase, the CSHO will discuss any preliminary findings, answer questions, and clarify possible violations. » Seek Clarification on Any Observations or Citations It’s essential to ask questions and fully understand any citations, associated standards, and the nature of identified issues. Taking detailed notes during the conference will be valuable if further action is required. » Request Additional Time for Follow-Up If the inspector

Once an inspection concludes and any citations have been issued, OSHA requires employers to post citations in a visible area within the workplace for at least three days or until the cited issue is corrected. This posting period offers transparency and helps reinforce accountability. » Establish a Corrective Action Plan For citations that require action, creating a corrective plan with clear timelines, assigned responsibilities, and specific steps can ensure timely completion. Document every step taken to remedy each issue, as this information may be reviewed in future inspections. » Document All Follow-Up Actions Each action taken should be documented and stored for future reference.

A comprehensive record not only aids in verifying compliance for future inspections but also supports continuous improvement in safety practices. » Maintain an Ongoing Compliance Program Implementing an ongoing compliance program ensures long-term adherence to OSHA standards. Regularly reviewing safety protocols, updating training programs, and conducting frequent audits are key to maintaining a safe work environment. For companies facing recurrent inspections or those in high-risk industries, such measures can significantly reduce the likelihood of future citations.

Leveraging Technology for Compliance Management Digital tools can streamline OSHA compliance by centralizing safety documentation, tracking audits, and simplifying incident reporting. Companies like VelocityEHS offer solutions that help automate many compliance-related tasks, enabling efficient management of safety protocols and providing real-time data insights. Solutions like VelocityEHS not only support compliance but also empower employers to proactively address safety issues before they result in incidents or penalties.

In Summary Successfully navigating an OSHA inspection comes down to thorough preparation, clear communication, and responsive follow-up. By maintaining up-to-date documentation, conducting regular audits, and fostering a culture of safety, organizations can minimize disruptions from inspections and focus on long-term improvement. Every step taken toward compliance is also a step toward a safer, more efficient, and productive workplace.

For more comprehensive support in managing safety protocols and preparing for inspections, visit VelocityEHS at EHS.com. The VelocityEHS Safety Solution offers centralized EHS management software to make OSHA inspection preparation seamless.

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IMD | 21

Manufacturing Showcase

HYDMECH Shines at FABTECH 2024: Innovations and Industry Insights from VP Rick Arcaro

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ctober 24, 2024 – FABTECH 2024, one of the largest metal forming, fabricating, welding, and finishing exhibitions in North America, showcased numerous industry leaders pushing the boundaries of manufacturing technology. Among them, HYDMECH stood out with its impressive lineup of machinery and forward-thinking approach to fluid power solutions. We had the opportunity to sit down with Rick Arcaro, Vice President of Sales and Marketing at HYDMECH, to gain deeper insights into the company's legacy, innovations, and future directions.

A Legacy of Excellence: Meet Rick Arcaro With 27 years at HYDMECH and nearly four decades in the industry, Rick embodies the company's dedication and expertise. "I've been with the company since 1986, and it's only the third job I've ever had. It's a great industry— addictive, really. You get to see new stuff every single day; you're never stale," he shared enthusiastically.

Rick's long tenure at HYDMECH underscores the company's stable and nurturing work environment.

"Working for HYDMECH is fantastic because we're not a stale company. We're very progressive, innovative, and just a great place to work. We have a lot of good people," he added, highlighting the company's strong internal culture and commitment to employee satisfaction.

Rick Arcaro, Vice President of Sales and Marketing at HYDMECH

the machinery effectively, minimizing downtime and maintaining productivity.

Rick also emphasized the practicality of HYDMECH machines in terms of maintenance and part replacement.

"Our machines are built with a lot of common components.

Anything on a saw that we don't machine, weld or fab, you can buy at a local supply house. So supply chain issues, replacement parts are very simplistic on HYDMECH machines." This approach not only reduces operational costs but also enhances the reliability and longevity of their equipment.

Driving Innovation in a Changing Market What Sets HYDMECH Apart?

When asked about what distinguishes HYDMECH's products from competitors, Rick provided a comprehensive overview.

"Our machines are bar none the easiest to run in the industry," he stated confidently. This ease of operation is a significant differentiator in a market where labor shortages and the need for efficient training are pressing concerns.

One of HYDMECH's standout features is their user-friendly interface. "We're the only machine tool builder that actually gives you a directions door chart in our PLC on our machine, how to run it. So if your operator's not there today, somebody can come over and be a saw operator and keep your production going." This level of accessibility ensures that even less experienced operators can manage

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Innovation remains at the core of HYDMECH's strategy.

"Keeping up with the market, one thing coming out of COVID taught a lot of people, how to deal with supply chain, but more so how to deal with labor and I believe more the lack of labor," Rick explained. The pandemic highlighted the vulnerabilities in global supply chains and exacerbated the existing labor shortages, prompting companies like HYDMECH to adapt and innovate.

To address these challenges, HYDMECH focuses on making their machines as easy and simple to operate as possible. "Our machines have to be easy, simple, and non-intimidating to run. So that basically, again, distinguishes us from some of the other competitors" Rick noted. This user-centric design philosophy ensures

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The original, horizontal pivot band saw is designed to give you the best cost per cut on the market.

that businesses can maintain high Targeting a Diverse Market production levels even with a limited HYDMECH's versatility is a key strength, pool of skilled labor. allowing them to cater to a broad Rick highlighted several key spectrum of industries. "HYDMECH innovations in HYDMECH's new for a lot of years has always been product line. "The innovations we a leader in fabrication. A lot of our have are easier to operate than they machines have the capability to miter were 10 years ago, 15 years ago. cut angles, shapes, products. That's Our production levels are higher. A where the business started. The owner lot of that's due to components on of the company was the innovator of machines. In fairness to our market, the first bandsaw machine where the a lot of it's due to the blades. We head moved instead of the material," build the machine, we don't build Rick recounted. the blades. The innovation of blades The company's flagship machine, have come a long way in the last 10 the S-20, stands as a testament to years as well." their innovative spirit. "If you go out Furthermore, HYDMECH is and Google an S-20, it's the highly expanding its reach into automation. most recognized machine name With the inclusion of an Inverter Drive, the band "We sell automation daily. The and brand in the world. It's the most speed of the machine can be controlled form the sawing market has now held a bit operator’s control panel eliminating the need for copied machine name and brand in the operator to walk around the saw to manipulate a of a different standard. 10, 12 years the world. So that's got to be some pulley drive system. ago, “a saw is a saw”. Now they're sort of flattery. We must be doing referred to as machine tools. And something right." it's a big difference. And you've got people buying Over the years, HYDMECH has expanded its capabilities high-end sheer press brakes and lasers, and now our beyond fabrication to compete in the chip market. "We've machines are going next to them." This shift signifies developed a much better standard of just straight cutting HYDMECH's commitment to integrating advanced for the chip industry. Where we hung our hat in fabrication, technologies that align with the evolving demands of we've certainly now compete daily in the chip market. So modern manufacturing. we've become a very large Swiss Army knife type company

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that we can walk into the small two-person machine shop to the service centers of automotive plants, forgers that may be employing 300 people. We fit all market segments," Rick elaborated.

This adaptability ensures that HYDMECH can serve a wide range of clients, from small businesses to large industrial operations, providing tailored solutions that meet their specific needs.

Commitment to Quality and Sustainability HYDMECH's commitment to quality is evident in every aspect of their operations. "Quality is at the core of HYDMECH's operations. We adhere to stringent quality control processes and hold various certifications, including ISO 9001 and ISO 14001," Rick emphasized.

Moreover, HYDMECH is dedicated to sustainable practices and corporate social responsibility. "We implement eco-friendly manufacturing processes, minimize waste, and strive to reduce our carbon footprint. Additionally, HYDMECH engages in community initiatives and supports various social causes, reinforcing our role as a responsible corporate citizen," Rick highlighted.

This holistic approach not only enhances the company's reputation but also aligns with the growing emphasis on sustainability within the manufacturing sector.

Riding on linear bearings, the left movable saw guide arm can easily be positioned and locked into place when adjusting to the workpiece.

Global Reach and Exceptional Customer Support With a global footprint, HYDMECH ensures that its products are accessible to customers worldwide. "We serve customers across different continents, ensuring that our products are accessible wherever needed," Rick stated. "We pride ourselves on providing excellent customer support, offering technical assistance, maintenance services, and training to ensure optimal performance of our products in the field," Rick added.

This comprehensive support system ensures that customers can maximize the efficiency and longevity of their HYDMECH machinery, fostering long-term partnerships and customer loyalty.

Promotions and Future Outlook As FABTECH 2024 closed, HYDMECH is keen on maintaining its momentum. "HYDMECH's offering a package on our machines. From now until mid-December, we're offering a 7% discount on several of our machines and accessories and packages. So we're looking to keep our backlog moving," Rick announced.

However, the company is experiencing high demand, with bookings already filling into early 2025. "One challenge for us is we're already booking into 2025 Q1, unfortunately some Q2. We've had a very good year and I'm certainly not going to apologize for that for lead times, but it's a challenge. I still got to give somebody an incentive to wait for a HYDMECH because there are other choices out there.

So I believe we're worth the wait," Rick assured.

This robust demand reflects HYDMECH's strong market position and the trust that customers place in their

The saw head can be swung a full 60 degrees simplifying the process of cutting angles when needed.

products. The company's ability to consistently deliver high-quality, reliable machinery ensures that it remains a preferred choice in a competitive landscape.

Looking Ahead As the manufacturing landscape continues to evolve, HYDMECH remains poised to lead with innovation and adaptability. Rick Arcaro's insights at FABTECH 2024 revealed a company that not only honors its rich legacy but also embraces the future with cutting-edge technology and a customer-centric approach.

"HYDMECH is a unique company in that area," Rick concluded. "We strive to reduce material handling, optimize processing, and give operators the tools they need to run multiple machines efficiently. This focus on innovation and efficiency sets us apart and ensures that we continue to meet the diverse needs of our customers."

With its unwavering commitment to quality, innovation, and customer satisfaction, HYDMECH is well-positioned to navigate the challenges of the modern manufacturing industry and continue its trajectory of success.

For more information about HYDMECH and their range of fluid power solutions, visit their website at HYDMECH.com.

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IMD | 25

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Industrial Automation

Taming the Complexity of Machine Vision AI: A Guide to Edge Hardware Solutions

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s manufacturing moves deeper into the era of Industry 4.0, machine vision technology is at the forefront of transformation.

Traditional machine vision systems, which rely on static algorithms and are highly sensitive to environmental variables, are often limited in their flexibility and adaptability. However, with the integration of artificial intelligence (AI) Images courtesy: Axiomtek. and edge computing, machine vision systems are now more capable of handling complex patterns, dynamic lighting, and a broad range of applications. This article delves into how AI-enabled machine vision, paired with the right edge hardware, can revolutionize manufacturing processes.

The Evolution of Machine Vision Historically, machine vision systems were built for controlled environments where consistent lighting and predictable object placement were crucial. As manufacturing environments evolved, these systems struggled to keep up with more complex requirements. AI has reshaped this landscape by allowing machine vision to analyze and interpret nuanced visual data, detecting subtle patterns and defects with remarkable accuracy.

Today, machine vision AI systems are capable of learning from vast datasets, adapting in real time, and continuously improving their performance.

One of the most significant advancements is the shift toward edge computing, where data processing happens directly on the production floor rather than in a centralized data center. This setup reduces latency, enabling real-time decision-making for applications like quality control, defect detection, assembly verification, and packaging.

and processing large volumes of visual data at high speeds.

Here are some key hardware requirements for effective machine vision integration: » Compute Power and Memory: AI models used in machine vision are data-intensive and require substantial computing power. Hardware equipped with modern CPUs and GPUs, as well as high-bandwidth memory, is essential to support these demands. » I/O Support: Machine vision systems typically require connections to various cameras and networked devices. Edge hardware should support diverse interfaces to facilitate seamless integration. » Environmental Protection: Industrial environments can be harsh, with exposure to dust, moisture, and temperature fluctuations. The selected hardware should be rugged enough to withstand these conditions. » Expansion and Customization: As machine vision applications evolve, the ability to expand and customize hardware becomes increasingly important. Flexible hardware solutions enable manufacturers to scale their machine vision capabilities without extensive reconfiguration.

Scaling Machine Vision with Axiomtek’s IPC962A Key Components of Effective Edge Hardware Implementing a successful AI-based machine vision system requires the right combination of software and hardware. Selecting the appropriate edge hardware is critical, as it serves as the backbone for running AI models

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One example of cutting-edge edge hardware designed for AI-enhanced machine vision is Axiomtek’s IPC962A, an industrial-grade computer that embodies the necessary robustness, power, and flexibility for these applications.

Engineered with the specific requirements of AI in mind,

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the IPC962A provides manufacturers with a scalable and adaptable solution. Key features of the IPC962A include: » High-Performance CPUs and GPUs: The IPC962A is equipped with advanced processors capable of handling complex AI algorithms, facilitating fast and accurate image processing. » Comprehensive Connectivity Options: With multiple I/O ports, this system easily connects to various types of cameras and other devices, supporting extensive machine vision configurations. » Multiple Display Capabilities: For high-resolution machine vision applications, the IPC962A supports multiple display outputs, allowing operators to monitor and control processes in real-time. » PoE (Power over Ethernet) Management: The device supports PoE, enabling the connection of cameras and sensors that rely on power through Ethernet cables, simplifying setup and reducing the need for additional wiring.

The IPC962A's versatility makes it ideal for a wide range of machine vision applications, from defect inspection in high-speed assembly lines to the verification of assembled components. With this solution, manufacturers can leverage the power of AI to achieve a higher level of quality control and operational efficiency.

The Benefits of AI-Driven Machine Vision By integrating AI at the edge, machine vision systems become highly efficient tools for quality assurance, capable of delivering unprecedented accuracy and speed.

The benefits are wide-reaching: » Enhanced Accuracy: AI-driven machine vision detects minute defects that traditional methods might miss, ensuring consistently high-quality output. » Reduced Downtime: Real-time processing at the edge allows for instant feedback, reducing downtime by identifying issues before they escalate. » Improved Traceability: With advanced data collection and analysis capabilities, machine vision systems enable comprehensive tracking and traceability of products, aiding in quality assurance and regulatory compliance. » Scalability: Edge-based AI systems can grow with the organization, adapting to new products, workflows, and market demands.

Axiomtek: Partnering for Future-Ready Solutions Axiomtek’s machine vision solutions are designed to meet the challenges of modern manufacturing, supporting Industry 4.0 and smart manufacturing initiatives. With the IPC962A and other offerings, Axiomtek provides a comprehensive solution for manufacturers looking to embrace AI at the edge. Their commitment to customization and customer support ensures that manufacturers can effectively integrate these advanced systems, enabling them to optimize processes and improve productivity across the board.

Images courtesy: Axiomtek.

By combining AI-driven machine vision with powerful edge hardware, Axiomtek is helping manufacturers realize the full potential of Industry 4.0, paving the way for a new era of precision, efficiency, and adaptability in industrial automation.

For more information, visit Axiomtek.

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IMD | 29

Workforce Development

Machine Shops Profit from Near Net Shape Forgings Reduce Machine Time, Waste Chips, Cutting Fluids, Tool Wear and Delivery Time

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achine shops often need open die forged parts for a variety of applications, including large, custom parts, small quantity runs, or when high strength and durability are required. When this is the case, machine shops often contract with forgers for “as forged” parts and then perform finish machining and other secondary operations to achieve the precise tolerances, dimensions, and surface finishes required by the customer.

However, purchasing a near net shape forging may be a better option, one that allows machine shops to reduce costs and improve their profit margins.

Near net shape forgings are seamless rolled rings or open die forgings with dimensions close to the final shape of the finish machined part. “As forged” components, on the other hand, often have a coarse surface finish (500 RMS or more) and may include metal scales and very uneven surfaces that must be machined away. This increases the cutting time, tool wear, and cutting fluid used, which eats into profits. When a customer is on a tight budget, extra stock material that becomes metal swarf can mean the difference between winning a job and losing one.

Fortunately, near net forgings are available with tolerances within 3mm on all dimensions and a much finer surface finish. Although the initial price may be higher, the reduced machining time, wear, elimination of waste, and faster delivery time to the customer translate into cost savings and profit improvements. Reduced machining time increases machine availability for additional projects as well.

Near net forgings are more than just ODs, IDs, and lengths. They include steps on round shafts, blocks, squares, rectangles, hubs, wheels, cylinders, blind cylinders, flanges, drive ends, tending ends, and complex shapes. All Metals & Forge is an ISO 9001:2015 and AS9100D-certified manufacturer of open die forgings, seamless and contoured rolled rings, and complex forged parts with stock allowances or near net shape tolerances.

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A near net shape forging reduces machining time, tool wear, and material waste, offering cost savings and improved efficiency for machine shops.

Machining Open-Die Forgings Open die forgings and seamless rolled rings play a crucial role as components in gears, turbines, bearings, clutches, brakes, couplings, drives, flanges, valves, machines, and rollers. Industries that rely on these types of parts include aerospace, automotive, defense, energy, engine and turbine, food processing, mining, oil and gas, petroleum, power generation, pulp and paper, and shipbuilding.

Given the critical role of these components, open die forgings provide a higher level of structural integrity than any other metalworking process by eliminating structural voids and improving the directional grain flow and grain size within the material.

Seamless rolled rings, like those made by All Metals & Forge Group, an ISO 9001:2015 and AS9100D-certified manufacturer of open die forgings, seamless and contoured rolled rings, and complex forged parts, for example, resist wear, fatigue, and stress, enabling better performance. Depending on the metal and alloy, the rings or forgings are also resistant to thermal and chemical damage, which further extends longevity while reducing the need for maintenance, repair, and replacement.

Open-die forging is particularly advantageous when fabricating large, custom components. All Metals & Forge Group can produce seamless rolled rings or contoured

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rolled rings up to 200 inches in outside diameter, and custom forgings up to 40 feet long or 80,000 lbs. Small parts down to roughly one foot cubed can be deliver as near net shape forgings as well.

Near net shape forgings may be slightly more expensive until all the machining cost factors and savings are calculated into the final part price.

When parts are machined from a basic profile, such as a block, round, or rectangle, significant stock can be lost, but you are still required to pay for the excess material. With open die forging, the part is shaped by the dies, significantly reducing material waste.

When the job is for multiple parts, near net shape savings begin to add up. There are also unseen savings, such as the time to reorder cutting bits, restock cutting fluids, recycle metal swarf, and the opportunity to increase machine time availability.

Greater savings can be achieved with the purchase of a near net shape forging with a fine surface finish when the final profile is more intricate. In the example of a 10-inch round bar 120 inches long with allowance to finish to final dimensions, one supplier may offer the forging with one-quarter inch allowance, or 10.25 OD x 120.25 inches long. The forging will weigh approximately 2,814 pounds in most steels. A supplier that can deliver the part with only a 3mm allowance reduces the weight of the bar to 2,739 pounds – a difference of 75 pounds. The extra 75 pounds on this simple profile increases the purchase price, waste, and machine time, which is invariably passed on to the customer.

Open die forgings can be made of carbon steel, alloy steel, stainless steel, tool steel, nickel, titanium, and aluminum. The forgings meet rigorous industry specifications such as ASTM, AMS, AISI, ASME, SAE, DIN, ASME B 16.5, ASME B16.47, and API 6A. In addition, ultrasonic testing routinely performed by All Metals & Forge Group at no extra cost ensures the absence of internal cracks, pits, or voids.

The limits of near net shape forgings are defined by the supplier. When even more precise tolerances and finer surface finishes are required, a company like All Metals & Forge can deliver parts to within +/-0.001 inch of drawing dimensions and 64 or 32 RMS surface finish.

Near net shape open die forgings and seamless rolled rings can be a strategic competitive advantage for machine shops of all sizes, whether a standalone business or one operating within an OEM facility.

By improving quotes by just a percentage point or two on each bid related to open die forgings or seamless rolled rings, machine shops have the potential to increase profits and internal cost savings.

For more information, contact All Metals & Forge, LLC at 75 Lane Road, NJ 07004; (973) 276-5000; Canada 416-363-2244, toll-free (800) 600-9290; fax (973) 276-5050 or visit www.steelforge.com.

Custom open die forged components from All Metals & Forge Group, designed for high strength and durability across various industrial applications."

Precision forged step shaft by All Metals & Forge Group, crafted to exacting standards for industries requiring high performance and structural integrity.

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New Technology

Transforming Resin Post-Processing: How Prototek Enhanced Production Efficiency with PostProcess Technologies

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s demand for 3D-printed parts in industries such as aerospace, medical, and consumer products continues to grow, manufacturers are under pressure to optimize production workflows and maintain consistent quality. Prototek, a leader in additive manufacturing, produces around 20,000 resin-based parts each month using cutting-edge 3D printing technologies.

However, Prototek encountered significant challenges with the traditional resin post-processing methods, which ultimately led them to adopt an advanced solution from PostProcess Technologies.

The Challenges of Traditional Resin Post-Processing Initially, Prototek relied on traditional isopropyl alcohol (IPA) dunking methods for removing resin from parts.

This method, while common in additive manufacturing, presented a range of challenges that impacted both efficiency and quality. Some of the main issues included: » Inconsistency in Cleaning: Resin removal via IPA baths often resulted in inconsistent outcomes due to variances in solvent concentration and the quality of the dunking process. Manual processing, especially in high volumes, led to variability in the surface finish and mechanical properties of the printed parts. » High Solvent Costs and Environmental Impact: Frequent replacement of IPA was necessary to maintain effectiveness. Not only did this contribute to increased operational costs, but the use of large quantities of IPA also raised concerns regarding environmental impact and workplace safety due to the volatility of the solvent. » Quality Control Issues: Variability in IPA concentration and temperature could lead to under-processed or over-processed parts. Insufficient resin removal resulted in compromised part quality and appearance, while over-processing could damage delicate features, making it challenging to maintain a consistent output. » Manual Labor and Time Consumption: The reliance on manual intervention to monitor and execute the dunking process was time-intensive and laborious.

A single job required dedicated time and focus

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from skilled operators, who had to manage multiple variables to achieve the desired finish.

These limitations drove Prototek to seek a more robust, efficient, and scalable solution to meet its growing production needs. After evaluating several options, Prototek selected PostProcess Technologies' DEMI 910™ automated resin removal solution to address these challenges.

Why Prototek Chose the DEMI 910™ The DEMI 910™, developed by PostProcess Technologies, represented a significant advancement in automated post-processing for resin-based parts. Unlike traditional solvent-based methods, the DEMI 910™ offered a closed-loop, automated solution that mitigates the issues associated with IPA dunking. Key features of the DEMI 910™ that made it the ideal choice for Prototek include: » Automated Resin Removal: By automating the entire resin removal process, the DEMI 910™ minimized human error and manual intervention, allowing Prototek’s operators to focus on other high-value tasks.

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» Precision with PLM-501-SUB Detergent: The DEMI 910™ uses PostProcess Technologies' proprietary PLM-501-SUB detergent, specifically formulated for elastomeric resin removal. Unlike IPA, PLM-501-SUB is engineered to remove resin at a consistent rate without losing efficacy over time. This contributed to more predictable and repeatable outcomes. » Enhanced Throughput: The DEMI 910™ allowed Prototek to process up to three jobs simultaneously, drastically reducing cycle times. With a processing capability of one job per hour, Prototek was able to achieve nearly triple the throughput compared to the previous method, significantly enhancing productivity. » Compatibility with Carbon® L1 Printers: Prototek’s adoption of the DEMI 910™ was driven in part by its compatibility with Carbon® L1 printers. These printers are widely used for high-volume, high-quality parts, and the DEMI 910™'s advanced automation features seamlessly integrated with Prototek’s existing infrastructure.

Streamlined Workflow and Improved Efficiency Prototek's transition to the DEMI 910™ resin removal system brought immediate improvements in workflow and efficiency. Before implementing this solution, Prototek faced significant bottlenecks in post-processing due to the manual labor required to monitor and adjust the IPA concentration and temperature for each batch.

The automated capabilities of the DEMI 910™ allowed Prototek to eliminate these bottlenecks by providing a hands-free solution.

By reducing the need for constant human oversight, Prototek’s team could allocate their time to other essential tasks, such as quality control, part finishing, and machine maintenance. This shift not only improved the company’s efficiency but also resulted in a more streamlined operation, allowing for faster turnaround times and more predictable schedules for customers.

Boosting Consistency and Quality Control The consistent output from the DEMI 910™ addressed the quality control issues Prototek previously encountered with IPA-based methods. Thanks to the PLM-501-SUB detergent’s stability, Prototek was able to achieve reliable, high-quality finishes without risking damage to the parts.

The controlled environment within the DEMI 910™ prevented issues related to temperature fluctuations and solvent degradation, which are common in traditional dunking methods.

Additionally, the automation provided by the DEMI 910™ allowed Prototek to maintain uniformity across multiple batches of parts. This consistency was especially important for Prototek’s clients, who require precision in their components, whether they are used for medical applications or intricate consumer products. With a reliable, repeatable process in place, Prototek established a strong foundation for quality assurance and customer satisfaction.

Sustainability and Cost-Effectiveness Beyond quality and efficiency, Prototek also considered the environmental and economic benefits of adopting the DEMI 910™ system. The PLM-501-SUB detergent’s extended lifespan and lower volatility reduced the frequency of replenishment and the costs associated with solvent disposal. Unlike IPA, which can evaporate quickly and must be frequently replaced, the closed-loop system in the DEMI 910™ minimized solvent waste and improved overall sustainability.

By transitioning away from IPA, Prototek also reduced its reliance on flammable solvents, creating a safer and more eco-friendly work environment. These changes not only contributed to cost savings but also aligned with Prototek’s commitment to environmental responsibility, an increasingly important factor for many manufacturing businesses today.

Future Outlook and Potential for Scaling Prototek’s success with the DEMI 910™ resin removal system has encouraged the company to consider additional applications for PostProcess Technologies’ solutions.

The scalability and flexibility of the DEMI 910™ open new possibilities for expanding Prototek’s capabilities in other areas of additive manufacturing. Prototek has already begun testing the system with new product lines, aiming to explore its utility across a broader range of materials and parts.

With PostProcess Technologies as a partner, Prototek is positioned to continue improving its operations by implementing advanced post-processing solutions tailored to meet the demands of high-volume production.

The two companies are working together to identify opportunities for further automation and efficiency gains, potentially integrating additional PostProcess systems as Prototek’s needs evolve.

Conclusion Prototek’s adoption of PostProcess Technologies’ DEMI 910™ represents a transformative step in resin post-processing for additive manufacturing. By addressing the limitations of traditional methods, the DEMI 910™ provides Prototek with a scalable, efficient, and environmentally friendly solution that supports consistent, high-quality production. This case study highlights the value of advanced automation in modern manufacturing, particularly in areas where precision and reliability are paramount.

As Prototek explores further applications for this technology, the DEMI 910™ stands as a testament to the power of innovation in driving operational excellence. With continued advancements in additive manufacturing and post-processing, companies like Prototek are well-equipped to meet the demands of today’s dynamic market while setting new standards for quality and sustainability in the industry.

For further information, visit PostProcess Technologies and Prototek.

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IMD | 33

Process

TRUMPF’s New TSC 200 Slat Cleaner: A Game-Changer in Laser Cutting Maintenance

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RUMPF, a leader in laser and machine tool technology, has launched the TruTool TSC 200 slat cleaner, a robust new solution for maintaining laser cutting machines. Available in North America, the TSC 200 addresses a longstanding issue in high-power laser operations: removing hardened slag from slats. This new tool offers a powerful, ergonomic solution that simplifies the traditionally labor-intensive task of slag removal, making it faster and more efficient.

Meeting the Challenge of Tough Slag High-powered laser systems, especially those using fiber lasers, produce slag that often becomes difficult to remove.

With standard slat cleaners struggling against this buildup, TRUMPF designed the TSC 200 to excel in tough conditions, reducing downtime and enhancing productivity. The TSC 200’s efficient design means it can be used with any standard laser cutting machine, making it a versatile addition to any manufacturing environment.

Innovative Features for Streamlined Operation The TSC 200 offers several advanced features that set it apart from existing solutions. TRUMPF’s new slat cleaning method combines a two-step roughing and finishing process, using both serrated and continuous cutting edges to effectively break up and remove slag. This method enables the TSC 200 to operate at speeds of 13 to 32 feet per minute, making it a highly efficient tool for cleaning slats with varying thicknesses between 0.080 to 0.150 inches.

The cleaning tools are also built from durable, hardened material, providing excellent wear resistance and a long lifespan. TRUMPF has even included wear indicators on the tools, allowing operators to visually assess when the tool needs to be rotated or replaced, a feature akin to tire tread indicators.

Enhanced Ergonomics and Reduced Operator Effort In response to the physically demanding nature of slag removal, TRUMPF has incorporated several ergonomic features into the TSC 200. One standout feature is the optional feed support, which mounts directly on the tool and is powered by the slat cleaner’s motor, pulling the tool across the slats. This feed support greatly reduces the manual effort required, especially when handling thick or

34 | IMD November 2024

mixed materials. A front handle makes the machine easy to position on the pallet, and position markings on the handle and housing help operators accurately align the cleaner.

Robust Design for Long-Lasting Performance TRUMPF has ensured the TSC 200 is built to withstand harsh industrial environments. With a 1,700-watt motor and a reinforced gearbox, the tool is protected against overload by an integrated slipper clutch. Separate chambers for drive components shield the motor and gearbox from dust and slag, enhancing durability without the need for extra seals.

The polyoxymethylene roller allows the TSC 200 to be easily transported to and from the laser cutting system, and it does not need to be removed during operation, simplifying setup and maintenance.

Intelligent Maintenance Notifications The TSC 200 includes a smart box with an off switch and LED indicators, which alert operators to maintenance needs.

This proactive feature is a key advantage for manufacturers looking to minimize downtime and ensure the TSC 200 remains in peak condition.

Ideal for North American Manufacturers The availability of the TSC 200 in North America is significant, as the tool’s features are well-suited for the demands of manufacturers in various sectors. With TRUMPF’s focus on ease of use, efficiency, and operator safety, the TSC 200 offers an accessible and powerful solution to an industry-wide problem.

A Tradition of Excellence in Power Tools TRUMPF’s expertise in sheet metal processing and power tools dates back to 1934, and the company has continued to innovate in this area. The TSC 200 joins an extensive range of TRUMPF tools that are valued by professionals across industries. With the introduction of the TSC 200, TRUMPF reinforces its position as a trusted provider of high-quality, efficient, and durable tools for manufacturing.

For more information on the TruTool TSC 200, visit TRUMPF’s website or contact TRUMPF’s press representative, Catherine Flynn, at catherine.flynn@trumpf.com or 860-255-6518.

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Industry Insight

The tools for machining the neck are located on the right-hand side of the compound slides and the tools for machining the ball are located on the left-hand side.

EMAG Introduces VST 50: Revolutionizing High-Speed, High-Precision Ball Pin Production

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utomotive manufacturing demands unparalleled precision and speed, especially for components like ball pins and ball sleeves, which are crucial to vehicle safety and performance. In response to the industry’s push for cost-effective, high-quality production, EMAG has unveiled the VST 50, a state-of-the-art machine that turns out a fully machined ball pin every seven seconds.

With a design engineered to meet intense production requirements, the VST 50 combines speed, precision, and automation to redefine standards in automotive component manufacturing.

Why Ball Pins Demand Precision Ball pins, typically found in automotive steering systems and chassis, are essential to a vehicle’s operation, allowing

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movement and flexibility between different parts while enduring constant physical stress. Given their role in vehicle safety, ball pins must meet stringent quality requirements with no margin for error, down to micrometer-level tolerances.

EMAG’s VST 50 was developed with this goal in mind, focusing on creating an ultra-efficient, automated system that maintains uncompromised precision in every machined component.

Engineering and Automation Innovations EMAG’s development team took a unique approach to designing the VST 50, integrating three independent robots to optimize productivity and achieve the sub-two-second chip-to-chip time that defines the machine’s performance.

The setup includes dual suspended workpiece spindles, which enable simultaneous loading, unloading, and

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machining to maintain a seamless workflow. One spindle is loaded and unloaded while the other actively machines the ball pin, maximizing operational efficiency and enabling continuous production.

Advanced Tooling Capabilities Tooling on the VST 50 is meticulously designed to achieve the high precision required for both the ball and neck of each pin.

On the machine’s left side, a rotary B-axis provides precision for machining the ball, supported by a linear U-axis to adjust the ball diameter and shape. On the right side, specialized tools manage the neck machining, completing a process tailored to meet demanding surface quality and dimensional specifications. This arrangement enables the VST 50 to handle both short and long ball pins, with diameters from 16 to 40 mm and lengths between 50 and 455 mm.

Integrated Robots for High-Productivity Loading and Tool Changing Rather than relying on a single robot for multiple tasks, EMAG chose a three-robot system, each responsible for specific tasks in the VST 50’s production line. The left and middle robots transfer workpieces to each spindle, while the third robot manages additional automation tasks outside the immediate machining area. This layout allows simultaneous movements, supporting the VST 50’s rapid cycle time and ensuring consistent, high-speed output.

INDUSTRIAL INK–CODE MARKING

• Product/date coding, dot/spot marking, lot/part numbering, pass/fail marking • Machines can be mounted in any orientation • The sealed ink system allows discontinuous operations with immediate start-up of comparable previous impressions • Machines can be modified or made to order for your particular marking application

The integrated robots also streamline the tool-changing process. Operators receive automated notifications on the machine’s central control panel when a tool change is necessary. With the press of a button, the tool magazine swings out for easy access, allowing the operator to change tools without disrupting production. Once the new tool is in place, the robot handles the actual tool replacement within the machine, ensuring minimal downtime and enhanced process reliability.

Precision Control and Quality Assurance For a component as critical as a ball pin, achieving flawless production quality is essential. To ensure each component meets required specifications, the VST 50 includes a high-resolution light band micrometer that measures both the ball and neck diameters instantly, flagging any deviations from the intended design. This real-time quality control allows manufacturers to maintain stringent standards, reducing waste and rework. Additionally, a process camera positioned at the machine’s loading point provides live images on the control panel, enabling operators to detect and resolve any issues immediately.

The Role of EDNA Apps in User-Friendly Operation To further enhance efficiency, EMAG equips the VST 50 with its EDNA app ecosystem. This digital interface simplifies machine operation, integrating control of the

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IMD | 37

The basic design of the VST 50 includes two workpiece spindles (top) and two tailstocks (bottom).

robots and measurement tools, and enabling intuitive interactions. Operators can seamlessly manage production parameters and monitor real-time performance metrics, making the VST 50 as user-friendly as it is efficient.

The EDNA apps support a range of production needs, including tool management, quality control, and predictive maintenance, ensuring the machine remains operational with minimal downtime.

Versatile Applications Beyond Ball Pins While the VST 50 is designed primarily for automotive ball pins, EMAG sees potential for its application in other industries that require high-precision machining of small, durable parts. The machine’s flexibility to work with ball pins of various sizes—as well as its capacity to machine ball sleeves—makes it an attractive solution for manufacturers across multiple sectors. EMAG estimates the VST 50 to be twice as fast as comparable production solutions, significantly reducing unit production costs and offering a competitive advantage.

EMAG’s Vision for the Future of Component Production According to Frank Haas, project manager and development engineer at EMAG, the VST 50 is a game-changer for ball pin production. "We’re taking the production of ball pins to a new level," says Haas. "With the VST 50, we can meet the automotive industry’s stringent demands for quality and precision, while also delivering on speed and efficiency."

EMAG’s commitment to innovation is evident in every aspect of the VST 50’s design, from the advanced robotics

38 | IMD November 2024

Focus on high-precision surfaces: The new VST 50 from EMAG ensures high-speed machining of ball pins.

to the EDNA-powered digital interface, making it a versatile and reliable solution for high-demand manufacturing.

As industries worldwide strive for increased efficiency and cost-effectiveness, EMAG’s VST 50 sets a new benchmark in automated component production. This machine not only meets current production needs but anticipates future demands for higher precision, faster throughput, and integrated digital control. With the VST 50, EMAG continues to pave the way for advancements in manufacturing technology.

For more information on the VST 50 and EMAG’s innovations in manufacturing technology, visit www.emag.com.

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

a thousand solutions. The new mobile app is a significant step in EXAIR’s efforts to provide the most advanced support for their customers. For more information or to download the app, visit https://exair.co/153-mob-ar.

For More Information: https://exair.co/153-mob-ar

Fixtureworks Introduces New Heavy-Duty Retractable Ball-Lock Fasteners

EXAIR’s New Mobile App Enhances User Experience EXAIR has launched the EXAIR AR Mobile App, available on both Apple and Google Play Stores, further expanding its suite of free tools designed to assist customers. This augmented reality (AR) app provides an interactive and immersive experience, allowing users to browse and virtually place EXAIR products directly into their work environments to ensure a perfect fit for their specific applications. The app streamlines the solution-finding process by enabling users to select product sizes and performance requirements, visualize 3D models within their actual workspace, and seamlessly navigate to purchase pages—all from their mobile devices. Additionally, the EXAIR AR Mobile App includes a comprehensive library of conversion calculators, facilitating quick problemsolving and on-the-go computations. This innovative tool reflects EXAIR’s commitment to enhancing customer value through advanced technology, enabling users to efficiently select process-improving solutions without leaving their facility or production line. Beyond the app, EXAIR.com offers a vast Knowledge Base with resources such as product videos, performance data, CAD files, installation and maintenance guides, air savings calculators, case studies, and an extensive application database with over

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Fixtureworks enhances its One-Touch Fastener lineup with the introduction of heavy-duty retractable ball-lock fasteners, designed to deliver superior clamping and holding forces. These new fasteners provide a clamping force of up to 450 lb (2000N) and a holding force of up to 1120 lb (5000N), making them ideal for quick-change applications that require frequent insertion and removal of fixtures. The heavy-duty retractable fasteners feature a unique retractable pin mechanism that allows the fastener to safely slide off the base without interference, perfect for slide and door applications. The fasteners remain locked until the knob is turned to the "OFF" position, causing the balls to retract into the shank and clear the base plate. Designed to pair seamlessly with the QCWES receptacle mounted to a base, these fasteners ensure positive locking and unlocking without the need for tools. Constructed from stainless steel, including the knob, body, balls, and spring, the QCWESA fasteners offer durability and reliability. In addition to the new heavy-duty QCWESA models, Fixtureworks continues to offer a range of retractable clamping solutions, including the QCTH-series with cam-locking systems. These fasteners

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replace traditional nut-and-bolt assemblies, allowing operators to lock and unlock plates, panels, and machine components effortlessly. Fixtureworks also provides a comprehensive selection of workholding supports, pneumatic clamps, sliding locks, and other fixturing accessories, ensuring versatile and efficient solutions for various industrial applications.

function. These enhancements ensure optimal machining settings, spindle protection, automatic calibration, and energy efficiency, respectively. The MILL P 800 U S is designed for flexibility, precision, and sustainability, making it a versatile choice for modern manufacturing needs.

For More Information: www.fixtureworks.com

Digital Airflow Monitor

New GF Machining Solutions MILL P 800 U S Grows for Production Needs GF Machining Solutions introduces the MILL P 800 U S, a full 5-axis milling machine engineered for scalability and seamless automation integration to meet increasing production demands. Designed to be compact with a reduced footprint, the MILL P 800 U S allows shops to start with a standalone unit and expand into fully automated multiple-machine cells as needs grow. A key innovation is the relocation of the electrical cabinet to the left side, enabling robots to load workpieces directly from the rear without the need for a pallet changer, thereby optimizing operator ergonomics and reducing the overall cell footprint. The machine features a unique twin-ballscrew drive and twin-linear scale gantry system, ensuring synchronized movements and compensating for imbalanced cutting forces, which enhances stability and precision while reducing wear and maintenance.

The StepTec spindle offers a maximum speed of 20,000 rpm, torque rating of 120Nm, and power output of 36Kw, making it ideal for both roughing and finishing operations.

Additional features include tool storage capacities of 120 and 170, a 15-pallet storage unit, and performanceenhancing options like the Operator Support System (OSS), Machine Spindle Protection (MSP), Automatic Machine Calibration (AMC), and the EconoWatt energy-saving

For More Information: www.gfms.com

HEMCO introduces the Digital Airflow Monitor, a cutting-edge device designed to continuously monitor the face velocity airflow of fume hoods, ensuring workplace safety and compliance.

Featuring a clear digital display, the monitor shows airflow velocity in meters per second (m/sec) or feet per minute (FPM), providing real-time data for operators.

An audible alarm alerts users to unsafe airflow levels, enabling prompt corrective actions. The device offers push-button calibration for easy setup and maintenance, ensuring accurate measurements over time. Additionally, it includes three programmable input/output relays, allowing for customizable integration with existing safety and automation systems. The Digital Airflow Monitor can be factory-installed or field-installed, providing flexibility and ease of deployment. This advanced monitoring solution is ideal for industries requiring precise airflow management, such as laboratories, manufacturing facilities, and healthcare environments. HEMCO’s Digital Airflow Monitor enhances safety protocols by delivering reliable and accurate airflow data, contributing to safer and more efficient operations.

For More Information: www.hemcocorp.com/airflowmon.html

KMP 600P Compact Mobile Platform Provides Efficiency and Flexibility in Confined Spaces KUKA introduces the KMP 600P Compact Mobile Platform, a versatile autonomous mobile robot (AMR) designed for confined production environments. As part of KUKA's high-performance P-series, the KMP 600P offers a payload capacity of up to 600 kilograms, making

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it suitable for various industries aiming to enhance production and intralogistics efficiency. This compact platform utilizes differential drive technology, enabling it to move forward, backward, turn on the spot, and navigate tight curves with precision—ideal for spaces with limited maneuverability. The KMP 600P is VDA 5050-compatible, facilitating seamless integration into diverse fleet management systems, and features inductive charging for continuous 24/7 operation, thereby extending battery life. Certified with international CE and UL standards, the platform ensures maximum safety and easy maintenance. Its modular design allows for quick and cost-effective replacement of components, minimizing downtime.

Additionally, the user-friendly KUKA.AMR Fleet software enables effortless commissioning and rapid workflow optimization without requiring programming expertise.

Julian Stockschlaeder, Head of AMR Business Development at KUKA, emphasizes that the KMP 600P expands KUKA’s AMR portfolio, supporting their growth as a leader in the AMR market.

For More Information: www.kuka.com

Mazak Advances Machine Connectivity with New SmartBox 2.0 Mazak launches SmartBox 2.0, an advanced machine connectivity solution designed to enhance productivity and security in manufacturing environments.

Building on the original SmartBox digital integration technology, SmartBox 2.0 incorporates MQTT and OPC communication protocols, significantly improving data exchange and interoperability with a wide range of industrial systems.

This latest version includes an industrial-grade edge compute PC as standard, boosting its capabilities for machine monitoring and analysis while incorporating robust cybersecurity protection. Leveraging MTConnect® technology, SmartBox

42 | IMD November 2024

2.0 provides real-time manufacturing data, enabling shops to optimize operations, increase efficiency, and swiftly adapt to market changes.

The integration of edge computing facilitates local data processing, reducing latency and ensuring high determinism by offloading tasks from controllers. Enhanced security features include an AES-compliant fully managed switch and a lean managed switch, providing IT server room-level protection tailored for factory environments. SmartBox 2.0 supports up to 10 machines for MTConnect monitoring and includes standard Industrial I/O interfacing, ensuring scalable connectivity for diverse manufacturing setups. Its universal compatibility allows it to work with any machine regardless of make or model, and it can be easily mounted on the side of machines without requiring integration into the electrical cabinet. Multiple standard input/output ports enable the connection of off-the-shelf sensors for comprehensive data collection and condition monitoring. SmartBox 2.0 redefines machine connectivity, equipping manufacturers with state-of-the-art tools to enhance operational efficiency and maintain a competitive edge.

For More Information: www.mazak.com

Precision Meets Performance With GPU-Accelerated Simulation ModuleWorks is set to release its GPU-accelerated simulation feature, enhancing material removal simulations by leveraging the high processing speed of workstation GPUs. Expected to be available for testing with the ModuleWorks 2024.12 software release, this new feature dramatically increases simulation speed, achieving up to ten times faster performance compared to traditional CPU-based methods. As machining processes become more complex, requiring precise and accurate simulations, ModuleWorks addresses the common compromise between speed and quality. By utilizing GPU architecture, the accelerated simulation can handle large-scale scenarios with over a million toolpath points, providing detailed and high-fidelity simulations without sacrificing speed. This integration allows CAM systems to adopt GPU-accelerated simulations seamlessly, maintaining the comprehensive feature set of ModuleWorks’ cutting simulation products while significantly boosting productivity. Additionally, the GPU-accelerated simulation supports efficient process planning, optimization, and verification, enabling engineers to iterate and refine machining operations rapidly. Dr.-Ing. Sven Odendahl, Principal Product Manager at ModuleWorks, emphasized that this advancement allows users to maintain high-quality standards while meeting tight deadlines. The GPU-accelerated simulation represents a significant leap in simulation technology, empowering manufacturers to enhance their operational efficiency and precision.

For More Information: moduleworks.com

Orbital Stretch Wrapper Secures Long, Awkward Products that Extend Beyond Pallet Edges TAB Industries, LLC introduces the TAB Wrapper Tornado, an innovative orbital stretch wrapping machine designed to secure long and oddly shaped products that extend beyond pallet edges. By wrapping stretch wrap 360 degrees around and under the entire length of the pallet and load, the TAB Wrapper Tornado ensures proper compression and stability, eliminating the need for custom pallets, crates, or banding. This patented machine is particularly effective for stretch wrapping rods, profiles, pipes, fittings, and a wide range of finished machinery and assembled products. Available in semi-automated and automated models with 115-inch, 100-inch, and 80-inch wrapping ring diameters, the TAB Wrapper Tornado accommodates tall pallet loads up to 95 inches and long pallet loads of any length, creating a secure, unitized load.

Manufactured at TAB Industries’ headquarters in Reading, PA, the wrappers are delivered ready for operation with a warranty and come with a companion line of stretch wrap. This versatile solution simplifies the logistics of transporting long and awkward products, enhancing delivery safety and efficiency. For a free brochure or more information, contact TAB Industries at www. tabwrapper.com.

For More Information: www.tabwrapper.com

New TRUMPF Laser Cutting Machine Generates Bevels While Cutting, Reduces Downstream Processes TRUMPF Inc. unveils the TruLaser Series 3000 Bevel Cut Edition, a new laser cutting machine that automatically prepares parts for welding by generating bevels during the cutting process. Showcased at FABTECH 2024 in Orlando, this innovative machine creates beveled cutting edges on both the top and bottom edges of components, ensuring optimal preparation for welding and reducing the need for additional downstream processes. The TruLaser Series 3000 Bevel Cut Edition is capable of applying chamfers

to sheets up to 1 inch thick and handles complex bevel geometries with ease, making it particularly suitable for mild and stainless steel applications. Equipped with two additional rotary axes, ultra-compact drive motors, and a specially developed nozzle for bevel cutting, the machine offers high flexibility in bevel design, including V and Y edges, as well as double V (DV) and double Y (DY) edges.

The cutting head can tilt up to 50 degrees, with collision protection ensuring process reliability and preventing structural damage. The machine also features an intuitive programming system with predefined cutting parameters, maintaining high productivity while allowing customization for complex bevels. The TruLaser Series 3000 includes TRUMPF’s proven features such as Highspeed Eco, FlexLine, and EdgeLine Bevel for enhanced efficiency and surface finish quality. Grant Fergusson, TRUMPF Inc. TruLaser 2D laser cutting product manager, emphasizes that this machine integrates downstream process steps into laser machining, offering manufacturers substantial savings in setup times, tooling costs, and material handling.

The TruLaser Series 3000 Bevel Cut Edition will officially launch at EuroBLECH in Germany and make its North American debut at FABTECH in Florida.

For More Information: www.trumpf.com

TRUMPF Launches Fully Automated PunchLaser Combination Machine for Connected Manufacturing to the North American Market TRUMPF launches the TruMatic 5000 manufacturing cell with the new SheetMaster, a fully automated punchlaser combination machine designed for connected manufacturing in North America. The TruMatic 5000 integrates automated laser cutting, punching, and forming capabilities, enhancing productivity and part quality while reducing energy consumption. Equipped with a 6kW fiber laser, the system ensures fast and efficient cutting of sheet metal parts, and its descending die prevents parts from being scratched during punching.

The machine features the patented TRUMPF Delta Drive, an energy-efficient electric drive that uses approximately INDUSTRIAL MACHINERY DIGEST.COM

IMD | 43

30% less energy. The introduction of SheetMaster technology fully automates the material flow within the manufacturing cell, utilizing grippers with suction cups monitored by sensors for flexible and rapid part handling. SheetMaster also connects to an automated STOPA storage system, which supplies raw materials, palletizes and sorts parts, and ejects finished parts for transport to subsequent process stages. Additionally, the TruMatic 5000 includes the ToolMaster, a tool changer with up to 90 tool cartridges, allowing for automatic switching between multiple punching and forming tools. An upcoming automatic nozzle changer with inspection capabilities will prevent unscheduled stoppages by detecting damaged nozzles. The TruMatic 5000 is designed for small batch sizes and high-mix production, offering seamless integration with existing connected manufacturing setups.

Roger Michaud, Product Manager for TruPunch and TruMatic at TRUMPF, highlights that the TruMatic 5000 is ideal for businesses looking to improve connectivity

Vericut, a global leader in manufacturing software solutions, announces the upcoming release of two innovative AI-powered tools: Vericut Intelligence (VI) and Vericut Assistant (VA). These tools are designed to revolutionize how users interact with and gain knowledge from Vericut's extensive software suite. Vericut Intelligence (VI) serves as a comprehensive knowledge hub for all Vericut products, including Vericut, Composites, Vericut Optimizer, and various other modules and features.

Accessible to everyone, VI provides in-depth information on any aspect of Vericut’s software, from basic inquiries like “What is Force?” to detailed functionalities like “What is X-Caliper?”. Vericut Assistant (VA), on the other hand,

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and productivity without increasing headcount. Suitable for industries such as industrial kitchens, control-cabinet manufacturing, and furniture manufacturing, the TruMatic 5000 will be available for delivery in North America starting in spring 2025.

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is designed to assist users with the practical application of Vericut software, offering step-by-step guidance and answering how-to questions directly within the software interface. For instance, users can ask, “How do I use AUTO-DIFF?” and receive precise instructions. As VA evolves, it will enable users to perform tasks like adding a tool with specific criteria directly within the software.

Gene Granata, Director of Product Management at Vericut, states that VI and VA simplify access to extensive information, making it intuitive and easy for users to deepen their understanding of the software. These tools also ensure customer privacy, as the platform is designed to protect user data and prevent its use in AI training.

Frankie Cates, Director of Information and Security at Vericut, highlights that the integration of VI and VA is part of a long-term AI strategy aimed at maximizing productivity while maintaining privacy. These tools will be available with the next major release of Vericut, enhancing the user experience by providing comprehensive support and simplifying onboarding for new users while offering advanced assistance to seasoned professionals. Shin Voeks, President of Vericut, emphasizes that this launch marks the first step in Vericut’s AI roadmap to enhance customer experience and streamline processes.

For More Information: www.vericut.com

Walter Cermet Indexable Inserts for Finish and Fine Finish Turning Walter introduces the WEP01C Cermet Turning Indexable Inserts, featuring the sharpest cermet cutting edge and optimized for finish and fine finish turning operations.

These new inserts boast a highly positive, soft-cutting FX4 chip breaker geometry, available in four basic shapes: CCGT, DCGT, TCGT, and VCGT. Crafted from a titanium-carbide-based cermet substrate with a cobaltnickel binder, the WEP01C inserts offer exceptional wear resistance and durability. The inserts are coated with an exceptionally hard PVD AlTiCrN multilayer coating, ensuring a smooth and even surface finish while providing ultimate protection against wear and preventing flaking.

The ground chip breaker design requires the inserts to be handed (left and right), but they are compatible with standard ISO turning holders. The 'M' or maximum material condition tolerance on the corner radii allows for

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machining small radius shoulders with enhanced corner radius strength. Primarily designed for turning steels and cast irons (ISO P and ISO K material groups), these inserts are also suitable for turning stainless steels (ISO M). Ideal for finishing and fine finishing with continuous or slightly interrupted cuts, the WEP01C inserts generate visibly shiny surfaces, prevent vibration, extend tool life, and increase productivity compared to carbide inserts.

Walter’s WEP01C cermet inserts provide maximum wear resistance and dimensional accuracy without the need for cutter compensation over long periods, making them an excellent choice for precision turning applications. For more details, visit www.walter-tools.com/us.

cutters for complex small parts. The MaxiMill 211-DC’s advanced cooling enhances tool life by 60%, while the CTEP110-P’s DRAGONSKIN coating provides improved wear resistance. CERATIZIT’s AluLine Micro cutters offer high precision and durability for intricate aluminum machining, benefiting machinists with superior chip flow and performance.

For More Information: www.walter-tools.com/us

For more information, visit: ceratizit.com

EMUGE TIN-Coated Thread Gages: Precision and Durability for Critical Applications

AIMS Connect: Boosting Tool Manufacturing Efficiency by 20% ANCA CNC Machines launches AIMS Connect, a job management and production control software that optimizes manufacturing efficiency in tool production.

AIMS Connect can increase productivity by up to 20%, addressing the need for streamlined operations in a competitive market. Key features include centralized machine file management for reduced errors, ERP/MES connectivity for efficient data handling, production control for consistency, legacy machine integration, and a worker guidance system. By focusing on machine connectivity, AIMS Connect enables smart, step-by-step factory integration, allowing skilled workers to focus on high-value tasks. Paired with AIMS Automate, ANCA offers a complete smart factory solution with AutoFetch robots managing tool pallet transfers for continuous efficiency.

For more information, visit: anca.com/AIMS-Connect

CERATIZIT UP2DATE Fall 2024: High-Performance Tools for Evolving Machining Needs CERATIZIT’s latest UP2DATE catalog introduces advanced tooling solutions for milling titanium, finishing steel, and micromachining. Highlights include the MaxiMill 211-DC milling system with 3D-printed coolant channels for improved titanium machining, the CTEP110-P cermet inserts for steel finishing, and AluLine Micro milling

46 | IMD November 2024

EMUGE-FRANKEN USA expands its precision gage line with TIN-coated thread gages, ideal for aerospace and medical applications demanding durability and wear resistance. With 3B class-of-fit, these gages are crafted from high-stability HSS with TIN coating, ensuring consistent measurement, reduced friction, and resistance to abrasion. Available in sizes #4 to 1" UNC/UNF and metric, they offer a robust solution for challenging environments. EMUGE-FRANKEN’s gages also include GO/ NO-GO plug gages, depth plug gages, and ring gages, all provided with a Certificate of Accuracy.

For more information, visit: emuge-franken-group.com

Top Quality Welding with Intelligent Robot Assistance Systems Fronius introduces innovative robotic welding assistance systems, including WireSense, TouchSense, SeamTracking, and TeachMode, to eliminate weld defects and improve efficiency. These systems transform the welding wire into a precision sensor, enabling the robot to detect and correct deviations in real time, reducing material use, costs, and rework. WireSense technology uses Cold Metal Transfer (CMT) drive to sense contours and air gaps, adjusting the weld path for perfect results, even on uneven surfaces. TouchSense and SeamTracking ensure precise welds, accounting for component tolerances and preventing errors, while TeachMode speeds up robot programming by up to 30%.

For more information, visit: fronius.com

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