Industrial Machinery Digest Quarterly - IMD Quarter 4, 2023 by Industrial Machinery Digest

IndustrialMachineryDigest.com | Q4 2023

The Industrial Machinery Digest Robotics & Automation Quarterly Resource!

How to Reduce Chatter in Robotic Milling Applications Getting Better at Building it Faster: Hypersonics and 3D Printing Velo3D, Lockheed Martin and Vibrant team up with DoD’s LIFT Institute on a data-driven approach to certifying materials and methods for additively manufactured aerospace systems

Electrical Parts Distributor Van Meter Leverages Eighteen Kardex Shuttles To Support Growth With 18 Vertical Lift Modules from Kardex Remstar, Van Meter has increased their picking throughput by 25%, reduced labor costs by 21%, and increased accuracy to 99.99%.

Titanium Machining — Special Materials for Complete Machining Heavy duty cutting places particular requirements on the machine and working processes.

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Table of Contents

QUARTER 4 2023 6 8 16

EDITORIAL DIRECTION INDUSTRY NEWS CASE STUDY How to Reduce Chatter in Robotic Milling Applications By Mark Fairchild

COMPANY PROFILE Getting Better at Building it Faster: Hypersonics and 3D Printing Velo3D, Lockheed Martin and Vibrant team up with DoD’s LIFT Institute on a data-driven approach to certifying materials and methods for additively manufactured aerospace systems

INTEGRATIONS Electrical Parts Distributor Van Meter Leverages Eighteen Kardex Shuttles To Support Growth With 18 Vertical Lift Modules from Kardex Remstar, Van Meter has increased their picking throughput by 25%, reduced labor costs by 21%, and increased accuracy to 99.99%.

MACHINES Titanium Machining — Special Materials for Complete Machining Heavy duty cutting places particular requirements on the machine and working processes. If this involves a material such as titanium, which is particularly hard to cut, specific knowhow is necessary to deal with these requirements. Thanks to its expertise, WFL Millturn Technologies GmbH & Co. KG impresses in this field with a machining solution for aircraft landing gear.

SOFTWARE & CLOUDWARE Genesis 4 – The new generation of build-job preparation and simulation software by AMSIS The Genesis 4 3D printer represents a significant advancement in 3D printing technology, combining a traditional preprocessor with simulation-based laser beam exposure.

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Editorial Direction Welcome to the latest edition of Industrial Machinery Digest Quarterly (IMDQ), where we continue our journey through the exciting world of Automation and Robotics. In this issue, we've gathered a diverse range of articles that shed light on the cutting-edge developments, innovative solutions, and exceptional stories from the industry. Our first feature article, penned by Mark Fairchild, delves into a critical aspect of robotic milling applications - "How to Reduce Chatter in Robotic Milling Applications." As automation and precision are paramount in this field, Mark's insights are bound to be invaluable to those seeking to enhance their milling processes. In our Company Profile section, we explore the collaborative efforts of Velo3D, Lockheed Martin, and Vibrant, as they join forces with the DoD's LIFT Institute to advance the realm of aerospace systems through 3D printing. Titled "Getting Better at Building it Faster: Hypersonics and 3D Printing," this article showcases the power of data-driven approaches and technological innovation. Our Integrations segment spotlights the achievements of Van Meter, an electrical parts distributor, as they leverage Kardex Shuttles to drive growth. With a 25% increase in picking throughput, a 21% reduction in labor costs, and a remarkable 99.99% accuracy rate, their success story is a testament to the transformative impact of automation. "Machines" takes us into the world of heavy-duty cutting, specifically focusing on machining solutions for aircraft landing gear. WFL Millturn Technologies GmbH & Co. KG demonstrates their expertise in tackling challenging materials like titanium, shedding light on the intricate processes that underpin this critical aspect of aerospace manufacturing. In the "Software/Cloudware" section, we introduce you to Genesis 4, the new generation of build-job preparation and simulation software by AMSIS. This innovative 3D printing technology promises reduced support structures, substantial material and cost savings, and an efficient solution for various printing needs. With simulation-based modules, it paves the way for a rapid and user-friendly transition. As always, IMDQ remains committed to bringing you the latest insights, trends, and success stories from the world of automation and robotics. We hope that the articles in this issue will inform and inspire you, whether you're an industry professional, an enthusiast, or simply curious about the fascinating world of machinery and technology. Thank you for being a part of our community, and we look forward to continuing this journey with you. If you have any feedback or suggestions, please don't hesitate to reach out. Regards,

William Strickland

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

Atlas Machine & Supply Expands Compressed Air Division with FS Elliott Partnership

and are the only factory-recognized service provider for FS Elliott equipment in the region. This partnership expands their range of oil-free compressed air solutions, making them a comprehensive resource for customers. Dave Sullivan, President of the Industrial Product Group at Atlas Machine & Supply, expressed excitement about adding FS Elliott to their premium compressed air solutions. He highlighted the expansion's reflection of their dedication to customer needs and their commitment to staying at the forefront of the industry. Customers in the Midwest can continue to rely on Atlas Machine & Supply for all their compressed air equipment needs, with exceptional servicing for systems from any manufacturer. The IPG Compressed Air Division offers a complete range of services, including products, parts, rentals, oil-free solutions, and technician services, ensuring consistent excellence. Atlas Machine & Supply's rapid growth in the compressed air market and the expansion of its Compressed Air Division mark a new era of success as they adapt to the evolving needs of their valued customers. To explore their complete FS Elliott product line, visit www. atlasmachine.com/compressed-air/fs-elliott/products.

Atlas Machine & Supply, a respected fourth-generation family business, is expanding its Industrial Products Group (IPG) Compressed Air Division by partnering with FS Elliott. The company, known for its remarkable legacy, recently unveiled a new building and is now adding FS Elliott to its product lineup for Kentucky, Tennessee, Indiana, and part of Ohio. This strategic partnership underscores Atlas Machine & Supply's commitment to providing advanced compressed air solutions and top-notch customer support. With FS Elliott as an official distributor, the IPG Compressed Air Division is poised to meet growing customer demands while maintaining its leadership in the field. The Compressed Air Division has already established itself as a dependable provider of high-quality compressed air solutions across the Midwest. Their factory-trained technicians in multiple states ensure excellent service

CENIT Unveils FASTSUITE E2 2023.2: Advancing Autonomous Offline Programming with AI CENIT is driving innovation in industrial manufacturing with its latest release, FASTSUITE E2 2023.2, which introduces 28 new functions and enhancements. This release marks a significant step towards autonomous offline programming, incorporating cutting-edge AI technology. The three major highlights of this release are automated AI-based path optimization, automated seam searches, and efficient planning of welding operations through the Weld Cockpit.

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These features collectively position FASTSUITE E2 as a vital tool for process optimization and cost-effectiveness in robot welding applications. FASTSUITE E2 2023.2 embodies CENIT's commitment to sustainable digitalization in manufacturing. Leveraging AI-based functions, the software supports manufacturing processes to enhance efficiency, resource management, and production quality. Jens Fetzer, Vice President Product Strategy at CENIT AG, highlighted that these new features eliminate the time-consuming manual fine-tuning of manufacturing operations. The release focuses on three key technology bundles: » Efficient planning of welding paths » AI-based offline programming (OLP) with automatic path optimization » Sensor functions for seam identification and tracing The automated path optimization for robot welding operations significantly accelerates programming. AI algorithms automatically generate robot paths, analyze them for issues like collisions, axis limits, and singularities, and then find optimal solutions. This eliminates the need for manual corrections and reprogramming, resulting in smoother and more efficient welding operations, reducing cycle times. Automatic seam identification and tracing enhance workflows by adapting to geometry deviations within components and clamping arrangements. This reduces the need for manual rework, ensuring highly reliable welding results. The Weld Cockpit enables precise planning of welding processes, supporting standardized tooling information transfer and ensuring consistency and reliability. It simplifies offline programming for welding experts by using recognized welding symbols and standards, reducing human errors and improving overall quality. CENIT's future FASTSUITE E2 releases will continue to advance autonomous programming, maximizing the benefits of industrial robots in manufacturing processes.

Jorgensen Enhances FlexForce Coolant System with Variable Flow Rates Jorgensen Conveyor and Filtration Solutions has introduced an enhanced version of its FlexForce high-pressure coolant system, offering variable flow rates ranging from two to eight gallons per minute (GPM). This addition provides customers with greater flexibility to adapt the high-performance through-spindle coolant system (TSC) to various applications, complementing the standard FlexForce unit with an eight GPM flow rate. Both the standard and variable flow rate options are available in 500 or 1,000 PSI configurations. The FlexForce system addresses the heat-generated vapor barrier at the cutting tool and workpiece interface, improving lubrication, heat dissipation, cutting speeds, chip control, and part surface finishes. It offers filtration down to 10 microns, with an optional 5-to-25-micron filtration available upon request.

Designed for reliability, the FlexForce system features a low-pressure suction pump that draws coolant from an existing reservoir into the FlexForce reservoir. A high-pressure pump then delivers pressurized coolant directly to the cutting point, enabling faster machine feeds and speeds for increased productivity. The system includes an onboard coolant reservoir, electronic sensors for lights-out operations, and automatic pressure regulators and machine-controlled dump valves to minimize the risk of system damage. It ensures safe and efficient operation in a compact design that easily integrates with existing coolant systems. FlexForce can be customized for applications beyond the standard 500 or 1,000 PSI models. This enhancement underscores Jorgensen's commitment to providing customers with versatile and efficient coolant solutions for machining processes.

KUKA Enhances Customer Experience with Expanded my.KUKA Digital Platform KUKA has unveiled an upgraded my.KUKA digital customer platform, offering a plethora of features designed to enhance customer convenience and accessibility. With a single online registration, users can seamlessly access a range of services, including purchasing robots, acquiring spare parts, managing KUKA assets, and accessing training materials and cloud-based software, accessible from any internet-enabled device. Robot and Spare Part Procurement: Customers can now purchase new robots directly through the KUKA Marketplace on my.KUKA.com. Even prospective users can explore basic product information. Registered users benefit from a system that assists in matching the right robot to specific applications. The ordering process is made simple and intuitive. Asset Management: Registered users can input product data for their KUKA robots, centralizing information and streamlining part orders. The KUKA Parts-Finder system offers a detailed list of applicable spares for each registered robot. Additionally, the platform helps users track and manage software packages and licenses for greater clarity. INDUSTRIAL MACHINERY DIGEST.COM

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Lantek v43: Streamlined Automation and Traceability for Sheet Metal Manufacturing

Order History and Tracking: Users can conveniently access their order history, providing a clear record of purchases. The "my Assets" feature simplifies parts orders by offering a customized view of all purchased items, particularly beneficial for users with multiple KUKA products. Technical Information and Support: The platform provides a unified customer support experience, allowing users to review support cases and request assistance directly. It also offers direct links to the KUKA Xpert knowledge database, Frequently Asked Questions, and the iiQKA customer forum, ensuring access to technical documentation and in-depth resources. Training Opportunities: Users can access a wealth of training resources, including introductory materials for new users and the KUKA College training catalog. This enables users to book both in-person and virtual instruction for comprehensive training and support. Redesigned for User-Friendliness: The revamped my.KUKA platform boasts an improved user interface, enhanced navigation, and expanded product-finding capabilities, ensuring an intuitive and time-saving experience for customers. KUKA's enhanced my.KUKA digital customer platform aims to streamline processes and offer comprehensive support, ultimately enhancing the overall customer

Lantek v43: Streamlined Automation and Traceability for Sheet Metal Manufacturing Lantek, a leader in digital transformation for sheet metal and metal cutting, introduces Lantek v43, featuring over 80 improvements focused on process automation and traceability. Enhanced Products: Lantek's suite, including Expert, Flex3D, Bend, MES, and Integra, now prioritizes efficiency, security, and digitalization across sheet metal manufacturing.

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Lantek Expert: Streamlines programming for faster machining. Offers easy nest reassignment between machines. Lantek Flex3D: Optimized performance reduces execution times, minimizes machine downtime, and introduces efficient nesting algorithms. Lantek Bend: Allows efficient folding tasks and expands multiplatform integration. Lantek MES and Integra: Enhance production planning, optimize inventory, maintain complete traceability, and enable efficient production management with features like intermediate warehouse management and automated machine reassignment. Juan José Colás, Chief Sales and Marketing Officer of Lantek, emphasizes the software's role in maximizing machinery efficiency, digitalizing manufacturing processes, and ensuring business sustainability. Lantek v43 is a significant advancement in automating and tracing sheet metal manufacturing, offering tools to boost productivity and efficiency while reducing waste.

ModuleWorks Unveils 2023.08 Software Components with Enhanced Features ModuleWorks has announced its latest digital manufacturing software components in the 2023.08 release, marking the second significant release of 2023. This update encompasses various enhancements across their entire product range, including 5-axis machining, laser-aided manufacturing, PrimeTurningTM, CNC simulation, and introduces a new 3D points probing product. User-Defined Tool Contact Point for 5-Axis Machining: For wireframe 5-axis machining with sphere mills, users now have the ability to define which part of the tool contacts the drive curve. This flexibility allows for optimized tool performance, extending tool life, and

increasing cutting speeds as needed for precision or speed. 3D Points Probing: The new ModuleWorks Probing product offers 3D touch point probing, enabling users to select points on a part. The system automatically recognizes part geometry and generates a probing toolpath with collision-free approach and retract motions, exportable as a canned cycle compatible with CNC controls. Laser Aided Manufacturing - Weaving with Automatic Amplitude Adjustment: Weaving patterns enhance part strength and aesthetics. ModuleWorks' weaving toolpath now adjusts pattern amplitude as the wall width varies, eliminating the need for manual adjustments, streamlining deposition, and ensuring consistent build-up. PrimeTurningTM – Tool Nose Radius Compensation: New cutter compensation options provide users with control over PrimeTurningTM post-processor output. Users can choose from four compensation types, offering flexibility for automatic or manual compensation and toolpath adjustments based on wear. CNC Simulation - Interpolation Turning: The update introduces direct CNC control simulation for interpolation turning, which is beneficial for machining large, non-symmetrical parts. This enables the simulation of cutting operations on a stationary workpiece by simultaneously interpolating multiple linear axes and tool spindle positions. The ModuleWorks 2023.08 release is available for download from their website, offering enhanced capabilities and improved functionality across various manufacturing processes. For more information and in-depth insights, you can refer to ModuleWorks' latest YouTube videos on "What’s New in ModuleWorks 2023.08."

Cetim Integrates ModuleWorks Self-Driving CAM for Simplified Cost Estimation Software Cetim, the Technical Centre for Mechanical Industries, has integrated ModuleWorks' Self-Driving CAM technology into its TechniQuote cost estimation software, simplifying and expediting cost estimations for milling operations. Machine shops and subcontractors rely on TechniQuote for generating detailed cost breakdowns to make informed decisions regarding pricing, process optimization, and resource allocation in mechanical manufacturing. Users load a CAD model and configure machining scenarios to generate estimates. For milling projects, Self-Driving CAM, integrated into TechniQuote, enhances the process with predefined machining templates, significantly accelerating cost estimation. Hervé Lallemand, Costing Product Manager at Cetim, highlights that Self-Driving CAM simplifies the estimation process by allowing users to select only a few parameters that control predefined CAM templates, ensuring rapid and accurate pricing. Soroosh Eghbali, Head of Technology CAM Automation at ModuleWorks, underscores the novel application of Self-Driving CAM for toolpath-based cost estimation, emphasizing the automation and streamlining of costing workflows within TechniQuote.

TechniQuote utilizes automatic feature recognition alongside machining templates to help engineers set up and conduct comparative cost analyses swiftly. The integrated Self-Driving CAM leverages ModuleWorks' toolpath algorithms, offering precise information on toolpath length and complexity. This enables TechniQuote to accurately estimate total machining time, tool wear, waste material, and energy consumption, enhancing the overall cost estimation process for milling operations.

MRPeasy Introduces Master Production Schedule for Small Manufacturers MRPeasy, known for its cloud-based manufacturing software catering to businesses with 10 to 200 employees, has unveiled a significant upgrade to its ERP/MRP software suite. The introduction of the Master Production Schedule (MPS) functionality positions MRPeasy as the first smallbusiness-oriented ERP/MRP system to offer both long-term production planning and short-term production scheduling. The MPS functionality combines long-term production planning with short-term production scheduling, making MRPeasy a unique solution in the small-manufacturingoriented ERP software market. MPS is a pivotal tool in manufacturing planning, outlining period-by-period production quantities based on factors such as customer demand, inventory levels, available materials, and production capacity. It empowers growing manufacturers by enabling structured production planning and scheduling, reducing lead times, minimizing costs, and aligning production with demand to prevent stockouts and overstocking. Additionally, MPS fosters inter-departmental collaboration, enhancing communication and problem-solving across sales, production, inventory, and procurement functions. This agility helps small manufacturers adapt swiftly to market changes and maintain competitiveness.

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Karl Heinrich Lauri, CMO at MRPeasy, emphasized the significance of this addition, stating, "This is an important step forward as it provides small manufacturers with an effective toolset similar to what larger corporations use for production planning." MRPeasy's commitment to innovation and continuous improvement is demonstrated through its ongoing expansion of software functionality, ensuring it remains at the forefront of manufacturing technology. The introduction of the MPS functionality underscores MRPeasy's dedication to equipping small manufacturers with the tools they need to excel in today's competitive landscape. Stephen Plumridge, Managing Director at Cantium Scientific, an electronics manufacturing company using MRPeasy since 2016, praised the software's role in effectively running their business and helping them stay on top of everything. For small manufacturers looking to simplify production planning and enhance overall efficiency, MRPeasy's new functionality offers a valuable advantage, aligning them with industry best practices and providing a competitive edge.

Platinum Tooling to Distribute Hommel & Keller's QUICK® Knurling and Marking Tools in North America Platinum Tooling, the leading importer and master distributor of tools such as live tools, angle heads, marking tools, Swiss tools, and multi-spindle tools from global suppliers, has announced its role as the North American importer of QUICK® knurling and marking tools from Hommel & Keller. The announcement was made by Platinum Tooling's president, Preben Hansen, at the company's headquarters in Prospect Heights, Illinois, near Chicago. Hommel & Keller, a renowned global leader in high-quality knurling and marking tools, manufactures the QUICK® line, focusing on the fusion of functionality and innovation. The QUICK® tools are renowned for their quality, precision, and stability, and Hommel & Keller has a rich history of offering customized solutions to meet customer needs. The QUICK® product range offers innovative solutions for various knurling technology applications, including form knurling and cut knurling, meeting the most rigorous quality standards and tackling challenging tasks. These knurling tools are suitable for a wide range of workpiece diameters, including small tools designed for Swiss-type lathes with a diameter as small as Ø 1.5 mm. QUICK® marking tools enable rapid marking of workpieces on various surfaces and part geometries. These tools allow for individual customization of marking text through single marking segments and are available in two diameters for interchangeable lettering, as well as custom logos. QUICK® knurling and marking tools find applications in industries such as medical, dental, automotive, aerospace, watchmaking, fishing equipment, and more, where precision and top-notch surface quality are paramount requirements.

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Stratasys Announces New Materials to Enhance End-use Production and Manufacturinggrade Prototyping Stratasys, a leading provider of polymer 3D printing solutions, is reinforcing its commitment to end-use production and manufacturing-grade prototyping with the introduction of several new materials for its P3™ DLP platform and F900™ 3D printers. For the P3™ DLP platform, Stratasys is launching four new performance-grade materials for Origin® One printers: » Somos® WeatherX™ 100*: Designed for environmentally durable applications, this material is ideal for vehicle interiors, motorcycle components, and outdoor consumer products. It meets stringent SAE industry standards for weatherability, durability, and dimensional accuracy. » Somos® PerFORM™ HW*: A ceramic-filled material suitable for injection molds or high stiffness fixtures that require rigidity. It offers excellent abrasion and high-temperature resistance. » P3™ Deflect™ 190 ESD*: Developed in collaboration with Henkel, this specialty resin enables AM for electronic and general manufacturing applications, including jigs, fixtures, tooling, and housing. It has a Heat Deflection Temperature (HDT) of 190°C, electrostatic dissipative properties (ESD), and high stiffness. » P3™ Stretch™ 80*: An elastomeric prototyping resin developed with Forward AM by BASF, suitable for soft or flexible parts like seals, gaskets, grips, and maskants. It provides an affordable option for users looking to explore elastomer printing. Stratasys is also enhancing its GrabCAD® Print software for the Origin® One with automatic support generation functionality, making workflows more accessible and efficient. Additionally, Stratasys is introducing two new materials for the F900™ 3D printer: » Kimya PC-FR: A flame-resistant polycarbonate material that meets EN45545 requirements for rail applications and is designed for end-use parts, including low-volume production and replacement components. » FDM HIPS: A cost-effective high-impact polystyrenebased material suitable for applications with low requirements. Furthermore, Stratasys is offering eight new colors for ULTEM™, PC, and PC-ABS materials on the F900™ platform, providing customers with greater flexibility and reducing post-processing costs. The introduction of these materials and software enhancements reflects Stratasys' commitment to delivering more choices and possibilities to its customers for additive manufacturing applications. Note: The asterisk (*) indicates the trademark symbol for the respective material names.

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Case Study

How to Reduce Chatter in Robotic Milling Applications By Mark Fairchild

ave you optimized the performance of your robotic arm as it performs milling operations? Machining with articulated robot arms is an attractive alternative to machine tools because they offer ease of set-up, repeatability, a large workspace, and versatility. However, machine tools are as much as 50 times stiffer than robotic arms. This lack of stiffness in robots makes it challenging to produce the desired performance. Minimizing chatter is a frequent concern and should not be overlooked to ensure the right results the first time. In this article, we explore some best practices for reducing chatter with a focus on the spindle and tooling.

The Crucial Importance of the Spindle Many robotics integrators will choose the robot first and leave the choice of the spindle to later. "It should be the other way around," says Kenny Wilson, a Precision Drive Systems project engineer with more than 25 years of experience. A spindle with a standard set of bearings may not offer longevity in a milling application because of the radial loads to which the spindle is subjected. Wilson goes on to explain: "Choosing a standard spindle for milling can be deceiving because, in initial testing, the system may do

16 | IMDQ | Q4 2023

the job. But then, at the customer's site, when put into the production environment, within six months or so, parts start to go out of tolerance, and the spindle can fail rather quickly. The customer is unhappy, and the integrator looks bad. They send the spindle to us for repair and want to know why this is happening." If the material is hard and the feed rates are sufficiently high, the standard spindle will not be able to handle the loads. To achieve greater radial stiffness and resilience, a triplex or quad set of bearings in the spindle may be needed to more effectively withstand the physical demands. "A quad set of bearings is often not something you can order from a catalog," remarked Wilson. "It often has to be custom built." He also pointed out a trade-off is involved because increasing the number of bearings to increase radial stiffness usually requires reducing the rotational speed of the spindle. That's because, with a larger number of bearings, the heat in the spindle increases. Custom building of spindles is a service Precision Drive System offers. To underscore the crucial impact of choosing the right spindle upfront, Wilson also commented that sometimes the integrator is stuck because adding bearings to a spindle increases its weight. And the integrator may have chosen

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a robot arm that can't handle the extra weight. This may happen after the integrator has supplied the customer with multiple robot arms. Therefore, the upgrade cost can be significant because of initial oversight. At that point, the robot integrators may resign themselves to having a system in which the spindles routinely fail after six to nine months. They are forced to buy additional or spare spindles to swap in so they can maintain the uptime of the system. And the result is that the customer is unhappy with the increased and unexpected costs and likely dissatisfied with the uptime or reliability of their automation investment. This is clearly not the optimal way of designing a new system and is far from an operating best practice. If the spindle had been properly considered first, then the robot that could handle that spindle would have been chosen, and such downstream issues would be avoided. Such a solution might have taken more time upfront, but everyone would be happier with the lower operating costs and greater longevity of the result. The design and products chosen would be optimized for the operating specifications of the customer application.

Tooling and Its Effect on Chatter "Reducing the number of flutes on the end mill may reduce chatter," said Wilson. Shortening the length of the tooling and increasing the speed of the spindle can help. "It's all about

feeds and speeds," he said. Sometimes cutting back on the feed rate can eliminate or minimize the chatter. "Most customers know they need to use balanced tooling," remarked Wilson. Sometimes the key is to use tooling with a larger diameter. The interface is also a crucial factor. It must have a sufficient gripping force to do the job. Various interfaces are available, and choosing the right interface for the task is vitally important.

The Fixture Can Be the Key "We've had cases where there was chatter, and it turned out it was the fixture," related Wilson. The workpiece was secured with a pneumatic gripper, and over time, dust and chips clogged things up. The result was the part itself was vibrating, and that was the cause of the chatter. By changing the nature of the fixture or making sure everything was cleaned out, and routinely maintained, the problem was solved.

Conclusion Reducing chatter in robotic milling is both an art and a science. One must take a methodical approach to investigating the root causes or operating variables and limits, which could be a combination of factors. Choosing the right spindle for the job as part of the design process is critically important. It is often the single greatest factor in a successful project versus one that needs to be reworked – or worse, completely re-designed.

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Company Profile

Close up of cut ramjet shows complexity of internal features. Velo3D

Getting Better at Building it Faster: Hypersonics and 3D Printing Velo3D, Lockheed Martin and Vibrant team up with DoD’s LIFT Institute on a data-driven approach to certifying materials and methods for additively manufactured aerospace systems

n the defense industry, there has been a recent and urgent need to advance aerospace applications. Global competitors are accelerating efforts to develop propulsion systems that can generate thrust to propel aerosystems at extremely high speeds. Supersonic (above Mach 1, the speed of sound) and even hypersonic(above Mach 5) flight vehicles and missiles are becoming more of a reality. This is an arena in which 3D printing is now seen as a technology that can deliver complex, single-piece engine designs at significantly lighter weights and in less time than conventional manufacturing. Materials development is advancing concurrently,with frequent news of newly certified, high-performance metal alloys for use in specific additive manufacturing (AM) provider’s systems. No matter what an advanced engine is printed out of, the ultimate proof of value is its ability to operate effectively under the extreme environmental conditions produced in

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hypersonic flight, performing as expected from takeoff to target. While“build and break '' prototyping has an ongoing role to play in achieving these goals,the U.S. Department of Defense is also being very deliberate about doing its due diligence on AM from the ground up—starting with a deep focus on materials science and manufacturing.

A public, private partnership with an eye to the sky An outstanding example of this is happening at LIFT, a nonprofit public-privatepartnership between the DoD, industry and academia. It is operated by the AmericanLightweight Materials Manufacturing Innovation Institute and housed in a 100,000-square-foot facility in Detroit, Michigan. LIFT is one of 17 manufacturing innovation institutes across the country (sponsored by either the DoD,Department of Energy, or the Department of Commerce) aimed at scaling new technologies into commercialization.

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Creator meets creation: former engineering student Jay Blake, now on the aerospace applications team at Velo3D, cleaning the ramjet after 3D printing. He came up with its original design as part of an undergraduate course assignment.

Among the more-than-50 active projects currently under contract at the nine-year-oldDetroit Institute are some that are participating in a “Hypersonics Challenge” funded by the DoD’s Manufacturing Technology Program, overseen by the Office of theUnder Secretary of Defense for Research and Engineering. The goal is to identify which materials and/or manufacturing processes can provide the most efficient,productive pathways to vehicles and/ or missiles capable of hypersonic flight. Dr.John Keogh, LIFT’s Engineering Director, is responsible for the “HighBay” [virtual tour] materials development area within the LIFT facility. Together with his counterpart, Dr. Amberlee Haselhuhn, Director for Materials & ICME, leads the engineering division at LIFT. Dr. Keogh and Dr. Haselhuhn have technical oversight of a number of R&D teams,by way of internal project oversight as well as external team projects. One of theHypersonics Challenge projects, an external team effort for which Lockheed Martinwas the industry prime and team lead, has now concluded the first phase of a study of a 3D-printed ramjet engine. Dr. Keogh served as the LIFT technical lead for this project. His background is an excellent fit for the integrated multiphysics challenges of materials and process development, AM and hypersonics. He earned his doctorate in analytical chemistry with a minor focus in physical

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chemistry, worked in academia for 15 years, then switched to the real-world excitement of engineering, where “it’s been a great road ever since,” he says. “When you’re traveling at Mach 5 or above, you have very high heating at the leading edges,” Keogh notes. “Sharp radii are particularly bad and lead to incredible heating, which is why reentry vehicles from space have reasonably wide radii. But Hypersonic vehicles need some semblance of a leading edge for aerodynamic purposes—and there are incredible forces that are compounding and dynamic at hypersonic speeds. It’s a confluence of aerodynamics, mechanics, thermal management, and chemistry that leads to all kinds of interesting and overlapping challenges that are fun to address. And you have to work with extremely high-temperature materials that survive these environments.”

Capturing data while printing a ramjet For the ramjet project, the team’s intention was to identify what data streams they could collect during the laser powder bed fusion (LPBF) build of a ramjet engine printed with Inconel 718 metal alloy—and then go through a well-established Design Of Experiments to interrogate those data streams; Lockheed Martin established the quality assurance verification approach used in the project. “AM is a relatively new manufacturing process and there’s a need to validate and certify parts for service and

mission-critical applications,” says Keogh. “We need a data-driven approach to test and certify components right out of a printer, as opposed to a statistically driven one where you have to build multiple parts first and only then gather statistical performance data (make-and-break). Our goal was to identify the signatures of physical quality found in process data and rapid post-process inspection for accurately certifying a component for the rigors of hypersonic flight.” The LPBF system used to print the ramjet was a Velo3D Sapphire 1 MZ, which is capable of printing objects up to one meter in height (the final ramjet version is 751 millimeters tall). Every Sapphire system contains hundreds of sensors that monitor,report and save metrics throughout each build. “Velo3D’s machine collects an immense amount of data,” says Keogh. “It also provides a very generous buildenvelope oriented towards volume manufacturing.” Two ramjets were printed, along with a variety of material test coupons affectionately named for having shapes like “dog bones” (larger at both ends for tensile pull-testing) and “detergent pacs” (for density and surface finish evaluation).

Student Project Gets an ‘A’ – and then AM The ramjet design itself has an interesting backstory. Rather than being created by a major aerospace company, it was originally dreamed up by an undergraduate aerospace

engineering student at Purdue as a classroom assignment to improve the performance of an existing engine design. Jay Blake’s homework project was inspired by the J-58 turbojet used on the SR-71 Blackbird (which, as of mid-2023, still holds a 1976 record as the fastest—Mach 3.2—supersonic air-breathing manned aircraft). “My thought was that, using 3D printing,you could incorporate the volume of the inlet spike of a ramjet into the turbojet, to act as a heat exchanger to warm the fuel so it combusts more efficiently,” Blake says.“The early ramjets had hundreds of different parts—injectors, struts, internal details—that required welding and brazing and took months to produce; my design idea was to consolidate all those parts into one so it could be printed in a matter of days.”He got an ‘A’ on his design—but then put it aside in sketch form while completing his studies. Serendipitously, several years after finishing his degree, Blake began working forVelo3D on aerospace applications for additive manufacturing. “I suddenly realized my ramjet idea could actually become a real thing,” he says. “That’s when I finally finished my original model, using the more advanced digital software tools that were now available to me.” Velo3D then printed a scaled-down version of Blake’s ramjet. No support material was needed, due to Velo 3Ds Intelligent Fusion and the Sapphire’s patented recoatertechnology: after each layer of powder is laid down,

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the blade that normalizes it is closely followed by a vacuum that picks up excess powder and leaves behind a perfect powder layer. This creates free space between the blade and the part,eliminating the risk of a collision as the part grows (as well as the need for supports,which are traditionally used to achieve the same goal). This advanced AM technology also produces a better surface finish at shallow angles; in the ramjet design, these angles were as low as 30 degrees. “It’s a very tricky geometry,” says Blake. “There are extremely thin walls at that aggressive angle, and those surfaces are perforated with 500-micron holes. There are also steep overhangs and a lot of added dimensions of complexity. Yet the first time we sent it to the printer it came out perfectly, without issue.”

Big Aerospace takes notice Aerospace manufacturer and Velo3D customer Lockheed Martin was shown a printed, scaled-down ramjet and wanted to learn more about AM’s potential to create single-piece engine geometries. While the original design was intended to be incorporated into a supersonic, not hypersonic, jet engine, a few additional tweaks could easily morph it into a scramjet (supersonic combustion ramjet). A scramjet can be thought of as a ramjet engine with adjustments in the design of the inlet and outlet nozzle that keep airflow speeds higher through the engine, with combustion occurring supersonically in the burner. Scramjetpowered vehicles can theoretically reach hypersonic velocities well in excess of Mach 5. In a ramjet, which has very few moving parts but an extremely complex interior structure, high pressure is produced by "ramming" external air into the combustor using the forward speed of whatever aircraft is carrying it. This is in contrast to the more common turbojet, where a compressor is used to mechanically compress the air prior to combustion. In a ramjet, this compression occurs through a series of shock waves. These shock waves and the engine geometry compress

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and decelerate the air until it becomes subsonic (below Mach 1) in the combustor section. Lockheed Martin collaborated with Velo3D and LIFT to support the team’s research into the maturity of metal AM for such applications, as well as the fidelity of the materials being used for it. “Obviously my design doesn’t have any ITAR-controlled geometry in it so it made a great demonstration piece for AM,” says Blake. “You can do all the necessary assessment on the metallurgy and structure and the 3D printing process— without having to deal with the limitations of ITAR and export control.”

Identifying echoes of quality with resonance testing The team had a variety of “dog bones,” “detergent pacs” and other test articles printed on several different Sapphire AM systems. “The goal was to assess laser-to-laser, build-tobuild, part-to-part, and machine-tomachine variability, and to identify that variability through in-situ monitoring, rapid non-destructive evaluation, and stat fusion methods,” says Keogh. With completed ramjets and some accessory parts in hand, the hunt began to determine specific “echoes of quality” that would tell whether a finished part was a good one. “Echoes” is an appropriate word here, because the primary method of assessment the engineers chose was based on acoustics: ProcessCompensatedResonance Testing (PCRT) from a company called Vibrant. PCRT uses ultrasonic frequencies (in this case, between 5 and 500 kHz) to excite the vibrational modes of a part or component for just a few seconds or minutes. The Natural resonance frequencies of the part, which are unique to both its individual geometry and its material properties, are recorded, saved and analyzed. Resonance Fingerprints will depart from nominal values as a reflection of stress state, partintegrity, geometry and even surface finish; for example, a component with invisible interior cracks will have significantly different resonances than an un-cracked one.

Vibrant PCRT system measuring resonance response of a Ramjet. Photo via Vibrant.

“This is a very attractive approach to couple with and complement additive manufacturing because it’s volumetric, rapid, and it doesn’t require destructive testing,” says Keogh. “It can provide indications of porosity, surface defects,aberration in the geometry and so forth. As an example, there was a population of dog bones’ that were slightly shorter than the others and that showed up very clearly in the resonance spectra.” Vibrant says that PCRT measurements can potentially be correlated to energy density and scanning-speed settings, raw material properties and sourcing, build position, cooling rates, post-processing methods like hot-isostatic-pressing and residual stress—essentially any process parameter affecting material state and mechanical properties. This can be particularly valuable for AM process-control monitoring over time when builds of identical parts are done in large batches over many months. As each part’s resonance values are captured at different frequencies, then plotted out and compared against the others, top-quality parts metrics will coalesce around the same values; outliers will literally stand out from the crowd in the graph and be easily identified. This enables

confidence-limit boundaries to be determined, provides feedback that promotes manufacturing consistency andensures final product quality from batch to batch.

The data are in As a follow-on to PCRT, the LIFT team is interested in developing predictive models to identify the principal contributors to why a resonance frequency and amplitude might change and shift, and what that indicates about the quality of a 3D-printed part. “The idea is that you couple all the post-build data, which is now an objective representation of quality, and you relate that back to the data streams that you collected,” Keogh says. “You apply machine learning and other data-fusion approaches to really start teasing out what are the right ways to interrogate those data streams and begin to pick out indications of quality.” The group also tried several other approaches to component inspection, includingCT scanning. They even knowingly created “good processes” and “bad” ones to see if their methodologies could distinguish the two. In one instance, some ducting elbow parts were inadvertently mixed up after printing—and the data alone was able to tell the researchers which was which. “When it all backed out, it was a very successful program,” says Keogh. “I was thoroughly impressed by the whole body of work. The team of Velo, Lockheed Martin

and Vibrant formed a powerful group of partners who are probably some of the closest—if not the closest—to solving this problem of qualification and validation or certification of AM components for mission-critical and safety-critical applications.We now have populations of data that are quite impressive and highly discerning between, say, different lasers or different build features and certain indications of quality. I was honored to be the LIFT tech lead on this program because it was very heartening to see it succeed.”

Next hypersonic flight plans Team stakeholders are hoping to move soon to a next-phase of the research that would consider the fatigue behavior of AM components and move toward “born-certified” parts. “We want to see hypersonic components born right out of the machine that are already certified by way of the data stream we’ve captured to back it up,” Keogh says. “At LIFT we’re perfectly situated between industry, laboratories and government to be an extended workbench where people can come to buy-down risk with us.” Just announced this Spring was a related LIFT initiative: sponsored research by undergraduate teams at Michigan Technological University to develop new materials and “road maps” for hypersonics applications. Considering the progress made by theLIFT ramjet project, it’s clear that students’ ideas can be worth paying attention to!

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Integrations

an Meter is a 100% employee-owned electrical parts distributor that has been committed to providing unparalleled customer service and superior electrical products to Iowa’s contractor, commercial, OEM, systems integrators, and energy markets since 1928. Operating out of Cedar Rapids, Iowa, their 300,000 sq. ft. Central Distribution Center (CDC) acts as the primary hub for picking and packing orders for their 12 satellite locations across Iowa and Nebraska as well as servicing over-thecounter customers and deliveries to local markets.

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Growing Pains Van Meter has grown rapidly in the past decade, with their lines picked per year increasing by 20% and peaking at over 1.08 million. Previously, Van Meter was filling orders from high bay racking (with forklifts and pallet-picking), and gray shelving (with workers hand picking products). As orders increased, the time spent walking and searching to fill orders grew, creating an inefficient process. This growth quickly outpaced their existing space – inventory became more difficult to manage, storage

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space was limited, and orders became more difficult to process. Continued growth depended on a solution which better utilized existing space and increased order picking efficiency and accuracy.

Building for the Future As part of a larger warehouse automation project, Van Meter rerouted orders via conveyor into new picking zones featuring 18 Vertical Lift Modules from Kardex Remstar. The Kardex Shuttles are arranged into 4 work zones each integrated with pick-to-light technology and Kardex Power Pick System software to enable batch picking within each zone. Kevin Foht, Director of Operations, commented, “Space is the very first thing that comes to mind when you think about vertical storage, and the ability to utilize the full height of the facility. There are a lot of things that go into a decision about a solution like this, but the very first thing was space and planning for our future.” Prior to implementing Kardex’s automated storage solution Van Meter used a mix of grey shelving and high-bay racking zones. After implementing the solution from Kardex, Van Meter was able to save 36 bays worth of high bay space and reduce travel distance for their associates.

Raising Throughput to Match With the addition of the VLM zones, Van Meter has increased their throughput by 25% - from 3,600 lines per day to 4,500 lines per day – and adding automation was the way to get it done. On average, Van Meter’s high bay zones pick at a rate of 20 lines per hour. Their gray shelving zones pick at a rate of 50 lines per hour. Kardex zones average 65 lines per hour, with peaks as high as 100 lines per hour. Moving 2,400 SKUs from gray zone shelving into Kardex Shuttles increased pick speed by 30%+ for those items. “When designing the system, we looked at what items we were picking the most, the received quantity, and which items were physically suitable for totes,” said Foht, “We’ve slotted our fastest moving, highest volume products into the Kardex zones. Only 10% of our inventory is in our VLMs, but that inventory accounts for 34% of our picks every single day.”

Increasing Accuracy Prior to implementing their warehouse automation overhaul, Van Meter boasted an impressive 99.89% order accuracy rate. Despite the high starting point, after their new conveyor and VLMs were installed they saw a 0.06% increase for a total of 99.95% order accuracy

warehouse-wide. While it may not seem like a large percent increase, when applied to a 1,000,000 lines per year central distribution center it’s nearly 600 less errors per year, almost two less errors per day. Not only did they see an overall increase in order accuracy – saving them money and securing their world class reputation for customer service – they were able to raise order accuracy specifically in the Kardex zones to 99.99%.

Doing More With Less Directly after the automation project, the 18 Kardex VLMs were divided into six zones with one worker picking from three machines per zone. Foht said, “Initially we saw efficiency going from shelving to six Kardex zones, but we didn’t know how efficient those zones would actually be. We eventually realized there was some downtime and were able to rearrange the existing 18 Kardex Shuttles into four Kardex zones within the Kardex Power Pick System. We are now managing picking and put away for the 18 machines with only four people, one in each zone. Phasing in these machines and reducing the total people in zones meant higher throughput, higher lines per hour, and less downtime." After the warehouse automation project, the warehouse fulfillment team consists of only 19 workers, saving 21% on labor costs associated with order picking, all while increasing throughput.

Automating the Process The process begins with orders dropping into their ERP system and displaying on an induction screen. A worker assigns each order on the screen to an order tote using a scanner and places them on a central conveyor that will carry the tote through the entire picking process. First, the totes pass through the gray shelving zones. Workers walk up and down aisles to pick items and fill totes as directed by RF INDUSTRIAL MACHINERY DIGEST.COM

IMD | 25

devices. Once all gray zone parts are picked, the tote travels to the VLM zones. Once there, the order totes kick off the central conveyor line into the correct VLM zone. A worker uses the Kardex Power Pick System to scan incoming order totes into a batch. Once the batch of orders is created, software directs the VLMs to deliver the SKU directly to the worker at the access window. When the SKU is delivered, the worker references the pick-to-light display on the VLM to see both the location of the SKU on the tray and the quantity they need to pick to fill the batch of orders. After picking the correct quantity of the SKU from the Kardex Shuttle, the worker turns to the batch of totes and follows the put-to-light display on the conveyor to distribute the items among the totes in the batch. As they distribute the correct amount of SKUs in the right totes, they push a confirmation button located beside each put light. While the worker is distributing SKUs, the VLM retrieves the next SKU required in the batch so there is no wait time. When an order tote has all of the items it requires, the put light will signal ”done” and the worker will push it onto the central conveyor. From there, the order tote goes to the high bay zone for further fulfillment or is routed to shipping if the order is complete.

Conclusion Van Meter’s transformation from a small Iowan electrical distributor carving a name for themselves in a post-depression economy, to a 100% employee-owned company known around the region for their exceptional customer service is nothing short of inspiring. In the face of rapid growth and rising order counts, Van Meter invested in automation solutions to solve their current

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issues and create an order fulfillment process built with the future in mind. Through automation, they were able to double their throughput, reduce their dependence on labor by 21%, and improve their already impressive customer service by increasing order accuracy to 99.98%. ABOUT KARDEX Kardex is a leading intralogistics solution provider of automated storage, retrieval and material handling systems. With two entrepreneurially managed divisions, Kardex Remstar and Kardex Mlog, the Kardex mission is to provide solutions and services to increase the efficiency in storing and handling of goods and materials on a global scale. The two divisions serve as partners over the entire life cycle of a customer's product or solution. From project analysis to realization and service, Kardex helps improve a customer’s performance every step of the way. With three own production plants in Germany and one in North America Kardex ensures high quality solutions. To maintain and strengthen its competitive position within technological innovation and outstanding customer loyalty, Kardex is investing in research and development, its supply chain, the expansion of its service organization as well as in new technology via acquisitions. Kardex actively partners with global leaders who share the same values and complement the Kardex solutions including AutoStore, Rocket Solution, Intertex and Sumobox. For more information visit: www.kardex.com Kardex Remstar, LLC Media Contact: Christina Dube Director Marketing & Communications North America christina.dube@kardex.com

Machines

Titanium Machining — Special Materials for Complete Machining Heavy duty cutting places particular requirements on the machine and working processes. If this involves a material such as titanium, which is particularly hard to cut, specific know-how is necessary to deal with these requirements. Thanks to its expertise, WFL Millturn Technologies GmbH & Co. KG impresses in this field with a machining solution for aircraft landing gear.

he aviation industry represents an important market segment for WFL. This industrial sector increasingly requires ever more materials that are deemed to be difficult to machine. Titanium machining in particular is a field in which WFL shines with its wealth of expertise.

resistance and capacity to withstand stresses. Although this material does have good empirical values and cutting data, processing it still remains one of the supreme disciplines in machining.

The titan of all metals Material with particular properties Titanium has always placed particular demands on tools and machines during the cutting process. In recent years titanium 3.7165 has become prevalent among lightweight materials as a material with outstanding properties, especially in the aviation and space industries and also in the medical sector. It is one of the most frequently used titanium alloys, containing 6% aluminum and 4% vanadium. This alloy, normally referred to as Ti6Al4V, exhibits a very good combination of strength, corrosion

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New titanium alloys are constantly being developed for special applications and these are often on the basis of specific customer requirements. A number of WFL customers require Titanium 5553 (Ti5Al5V5Mo3Cr) for the production of landing gear in the aviation industry. This material stands out due to improved properties with regard to strength and toughness. It is also less sensitive to structural changes during heating. This material is indeed one of the real Titans in the field of machining and takes its name from Greek mythology.

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Ti5553 is at present one of the hardest materials on the market to machine. A cutting speed of 45 m/min should not be exceeded when it is being processed as shear stresses of up to 2,780 N/mm² can develop at cutting speeds as low as 60 m/min.

Challenges in titanium machining Problems like point heat due to poor heat conduction and associated chemical changes in the material (embrittlement at higher temperatures) and the formation of built up edges occur to a greater extent with this material than with other titanium alloys. Therefore it is particularly important that cutting speed, feed rate and penetration depth are matched to one another accurately when working with Ti 5553. The use of suitable cooling lubricants is just as important as the correct cooling strategy. A quick and continuous removal of swarf must be guaranteed; the heat dissipation occurs to a much greater extent via the tool. Removal of the forging skin, referred to as "elephant skin" by experts, is an additional challenge with this material. The upstream forging process and the resultant thermal and metallurgical influences give this skin a very high level of surface hardness. The low modulus of elasticity means that titanium tends to evade the pressure of the tool and to fuse with the cutting edge. The machining should therefore, as already mentioned, occur at a low cutting speed but with a relatively high and even feed rate. Vibration free, clamped, sharp tools must be ensured in any case. High speed steels with a high cobalt content, carbide or Stellite are used as cutting materials.

Materials which are hard to cut like titanium have influenced the development of the WFL machines. WFL provides individual solutions for exactly these kind of demanding applications. These also cover aspects such as cooling and production strategy as well as the actual machine. "In order to be able to offer WFL customers reliable solutions, WFL has developed components which make it possible for us to match the design of the machine precisely to the relevant application case." – Reinhard Koll, Head of Application Engineering WFL.

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Experience is the decisive factor All this shows that titanium calls for a lot of experience in the selection and use of the tools as well as the machining strategies. It is essential that the ability to cater for critical aspects of machining during manufacture is demonstrated as early as the design phase. For example it is necessary to take into consideration the fact that different material thicknesses in the blank workpiece require modified machining strategies. Heat affected zones must also be taken into consideration together with the cutting forces which occur.

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Software/Cloudware

Fast thermal simulation for the automatic detection of overheated zones of an impeller (100 x 100 x 13mm) made of Ti64. Simulation duration: approx. 90 seconds. The green to red color gradient represents the criticality level for overheating. Red areas represent an increased risk of overheating.

Genesis 4 – The new generation of build-job preparation and simulation software by AMSIS The Genesis 4 3D printer represents a significant advancement in 3D printing technology, combining a traditional pre-processor with simulation-based laser beam exposure. This innovative approach notably reduces the need for support structures, allowing for the creation of parts with overhangs ranging from 45 to 20 degrees. Users benefit from material and cost savings due to minimized support requirements. Additionally, the introduction of simulation-based modules facilitates a rapid transition to this support-minimizing 3D technology, making it a user-friendly and efficient solution for various printing needs.

ith the further development of Genesis to the level of Genesis 4 Beta, AMSIS is presenting the latest generation of build-job preparation and simulation software at Formnext 2023 in Frankfurt, Germany. This universal software offers new features for both equipment manufacturers as well as end users in the field of 3D printing of metals to improve laser exposure quality and

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minimize support structures. The potential for cost optimization for users of powder bed-based laser melting is between 10 and 30%, depending on the application. The Genesis 4 modules can be integrated into 3D printer software. Genesis 4 supports end users along the entire process chain of build-job preparation: importing of STL data, optimal placement and nesting of parts in the build space,

generation of support structures, slicing, hatching and exporting the build-job. The USPs of Genesis 4 are the simulation-based functionalities: automatic identification of the overheated zones of a part, automatic reduction of the energy input depending on the overheating intensity, and the hatching design of the optimal orientation and sequence of the exposure paths.

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Fast thermal simulation as a core technology Fast thermal simulation within seconds for small parts and up to just a few minutes for large parts enables the precise identification of overheated zones of a part and a quantified depiction of the overheating intensity (criticality). On the basis of the calculated overheating intensity, a specific reduction of the energy input in the overheated areas is carried out. Using the results gained from the thermal simulation, hatching strategies for the optimal orientation and the sequence of the exposure paths are also realized. Together, all of the above simulation-based functionalities result in an optimized thermal management of the overheated part zones, a significant reduction in support structures, as well as an improvement of the mechanical material properties and quality of the part surfaces. Prof. Dr.-Ing. Vasily Ploshikhin, Managing Director of AMSIS explains: “Optimized thermal management increases the process stability of the 3D part structure. End users can significantly increase the performance of their existing machines with Genesis 4 and print higher quality parts with either minimal or no support structures.”

Genesis 4 versions: Classic or Innovative As stand-alone software, Genesis is available in two versions: Classic and Innovative. Genesis Classic, the basic version, has all the functionalities for build-job preparation. It can be used as an inexpensive alternative to established software tools for build-job preparation, such as Magics from Materialise or Netfabb from Autodesk. In the advanced version, Genesis Innovative, classic build-job preparation is complemented with simulation-based functionalities. These include the fast-thermal simulation module to identify overheated zones, the module for simulation-based local parameter adaptation and the hatching module for designing the optimal orientation and sequence of the exposure paths. The two software versions currently run via native machine formats on 3D printers from Aconity3D, DMG MORI, EOS and SLM Solutions.

A modular system for better integration into other software tools Genesis’ modular structure makes it possible to integrate the individual software modules as parts into other software tools. This is particularly beneficial for manufacturers of 3D printing machines. Integration of the thermal simulation and parameter adaptation modules into the machine software will make it possible to automatically reduce the laser power of a 3D printer in hotspots and thereby avoid overheating. An additional use of the module for optimized hatching regarding the orientation and sequence of exposure paths makes it a quick and inexpensive way for machine manufacturers to access technology that minimizes support structures.

Improving cost-effectiveness by reducing support structures

Prof. Dr.-Ing. Vasily Ploshikhin, Managing Director of AMSIS: “Thermal simulation within seconds to identify overheated zones and a simulation-based reduction of the energy input in these critical zones with Genesis 4 enable exposure that minimizes support structures with all conventional hatching patterns. This support-minimizing strategy works even more efficiently when using innovative 3DF hexagonal hatching patterns from Genesis.”

reduce support structures with their existing 3D printer or to print support-free parts. There is no need to invest in new hardware such as new 3D printers. Depending on part geometry, using Genesis 4 currently reduces support-free overhangs of 45 down to 20 degrees for titanium alloys and down to 25 degrees for steel, Inconel or aluminum.

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The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

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IMD | 31

Build-job preparation with Genesis 4: an automated pre-process, straightforward and reproducible Genesis 4 offers various automated tools to prepare for a build-job. First of all, STL data is imported and nesting configuration on the build plate in the building chamber is carried out. The parts are nested in the building chamber according to the user's desired criteria (e.g. minimal build time or minimal support structures). In the part on the left, the overheated zones were ascertained based on the simulation and marked red. The adjustment of After the necessary support the laser’s power based on the simulation is shown in the part on the right. The exposure areas with a higher standard laser structures have been power are marked in red. Laser power is continuously reduced in the overheated zones. The exposure areas with low laser generated, fast slicing of power are shown in blue. the individual layers of the part is realized. This is then followed by a fast-thermal thermal simulation, hotspots in the deformation of the overhang edge in simulation to identify hotspots, as well part are identified within seconds the build direction and, as a result, to as a simulation-based hatching for the or minutes and the energy input in an increased risk of a crash between optimal orientations and sequence of these zones is modulated locally. The the part and the recoater. In addition the laser paths. In the following step, energy input is usually adjusted by to all conventional hatching patterns, energy input is automatically reduced reducing the laser beam power locally Genesis 4 also offers new, innovative in the overheated zones. Finally, all or by increasing the scan speed. The so-called 3DF hatching patterns, build-job parameters can be saved localized reduction of heat input in the such as hexagonal patterns. 3DF in a template manager to ensure a hotspots is possible for every common means “three degrees of freedom”. repeatable process. hatching pattern (e.g. for conventional Deploying hexagonal 3DF hatching stripe exposure). The optimization patterns makes it possible to reduce Automatic identification instead of energy input works even more the angle between the scan vector of manual settings efficiently when using new, innovative and the edge of the overhang down With Genesis, the simulation-based 3DF hatching patterns generated to 30 degrees. These innovative identification of overheated zones is from Genesis. 3DF hatching patterns from Genesis completely automatic. This means the enable better adaptation of scan manual setting of down-skin areas New 3DF hatching patterns vectors to the geometry of the critical that is practiced today, based on the reduce crashes with the recoater overhangs of a part. This leads to user's experience, can be eliminated. The angle between a scan vector a reduction in the deformation of The size of the identified overheated and the edge of an overhang is very unsupported overhang edges in the zones and the level of overheating important for support-minimizing build direction and thus to a reduction intensity automatically change technology. The smaller this approach in possible impacts of the built part depending on material properties angle is, the more advantageous with the recoater. Prof. Dr.-Ing. and local peculiarities of the part for the application. Conventional Vasily Ploshikhin, Managing Director geometry. This results in a major hatching patterns only provide for AMSIS: “Thermal simulation within benefit compared to conventional two possible orientations of the scan seconds to identify hotspots and a manual setting of the down-skin areas, vectors (e.g. 0 and 90 degrees to simulation-based reduction of the which is currently carried out without the preferred direction of a stripe) energy input in these critical zones consideration of local geometries and and thus represent hatching patterns with Genesis 4 enable hatching that material properties. with two degrees of freedom (2DF). minimizes support structures with all In the case of conventional hatching conventional hatching patterns. This Optimized thermal management patterns, the angle between the support-minimizing strategy works Planning of the support-minimized scan vector and the edge of the even more efficiently when using build-job is all done during the overhang can be up to 90 degrees. innovative 3DF hexagonal hatching pre-processing phase. Using fast This orientation leads to a greater patterns from Genesis.”

32 | IMDQ | Q4 2023

Continuous parameter adaptation prevents unwanted porosity With conventional hatching strategies, the critical down-skin zones are exposed as separate areas. The process parameters in the internal area of the part and in the down-skin area are usually different. This leads to a sharp overhang and thus to increased porosity in the core-to-skin overhang areas. With Genesis 4, there is a continuous reduction of energy input in overheated zones. No sharp transition areas are formed, significantly reducing the risk of porosity in the overhang areas.

Optimal sequence of scan vectors prevents build-up of loose powder With conventional hatching strategies, it cannot be avoided that scanning starts in loose powder. This leads to poor surface quality and also prevents a support-free part build. However, with Genesis 4, the sequence of the scan vectors is controlled based on the simulation. The optimal sequence of scan vectors results, among other things, to a significant reduction in the undesirable start of a scan vector in loose powder.

Greater cost effectiveness in the process chain The use of Genesis 4 provides support along the digital process chain of a 3D build-job during the pre-process, in-process and post-process phases. Cost advantages occur in three dimensions: 1. A build-job with minimized support structures decreases manufacturing costs. 2. The build time for the build-job decreases. 3. Material consumption decreases. Post-processing costs of a part are reduced. The aim here is to have to remove fewer support structures, to increase the powder recycling rate and shorten surface treatment time. Another special feature is the easy powder removal through the use of so-called arc supports.

Conclusion Genesis 4 is a new generation build-job preparation and simulation software that combines the functionalities of a classic pre-processor with simulation-based thermal management and simulation-based hatching optimization. Overheated zones and the intensity of overheating of a part are automatically calculated with the help of thermal simulation which takes place within seconds. Optimized thermal management is ensured by targeted reduction of the energy input in the overheated zones. In addition to optimized thermal management, Genesis 4 ensures a simulation-based design of the optimal exposure sequence for all conventional hatching patterns. Additionally, the software offers new simulationbased hatching patterns with better adaptation of the scan vectors to the contours of overhangs. Depending on the part geometry, the use of Genesis 4 reduces the support-free overhangs from 45 down to 20 degrees for titanium alloys and down to 25 degrees for steel, Inconel and aluminum. Prof. Dr.-Ing. Vasily Ploshikhin, Managing Director AMSIS: “Genesis 4 was designed to increase the deployment potential of existing AM systems for support-minimizing technology. The user not only gets a very capable tool for build-job preparation, but also the opportunity to reduce build time and post-processing costs by significantly reducing material support structures.”

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Genesis 4 scope of features compared to the previous Genesis 3 version Genesis 4 offers users many new tools to improve process and part quality. The basic functionality – fast thermal simulation – runs even more quickly compared to the previous Genesis 3 version. Thanks to visualization, this thermal simulation can now be viewed by the user. Another module enables automatic reduction of the energy input in the identified hotspots. This occurs, for example, through reduction of the laser power. With the help of a new orientation module, optimal orientation can be found for the minimal quantity of support structures or for a decrease in the build time of the part. With the distortion simulation module, a preform part geometry can be calculated in order to achieve maximum geometric accuracy despite distortion. The new functionalities are rounded off by the AI-supported module for analyzing process monitoring data. This module enables users to identify and classify defects in printerspecific photographs. The locations of the identified defects are overlaid with the hatching pattern used in order to ensure better analysis of the cause of defects.

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IMD | 33

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

Alloy Enterprises Launches Aluminum Cold Plate Components Alloy Enterprises, a forward-thinking tech startup in the metal fabrication industry, has released aluminum cold plate components that feature intricate internal channels and require no additional assembly. The innovative company, now in its third year of growth, is expanding its suite of solutions to include thermal management applications like cold plates. What sets Alloy apart is its ability to manufacture aluminum cold plates Alloy Enterprises Launches Aluminum Cold Plate Components with complex geometric designs without the need for tooling or diameter. This machine introduces cutting-edge technology extra assembly. These cold plates boast superior material that enhances surface finish, accuracy, and controlled properties, including high strength-to-weight ratios, optimal runout, ensuring batch consistency from the first tool to the thermal conductivity, integrated cooling, and conformal last. Ideal for producing ballnose, corner radius endmills, surfaces. Such attributes are vital for enhancing heat transfer and intricate profile tools, the FX7 ULTRA is a game-changer and product performance. for industries relying on small tools like electronics, Alloy's cold plates offer numerous benefits, including telecommunications, medical devices, aerospace, durability, no porosity issues, and no de-powdering or and automotive. additional assembly steps. Customers can enjoy customized designs, quick iterations, and reduced assembly time. Alloy's Sheet Forging process enables faster product launches, design optimization, and cost savings compared to traditional manufacturing methods. Alloy Enterprises also specializes in other thermal management applications, such as heat exchangers, heat sinks, casings, and housings. They offer flexibility with no minimum order quantity and unlimited design changes, positioning themselves as a reliable U.S.-based supplier capable of aiding manufacturers in scaling from prototypes to production.

ANCA's FX7 ULTRA Precision Grinder for Small Tools ANCA's latest innovation, the FX7 ULTRA precision grinder, is designed to revolutionize the precision grinding of small tools, achieving unparalleled accuracy down to 0.1mm

34 | IMDQ | Q4 2023

ANCA's FX7 ULTRA Precision Grinder for Small Tools

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

Key features of the FX7 ULTRA include a one nanometer control system, new servo control algorithm for smooth motion, improved stiffness and rigidity, in-process measuring, balancing, and runout compensation, Motor Temperature Control (MTC), and expert training support. The machine not only grinds tools faster but also delivers superior surface finishes and accuracy, resulting in enhanced tool performance and quality. ANCA's co-founder, Pat Boland, notes that the FX7 ULTRA is set to revolutionize small tool manufacturing.

in the desired direction for improved hose payout and rewind experiences. The innovative design offsets the reel's front to track with hose payout when left un-locked. The swivel brackets come in two sizes, SMK-702-8 and SMK-702-12.5, catering to different reel widths. Coxreels continues its commitment to offering a comprehensive range of reels and reeling accessories, reinforcing its position as an industry leader in hose, cord, and cable reels.

Beckhoff Expands Electric Cylinder Lineup for Enhanced Efficiency

Beckhoff Expands Electric Cylinder Lineup for Enhanced Efficiency Beckhoff is expanding its scalable AA3000 electric cylinder series with the introduction of the AA3100 series, offering superior energy efficiency, sustainability, and cost-effectiveness. These electric cylinders are designed as replacements for hydraulic and pneumatic actuators, eliminating excess energy waste and floor space. The AA3100 series provides the necessary force, dynamics, and compactness required for linear motion applications while harnessing the advantages of servo technology, including precise positioning, safe holding, and high efficiency. The new series features two variants: AA3123 and AA3133 electric cylinders, each with distinct force and speed specifications. They share common benefits with Beckhoff's electric cylinders, including integrated mechanisms for precise motion, rapid commissioning with advanced encoder technology, simplified data access through TwinCAT 3 automation software, and customization options such as various spindle pitches and a backlash-free holding brake. Beckhoff's AA3100 series presents a compelling solution for industries seeking more efficient and sustainable linear motion applications.

Coxreels Introduces Swivel Mounting Brackets for 100 Series Hose Reels

EMAG Weiss Unveils W 11 CNC Cylindrical Grinder EMAG Weiss introduces the W 11 CNC cylindrical grinding machine for workpieces up to 500mm in diameter and 1,500mm in length. Designed for precision and efficiency, this machine is ideal for various industries, including contract grinding and medical technology. It offers extreme dimensional accuracy and rapid retooling, making it suitable for smaller series and prototypes. The W 11 CNC combines CNC-controlled externalinternal cylindrical grinding with manual operation. It provides flexibility with different grinding wheels, intuitive controls for common grinding cycles, automatic dressing, and in-process measurement options. Its mechatronic features ensure fast changeovers, with many processes taking just five minutes.

Coxreels Introduces Swivel Mounting Brackets for 100 Series Hose Reels Coxreels expands its mounting bracket offerings with the introduction of the SMK-702 SERIES, designed as a swivel bracket accessory for the 100 SERIES HOSE REELS and V-100 SERIES VACUUM REELS. Crafted in the USA from heavy gauge steel, these wall mount swivel brackets provide 360-degree rotation and offer multiple locking positions through an ergonomic pin lock. Powder coated in gloss black, these brackets allow users to orient the reel INDUSTRIAL MACHINERY DIGEST.COM

IMD | 35

Fastems Introduces Modular Automation System FPS for 4- and 5-Axis Milling Machines

This machine delivers exceptional dimensional accuracy with tolerances as low as 0.001mm, making it a versatile and future-proof solution for various tasks.

Fastems Introduces Modular Automation System FPS for 4- and 5-Axis Milling Machines Fastems presents its Modular Flexible Pallet System (FPS), a cutting-edge CNC automation solution designed for 4- and 5-axis milling and mill-turn machines, as well as compact vertical 5-axis machines. The FPS offers lights-out manufacturing and high spindle utilization, making it ideal for high-mix production environments. Its unique 360-degree modular design ensures compatibility with any shop floor layout, even in tight spaces with low ceilings. The system can integrate with CNCs from over 90 different brands and can be extended or upgraded as production needs change. Key features include configurable pallet storage modules, efficient use of vertical space, and an in-built coolant collection system. Fastems' Manufacturing Management Software (MMS) serves as the control system, providing real-time production insights, optimizing resource allocation, and adapting to changing production demands. The FPS offers manufacturers the flexibility and efficiency needed to maximize machining capabilities and profitability. The first systems will be available in spring 2024.

Fronius WeldCube Navigator: Enhancing Welding Precision and Efficiency Fronius introduces WeldCube Navigator, a software solution for its TPS/i welding systems. This digital welding sequence planning tool offers a seamless, error-free welding experience. It combines two essential functions: a sequencer that visually guides welders step-by-step through

36 | IMDQ | Q4 2023

Fronius WeldCube Navigator: Enhancing Welding Precision and Efficiency

work instructions and an automatic selection of predefined welding parameters. This system enables companies to optimize manual series production by setting standardized sequences that ensure high weld quality, reduced production time, and cost savings. It's user-friendly and eliminates errors by immediately notifying users of deviations from the welding sequence plan. The WeldCube Navigator simplifies onboarding for new welders and allows experienced workers to switch between workstations effortlessly. This standardized approach reduces the reliance on paper instructions and languages, making it a practical and efficient solution. Fronius emphasizes the economic and ecological benefits of weld sequencing, promoting time and material savings, error reduction, and efficient production processes. It also enhances quality assurance through standardization, making it ideal for various welding needs.

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Heck Industries/Woodward Fab Unveils Compact Rotary Weld Positioner Heck Industries/Woodward Fab has introduced the Model WFWP200-T compact rotary weld positioner. This versatile tool is designed for various welding applications, offering a 200-pound capacity and a variable speed range of 0-6 RPM. Powered by a 110-volt motor, it features an industrial gear case for continuous operation. The table can be manually tilted using a handwheel, and it includes a large 2 3/8" through hole for securing long tubes. Additionally, a 3-jaw chuck is provided. This compact rotary weld positioner enhances welding capabilities for small parts and large assemblies.

Heck Industries/Woodward Fab Unveils Compact Rotary Weld Positioner

TechniDrill Introduces Gundrilling Machine for Aerospace Aileron Actuation Cylinders TechniDrill presents the 2.00-30-48 gundrilling machine designed for the production of airplane aileron actuation cylinders. This machine can drill the large primary hole in a single pass without requiring a pilot hole, followed by secondary processes to finish the cylinder. With a gundrilling diameter capacity of 2.0 inches (50.8 mm) and a maximum depth of 48 inches (1219 mm), the 2.00-30-48 features a 30 horsepower AC spindle motor and a two-speed gearbox for versatile gundrilling capabilities. Pneumatically operated 3-jaw chucks enable counterrotation of the workpiece during gundrilling, enhancing hole accuracy. TechniDrill machines are manufactured by Kays Engineering in Marshall, Missouri, USA.

Kurt Workholding Introduces TriLock 3-in-1 Vise with CARVESMART Integration Minneapolis-based Kurt Workholding launches the Kurt TriLock product line, featuring a 3-in-1 vise design with integrated quick-change dovetail jaws from CARVESMART, recently acquired by Kurt. These 6-inch Kurt TriLock vises can easily convert between three vise sizes and accommodate double-station or single-station configurations. Equipped with CARVESMART dovetail jaws, they offer maximum workholding flexibility. The vise's preinstalled hardened steel jaw plates can be swiftly transformed into CARVESMART machinable aluminum jaw extrusions or various other CARVESMART jaw plate options for custom part holding and high-variability

38 | IMDQ | Q4 2023

Kurt Workholding Introduces TriLock 3-in-1 Vise with CARVESMART Integration

production work. TriLock vises with CARVESMART jaws are currently available for purchase.

Markforged Introduces FX10 Industrial 3D Printer for Enhanced Manufacturing Productivity Markforged Holding Corporation (NYSE: MKFG) has unveiled the FX10, an industrial 3D printer designed to enhance manufacturing line productivity. The FX10 enables on-demand part production, reducing costs and lead times compared to traditional methods. It features modular systems that can be expanded and upgraded with additional capabilities, including a printhead-integrated vision module for quality assurance. The FX10 incorporates the 5th Generation Continuous Fiber Reinforcement (CFR) print system, offering

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high-quality printing in a heated chamber for faster print speeds and larger print sizes. It aims to replace metal parts with advanced composites. The printer is designed for easy adoption on the manufacturing floor, with a user-friendly touchscreen interface and automation features that reduce the need for operator interactions. Printhead-mounted optical sensors ensure dimensional accuracy and machine health during printing, while a laser micrometer assists with automatic calibration. Markforged's Digital Forge, an additive manufacturing platform, complements the FX10 by offering cloudenabled software, process improvement tools, and a wide range of industrial materials. This platform integrates into existing manufacturing ecosystems, enabling users to share parts across their organization and monitor fleet performance centrally.

Mitsui Seiki Unveils J350G CNC Jig Grinder for Versatile, Precision Grinding Mitsui Seiki has introduced the J350G CNC jig grinder, offering exceptional application flexibility, precision,

reliability, and user-friendly operation. With the largest grinding infeed stroke available among its competitors, the J350G features a U-axis range of -3mm to +50mm relative to the spindle center, enabling the grinding of small and large diameter holes and multiple features using a single wheel. Equipped with the Fanuc 31i-B control, featuring a 15" touch panel LCD screen and G-MAPS conversationalstyle programming software, the J350G allows for both automatic and manual programming with ease. The machine prioritizes accuracy, with hand-scraped X and Y axes, V-F flat-shaped slide ways, and customdesigned Heidenhain scales, ensuring precision within +/0.0007mm on all axes. With a compact footprint and a range of spindle motor options, the J350G is designed for modern manufacturing environments, maximizing floor space efficiency while delivering high-quality results.

Murata Machinery USA Unveils Versatile Combination Punch Press and Fiber Laser System Murata Machinery USA has introduced a versatile Combination Punch Press and Fiber Laser System that integrates turret punching and fiber laser cutting capabilities into a single compact machine. This hybrid machine offers precise cutting, punching, tapping, and forming operations on various materials, making it suitable for a wide range of applications. With a press capacity of 33 tons and a rated output of 4.0kW, this multifunction machine delivers precise and efficient operations. It features a large turret capacity to reduce tool changeouts and a fiber laser for contour cutting and low-volume punch tool requirements. The system is designed for speed, reliability, and flexibility, making it ideal for industries like automotive, aerospace, and electronics. Its integrated features and automation options enhance productivity and efficiency, making it a valuable addition to the manufacturing landscape.

Murata Machinery USA Unveils Versatile Combination Punch Press and Fiber Laser System

40 | IMDQ | Q4 2023

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ANNUAL SUPPLIERS DIRECTORY

» 2023 Featured Suppliers » 2023 Annual Suppliers Guide Listings

Featured Listings

2023 ANNUAL

SUPPLIER'S DIRECTORY FEATURED SUPPLIERS

Actek Manufacturing & Engineering

AeroGo, Inc.

Since 1989, Actek® Manufacturing & Engineering has established a reputation for providing top-quality products as well as excellent service. Actek hoist rings are ISO 9001:2015 certified, 200% proof-load tested, and come with a certificate.

AeroGo manufactures innovative load moving equipment, utilizing wheels and hovercraft technology, that move heavy, awkward, or delicate loads in factories. AeroGo works with companies large and small to find a load moving solution that is safe, efficient and cost-effective.

AGMA – American Gear Manufacturers Association

American Technical Publishers

AGMA is the global network for technical standards, education, and business information for manufacturers, suppliers, and users of mechanical power transmission components. The association includes about 490 of the world’s top gearing companies across more than 32 countries around the world.

American Technical Publishers (ATP) produces effective training materials for technicians and skilled-trades workers in construction, electrical, mechanical, and maintenance industries. Our high-quality instructional materials are widely used in apprenticeship and industrial training programs.

AMS | Press Brake Safety

Behringer Saws, Inc.

Advanced Manufacturing Solutions | Press Brake Safety is a leading industry advocate for press brake operator safety. PBS is the exclusive North American installer of Germany-based Fiessler AKAS® laser safety systems, the most sophisticated press brake safety systems in the world.

BEHRINGER SAWS manufactures high-performance bandsawing machines, circular cold saws, and structural fabricating equipment. Our primary goal is to create additional value for our customers by striving to achieve the highest combination of speed, accuracy, and cost-effectiveness.

Betenbender Manufacturing, Inc.

Burr King Mfg., Co., Inc.

The Betenbender Family of American Hydraulic Shears and Hydraulic Press Brakes is made by Betenbender Manufacturing,Inc. in Coggon, Iowa, U.S.A. Now in their fifth decade in business, this Midwestern Company continues to produce, what they believe, is America’s best built Shears and Press Brakes.

Since 1951 Burr King grinders, polishers, and mass finishing systems have utilized innovative designs of uncompromising quality. They are industrial grade and intended for use on metals, woods, composites, plastics, rubber, stone, fiberglass and other materials.

Carell Corporation

Clamprite, LLC

Founded over 30yrs ago, Carell's experience in worldwide fabrication machinery & technology solutions continues to provide options that maximize efficiency while matching almost any budget. From small shops to large automated production systems we proudly maintain our goals & commitment to Faster Deliveries, Quality, Performance & Service

The most economical tool for spindle drawbar testing! No batteries or clumsy extension cords, no delicate electronics to adjust or burn out. Clamprite Gages are designed for years of daily use in the shop!

42 | IMD Q3 2023

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

Combilift

Cosen Saws, North America

Combilift is a specialist 4 directional forklift & straddle carrier manufacturer producing a wide range of customized handling solutions, all of which are designed for the safe, space-saving, and very productive handling of long and awkward loads. Capacities from 3,200 lbs. to 180,000 lbs.

Cosen Saws is a global leader in manufacturing industrial band saws and technologies. Offering cutting solutions for a wide variety of industries and applications, we offer over 70 different models with nearly 200 units in stock and ready to ship from our Charlotte, NC HQ.

COXREELS

Dynabrade, Inc.

COXREELS® has remained focused on manufacturing high-quality professional-grade hose, cord, and cable reels since 1923. Offering a full product line serving the industry in every channel and application, COXREELS® designs, builds, and supports their products in America.

Dynabrade has earned a reputation in the innovative design and manufacturing of unique portable pneumatic abrasive power tools, related accessories, and dust collection. Dynabrade tools have been proudly designed, manufactured, and built in the USA since 1969.

Eagle Bending Machines

Essex Structural Steel Co., Inc.

Eagle Bending Machines' precision engineered quality is designed to meet the demands for tough, dependable Section Benders for bending pipe, tube, profiles, sections, and ornamental pieces and working day after day with minimum downtime.

Essex Structural Steel has been manufacturing pre-engineered building since 1972. Their buildings are designed for easy erection, energy efficient, designed to exceed local and state codes and are built in the USA by American Workers.

Federal Knife, Inc.

Formdrill USA, Inc.

A global supplier of high quality machine knives and blades of all types. We can provide the correct replacement blade for your equipment from our large inventory or custom manufacture blades to your specifications.

Formdrill helps you produce your own inserts out of the same parts material. Users save money by eliminating the need to buy nuts or threaded inserts. You do not need to weld or install fasteners.

Fortville Feeders, Inc.

Fumoto Engineering

Fortville Feeders is a manufacturer of Feeding Systems that are engineered to easily integrate into your automation system. Maintenance and changeover friendly. Turnkey capable. Of the highest quality and ability.

Invented in 1976 in Japan and shipped to millions of satisifed customers all over the world, the Fumoto Valve continues to offer individuals, companies, mechanics and technicians, an easy tool that saves valuable time and resources for routine oil changes.

Furnace Brokers International

H&K Equipment

Furnace Brokers International maintains the largest database of available heat treating equipment in the world. Along with equipment sales and buying, Furnace Brokers does appraisals and exports worldwide. Whether buying or selling one piece or an entire plant, call us.

H&K Equipment provides specialized material handling solutions and exceptional service to our customers wherever and whenever we are needed. We strive to earn our place as the leading authority in our field! INDUSTRIAL MACHINERY DIGEST.COM

IMD | 43

HE&M Saw

HMI a Division of Betenbender

HE&M Saw manufactures more than 70 different models of production band saws for the metalworking industry. Their product line, includes vertical, horizontal, plate and double column saws with capacities ranging from 12” x 12” to 80” x 80” machines.

HMI offers the most versatile C-Frame press or punch of all machines available today. Their frames are designed to have fewer tons-per-square-inch of pressure on their side plates, thus reducing spring back of the frame and reducing tool wear.

HYDMECH Canada Corp.

Hypneumat, Inc.

HYDMECH is a world leader in metal band saw and cold sawing solutions. Their innovative solutions are geared to meet the practical needs of the aerospace, automotive, steel service centers, metal fabrications shops, racing, and other sectors.

Hypneumat, Inc. manufactures an array of automatic drilling units, tapping units and multiple spindle heads under the Hypneumat, Commander and Snow brands. Hypneumat also specializes in contract machining services offering multi-axis turning and vertical machining capabilities.

Industrial Magnetics, LLC

KEC Incorporated

Industrial Magnetics, Inc., provides off-the-shelf industrial magnet products. Our ability to provide customerspecific solutions to unique challenges that set us apart from others in the industry. We pride ourselves on quickly providing the best possible magnetic solution for our customer's requirements and without sacrificing quality.

KEC Incorporated specializes in Tank Turning Rolls, Welding Positioners, Floor Turntables, Sub Arc Manipulators, Head & Tail stocks. We also have a large inventory of Radial drills, bandsaws & other machine tools.

KHK-USA

L&L Special Furnace

Having been a company solely devoted to the manufacture of gears for 80 years, KHK is world renowned for their brand of gears. KHK USA is a factory direct, full-service distributor of KHK gears to meet your gearing needs.

F U R N A C E C O , I N C L&L Special Furnace, has a reputation for designing special industrial furnaces, ovens, kilns, quench tanks and heat treating systems. We continually update our product offerings and improve quality.

Lenzkes Clamping Tools, Inc

LS Industries

Lenzkes clamps assist with QMC-Quick Mold Change, QDC-Quick Die Change, SMED-Single-Minute Exchange of Die and other machining/safety issues. Their Free Trial program allows use in real-time working situations (such as Stamping, Milling, and Injection Molding) without obligation to purchase.

For more than 45 years, LS Industries has designed & manufactured a diverse product line of custom surface treatments and metal cleaning equipment. We also provide highly responsive service for your equipment.

Motion + Power Technology Expo (formerly Gear Expo)

OnRobot

At Motion + Power Technology Expo 2023 in Detroit, MI. October 17 - 19. The Motion + Power Technology Expo is a three-day show that connects professionals looking for motion power solutions with manufacturers, suppliers, and buyers.

44 | IMD Q3 2023

OnRobot’s cutting-edge robotic tools for lightweight industrial automation empowers end-users to work alongside cobots on applications such as machine tending, quality control, materials handling, packaging, assembly, or surface finishing. Their One System Solution yields unified programming, easy deployment, and zero complexity.

Precision Drive Systems | PDS

Pro-Line Work Benches

Precision Drive Systems (PDS), a leading global provider of precision motor spindle support and repair based near Charlotte, North Carolina. In addition to better-than-factory repairs and rebuilds, PDS stocks an extensive line of new and rebuilt spindles, gauges, aggregates and variable frequency drives.

Pro-Line has been a leader in workbench manufacturers since 1978. Proline offers a wide selection of workbenches that feature a modular designs and interchangeable accessories. Pro-Line continues to be on the leading edge of modular ergonomics.

Radwell International, LLC

RHH | Russell, Holbrook & Henderson, Inc.

Radwell International stocks and sells New and Surplus Industrial Automation, MRO, Pneumatic, Motion, Electronic, Hydraulic, HVAC and Electrical Control Equipment for plant floor and facilities maintenance machinery. Radwell has full component level repair capabilities for Industrial Electronic and Electrical equipment.

Specialists in fine pitch Carbide Gear Hobs, Gear Shaper Cutters, Spur + Helical Master Gears. Our precision line of TRU-VOLUTE gear products are known for reducing setup times, improving gear quality, and producing more parts per regrind. Quality Products Since 1915

Salinger Electric Co., Inc.

Scotchman Industries

Salinger Electric Co., Inc. has been selling quality new and reconditioned electrical equipment and electrical supplies since 1946. We are distributors of Siemens, Eaton, Continental and many others. We have locations in Troy, Romeo and Farmington Hills, MI.

Scotchman is the most trusted hydraulic ironworker manufacturer in the USA, and also builds a complete line of Circular Cold Saws: manual to fully automatic, plus distributor of quality Digital Measuring Systems, Band Saws, H-Presses, and Tube & Pipe Notchers/Grinders.

Sprinter Marking

Standard-Direct.us

Sprinter Marking manufactures a range of machines models that automatically ink code-mark message on a wide range of porous and non-porous surfaces. While very small in physical size, they are designed for rugged industrial operation.

Welcome to Standard-Direct.us, your number one source for industrial fabricated carts, shelf trucks, security trucks, storage cabinets and workbenches and much more. Industrial Shelving systems.

Stor-Loc

Suhner Industrial Products Corp.

The original heavy duty Modular Storage Drawer Cabinet that was the norm in the industry until the early 1990s is available only from Stor-Loc®. Their durable Modular Drawer Cabinet comes complete with a unique 55 Year Satisfaction Guarantee.

Suhner, we Bring Solutions to help our Customers Create their perfect success-critical Metal workpiece or Metal component. Since 1914, Suhner has offered a variety of solutions with machining & abrasive products, tool holders for machining units, customized flexible drive shafts, and repair services for Machining Spindles.

Sunnen Products Company

Sure Tack Systems, LLC

Sunnen has been a global leader in the manufacturing of bore creation, sizing and finishing equipment, since 1924. The Sunnen product line includes machines for honing, lapping, deep hole drilling and skiving/roller burnishing, plus the tooling, abrasives, cutters and bore gages to finish the job correctly!

Sure Tack Systems, a division of Crist Company, Inc. established in 1980 and offers a diverse product line for your hot melt adhesive equipment and application needs. Whether your need is for high-speed extrusion, wide web spray, slot coating or manual product assembly; STS has a hot melt system to fit your individual needs and budget. INDUSTRIAL MACHINERY DIGEST.COM

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Syclone ATTCO Service (Sky Hook)

Tormach

Manufacturer of the Sky Hook, a small, portable, ergonomic lifting device designed to provide safe, high quality lifting solutions that can assist in applications involving hard to reach loads up to 500 lbs. Proudly family owned and operated since 1969.

At Tormach, we are dedicated to providing exceptionally engineered compact CNC mills, lathes, routers, plasma tables, and industrial robots, as well as tooling and related products. We serve customers with best-in-industry technical support and customer service.

Trilogy Machinery, Inc.

Trim-Lok, Inc.

Trilogy Machinery, Inc. is committed to bringing the highest standards of professionalism, integrity and service in order to achieve a reputation as a leader in the metal fabricating machinery industry. Trilogy proudly offer products from Italy, Sweden, Turkey, and Taiwan.

Trim-Lok, Inc. manufactures high-quality plastic and rubber extruded trim and seal profiles. From plastic edge trims to sponge rubber seals, our profiles add protection from rough edges while sealing out moisture and debris with a clean, finished look to your application. In-stock profiles and custom engineering is available.

TS3, LLC

US Metal Crafters, LLC

TS3 – The Saw Sales and Service Company – provides all aspects to support your saws - Names you know and trust – Amada, Marvel, Tigerstop, MK Morse, and many more. New machine sales, on-site repairs, applications and replacement parts. TS3 - factory trained or factory authorized in many current and former saw manufacturers.

American-owned and operated, US Metal Crafters knows the right supplier transforms your supply chain. Our broad service offering coupled with our commitment to quality & on-time delivery will transform & simplify yours. Laser cutting, stamping, fabrication, assembly, powder coating, tool & die services, and more all under one roof!

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Featured Surplus Listings

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FEATURED SUPPLIERS

BidIndustrial.com, LLC

BTM Industrial

BidIndustrial.com is a Commercial & Industrial Auction Company for industrial machinery & equipment. We specialize in UNRESERVED auctions of heavy equipment & machinery, commercial & industrial inventories. www.bidindustrial.com | (888) 777-9888

BTM Industrial is the one source for every aspect of Metalworking Surplus - Machinery, MRO/CNC Parts, Tooling, Material Handling

www.btmindustrial.com | (616) 745-5953

Capital Recovery Group, LLC

Cincinnati Industrial Auctioneers, Inc.

CRG is a global private equity firm that creates liquidity through expertise, innovative solutions, and access to worldwide markets by revitalizing idle or marginally productive assets and liquidating surplus. www.crgllc.com | (860) 623-9060

Since 1961, we pay cash for used industrial and manufacturing equipment as well as conduct auctions on your behalf. www.cia-auction.com | (513) 241-9701

CNC Exchange

Comly Auctioneers & Appraisers

CNC Exchange, Division of Gray Machinery Company, specializes in buying and selling high-quality, pre-owned CNC Swiss-type lathes, turning centers and machining centers and other types of industrial equipment. www.cncexchange.com/ | (847) 537-7700

Comly is the oldest family-owned industrial auction company in the U.S. The Comly family of auctioneers and real estate brokers has been specializing in industrial auctions for decades. Certified ASA appraisers. www.comly.com | (215) 634-2500

Compass Auctions

Country Boys Auction & Realty, Inc.

Compass Auctions provides support, advice & transparent communication throughout the auction process so you can make the most informed decisions. We host monthly industrial machinery & equipment auctions. www.soldoncompass.com | (423) 702-6180

For 50 years, Country Boys Auction & Realty, Inc. has specialized in the auction & liquidation of all types of industrial machinery, heavy equipment, and real estate throughout NC, SC, & VA. www.countryboysauction.com | (252) 946-6007

Denver Breaker & Supply

Glenn A. Winternitz, LLC

Denver Breaker and Supply was established in 1984 and has always had a “Customer First” approach of doing business. They provide new and reconditioned electrical equipment and guarantee the finest quality and best prices you can find in the business. www.denverbreaker.com | (800) 544-7375

With a history of four generations as auctioneers, Glenn A. Winternitz, LLC brings the knowledge and experience necessary to navigate these challenging economic times. We are knowledgeable in what we sell! www.winternitzauction.com | (773) 290-1827 INDUSTRIAL MACHINERY DIGEST.COM

IMD | 47

Harris Auctions

Harris Machine Tools, Inc.

Harris Auctions Specialists in Surplus Asset Management. We utilize online timed auctions, live webcast, and live on-site auctions, and have an aggressive marketing system to reach a wide audience of bidders. www.harris-auctions.com | (713) 462-5800

Harris Machine Tools, Inc. has been an international leader in the used metalworking marketplace for over 44 years. Our team has worked to earn an outstanding reputation for quality, service, and integrity. www.harrismachinetools.com | (713) 462-5800

Heath Industrial

Henderson Auctions

We are auctioneers and appraisers who provide advice on the proper method to liquidate a firms’ assets and accurate appraisals by senior certified appraisers for banks, financial institutions, partnerships, estates, and business owners. www.heathindustrial.com | (855) 884-3284

Henderson Auctions is one of the oldest equipment auction firms in existence and is recognized as a leader in the industry. We specialize in heavy construction machinery, truck and trailer, mobile home, travel trailer, industrial equipment, and real estate auctions. www.hendersonauctions.com | (225) 686-2252

Heritage Global Partners

Integra Asset Solutions

Heritage Global Partners, Inc. is a full-service auction and asset advisory firm in 25+ Industrial sectors, globally. Subsidiary of Heritage Global Inc (NASDAQ: HGBL) www.HGPAuction.com | (858) 847-0659

Our decades-long expertise in industrial/ commercial valuations & liquidations allow us to optimize the value of any distressed/ nonperforming/surplus asset. We customize our services for businesses of all sizes. integra-as.com | (888) 243-6161

Joiner Sales Corp.

Lee Stevens Machinery

Joiner Sales Corp has over 46 years of experience in providing market leading Industrial Auctions and Appraisals in Canada. We are a family team of experienced industrial auctioneers and machinery appraisers! www.joinersales.com | (604) 852-8711

Since 1948, we have supplied quality, late model used tool room, production and CNC machinery to Manufacturers in the US and abroad. We assist our clients with tooling up or replacing existing capital equipment. Auctions, Liquidations and Appraisal Services. www.stevensmachinery.com | (248) 926-8400

Lee Stevens Machinery Auctions, LLC

Link Auctions

Link Auctions has unrivalled knowledge & expertise in auctioning Industrial Assets. Our principals have more than 100 years of combined experience valuing equipment & customized programs for auctioning assets. www.linkauctions.com | (631) 847-5530

Moecker Auctions, Inc.

Motleys Industrial

Moecker Auctions Inc is a trusted company in Florida. Our team of experienced, accredited professionals have successfully delivered state-wide auctions, appraisals, and liquidations with accountability. www.moeckerauctions.com | (954) 252-2887

Whether it is one piece of equipment, a fleet, or an entire company, Motleys Industrial utilizes auctions, brokerage, cash buyouts, and appraisals to exceed expectations for all your buying and selling needs. www.MotleysIndustrial.com | (804) 486-4550

48 | IMD Q3 2023

Pacific Industrial Auctions and Appraisals LLC

Prime Machinery, Inc.

We are an industrial auction and appraisal firm that has been in business for over 30 years. We specialize in commercial, industrial assets and business liquidations in Oregon, Washington, Idaho and California. www.PIAuctioneer.com | (541) 913-7455

Prime Machinery is one of the nation's most trusted quality used machinery dealers, specializing in buying and selling vertical horizontal boring mills, CNC machining centers, CNC turning centers, lathes, EDM’s & fab equipment. www.primemach.com | (516) 922-7977

RAAR Group USA LLC

Rabin Worldwide, Inc.

Auctions, Machine Tools, Power Generation Equipment, Motors and Transformers.

www.raargroupusa.com | (310) 487-3800

In business for over 70 years, led by the 2nd generation, Rabin is a family-held auction and real estate investment company, which acquires and sells industrial facilities and equipment around the world. www.rabin.com | (415) 522-5700

Resell CNC

Resell CNC Auctions

Resell CNC is proud to be the leading Used CNC Dealer in today’s global market for used CNC machinery. Resell CNC also provides you with a unique, trusted, and timed online auction platform to buy and sell surplus equipment effortlessly. www.resellcnc.com | (844) 478-8181

Resell CNC Auctions provides you with a unique, trusted, and timed online platform so you can buy and sell surplus equipment effortlessly! Resell CNC is also the Leading Used CNC Dealer in today's global market. www.resellcnc.com | (844) 478-8181

SIGMA Auction

Stone Auctioneers & Appraisers

SIGMA Auction has developed a system that will assess your surplus equipment and then help you turn your assets into immediate liquidity. We offer a no-stress solution to turn your idle equipment into profits. www.sigma-auction.com | (812) 618-2048

Our Mission - to provide the highest quality services possible, continuously educating, training and conducting ourselves in a manner that reflects integrity and keeps our client's goals and interests Priority One. www.stoneauctioneers.com | (205) 373-1130

Westbrook Asset Management

Winternitz Industrial Auctioneers & Appraisers

Westbrook Asset management is a full-service industrial auction and liquidation company. We offer a wide range of programs for sellers to quickly turn their surplus machinery and equipment into cash. www.westbrook-auctions.com | (800) 899-8182

National Leading Asset Disposition Services Firm, Serving All Industrial Sectors. Auctions Conducted Throughout the US/CAN/MEX. Global Reach with Buyers from over 75-Countries. Specializing in Complex Facilities, Entire Plants, Multi-Locations. Since 1894! www.Winternitz.com | (847) 272-0440

Workingman Capital Corp. "Our Promise: Professional solutions for industrial businesses. Selling your factory? We sell industrial factories and assets. Selling your business? We bring buyers and sellers together."

www.IndustrialMachineryDigest.com

www.workingmancapital.com | (416) 847-7336 INDUSTRIAL MACHINERY DIGEST.COM

IMD | 49

Surplus buying and selling

Mention SBSDA2023 for a 10% Discount!

YES...We Have That!

Denver Breaker & Supply One of the Nation’s Largest Inventory of NEW, Obsolete, Inspected & Tested Electrical Equipment! • Circuit Breakers • Panel Mount Switches • Motor Controls • Bus Duct Plugs • Transformers • Starters • and More!

WE SPECIALIZE IN THE TOP BRANDS & CARRY THE HARD-TO-FIND ITEMS Providing Same Day, Next Day Air Shipments for Emergency Needs!

WE ALSO BUY YOUR USED EQUIPMENT…

CALL US TODAY!

855-4UR-BRKR WWW.DENVERBREAKER.COM All Breakers are Insured and Guaranteed — All Material is Fully Load Tested.

50 | IMDQ | Q4 2023

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Advertiser Index Actek Manufacturing and Engineering Inc. — www.actekmfg.com ........................................... 6

ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ............ IFC, 8, 29, 31, 33

Betenbender Manufacturing, Inc — www.betenbender.com ...................................................... 9

SERVING AMERICAN MANUFACTURERS FOR OVER

37 YEARS

Cosen Saws, USA — www.cosensaws.com ..................................................................................... 5

Denver Breaker & Supply — www.denverbreaker.com ...............................................................50

Design-2-Part Shows — www.d2p.com ......................................................................................... 27

Dynabrade, Inc. — www.dynabrade.com ................................................................................... 3, 15

ENM Co — www.enmco.com ........................................................................................................... 52

Essex Structural Steel Co. — www.essexstructuralsteel.com .....................................................39

H&K Equipment, Inc. — www.hkequipment.com ......................................................................... 51

HyPneuMat Inc. — www.hypneumat.com ..................................................................................... 19

IMDauctions.com — www.imdauctions.com ..................................................................... 8, 51, 52

ARE YOU LISTED? We have launched our online, searchable directory with over 400 categories specifically designed for the industrial machinery industry. IF YOU’RE NOT LISTED, YOU’RE MISSING OUT!

KHK Gears — www.khkgears.us ..................................................................................................21, 23

L&L Special Furnace Co., Inc. — www.llfurnace.com .................................................................. 52

Pro-Line — www.1proline.com ......................................................................................................... 52

Royal Products — www.mistcollectors.com .................................................................................. 52

Schweiss Doors — www.schweissdoors.com ............................................................................... 52

Standard Direct — www.Standard-Direct.com ............................................................................. 51

Stor-Loc — www.storloc.com ............................................................................................................ 7

Tormach — www.tormach.com ........................................................................................................17 INDUSTRIAL MACHINERY DIGEST.COM

IMD | 53