Manufacturing Technology

Picture: The improved collision detection in PowerMILL 2015 will be demonstrated at IMTS. Delcam will launch the 2015 version of its PowerMILL CAM system for high-speed and five-axis machining at IMTS 2014 in Chicago from 8th to 13th September on booth E3222, the largest CAM software booth at the show. The new release will include improvements to the Vortex high-efficiency area-clearance strategy, improved collision checking to also cover near misses, and more efficient raster finishing. The Vortex area-clearance strategy produces safe toolpaths with a much deeper cut by using a controlled engagement angle that maintains the optimum cutting conditions for the whole toolpath. As a result, higher feed rates and material-removal rates are possible, making the cutting time shorter by as much as 70%. In addition, cutting is undertaken at a more consistent volume-removal rate and at a near constant feedrate, so extending tool life and protecting the machine.  Two enhancements in PowerMILL 2015 will give even greater reductions in machining time compared to conventional roughing. The first change allows toolpaths to approach the part from outside the stock at the cutting height for open pockets or in areas where earlier cuts have made this possible. Previously, all entry moves had to be made by plunging onto the surface or by ramping into the material. The second change allows an increased feed rate to be set for non-cutting moves. The default value is set at double the rate for the cutting moves but this can be altered as required for each machine tool. The extra time that can be saved depends on the shape of the part but an additional saving of around 20% should be expected above the earlier releases of Vortex. Another problem in previous versions of PowerMILL was that unnecessary lifts could be added to area-clearance toolpaths […]

Picture:Warwick Downing of TiDA and Ian Brown of Callaghan Innovation. New Zealand businesses stand to benefit from a top-class 3D printing facility that can create objects from titanium and other metals, enabling the development of a range of new export products. Callaghan Innovation and the Titanium Industry Development Association (TiDA) have jointly purchased a Selective Laser Melting instrument, now in operation at TiDA’s Tauranga site. This instrument has the ability to make state-of-the-art 3D objects by ‘printing’ them using metal powders, such as titanium alloys and stainless steel. Callaghan Innovation’s Advanced Materials research team will work with TiDA to use the Selective Laser Melting machine for research and to help businesses commercialise products. “The future of high tech manufacturing is driven by 3D printing,” says Dr Ian Brown, Callaghan Innovation’s Materials Research Manager. 3D printing techniques – known as Additive Manufacturing – are very efficient ways to transfer complex industrial designs to commercial production. “Titanium is tremendously expensive and traditional ways of machining something from this material involved throwing away 90% of the metal. Using 3D printers, you build the product layer by layer, with very little material wasted,” Dr Brown says. TiDA CEO Warwick Downing says manufacturing using advanced metal alloys is very cost effective when using smart design and clever technology, creating high growth industry that has tremendous potential for New Zealand. “TiDA has well-established skills at designing for and the application of 3D printing in metals. New Zealand is leading the way in research that supports this industry,” Mr Downing says. “Having the Callaghan Innovation team onsite will promote closer working ties and will enhance our materials research capability. We are already seeing the results with new products for companies already being worked on and a faster product turn-around through the combination of the two sets of […]

“Green diesel approval would be a major breakthrough in the availability of competitively-priced, sustainable aviation fuel”. Airline manufacturer Boeing claims to have identified a new renewable fuel that emits at least 50% less carbon dioxide than fossil fuel over its lifecycle. The company is working with the US Federal Aviation Administration to gain approval for its new ‘green diesel’ which could power aircraft, cutting the aviation industry’s carbon footprint significantly. Boeing researchers have found that green diesel, which is made from oils and fats, is chemically similar to today’s aviation biofuel. If approved, the fuel could be blended directly with traditional jet fuel. “Green diesel approval would be a major breakthrough in the availability of competitively-priced, sustainable aviation fuel,” said Dr. James Kinder, a technical fellow in Boeing Commercial Airplanes Propulsion Systems Division. “We’re collaborating with our industry partners and the aviation community to move this innovative solution forward and reduce the industry’s reliance on fossil fuel.” “Green diesel approval would be a major breakthrough in the availability of competitively-priced, sustainable aviation fuel”. Significant green diesel production capacity already exists in the US, Europe and Singapore that could supply as much as 1% – about 600 million gallons – of global commercial jet fuel demand. The wholesale cost – about $3 a gallon with US government incentives – is competitive with petroleum jet fuel. Boeing, the FAA, engine manufacturers, green diesel producers and others are now compiling a detailed research report that will be submitted to key stakeholders in the fuel approvals process. In 2011, Boeing worked with the aviation community to include a blend of up to 50% aviation biofuel in international jet fuel specifications. Biofuel approved for aviation must meet or exceed stringent jet fuel performance requirements. “Boeing wants to establish new pathways for sustainable jet fuel, and […]

The new Objet500 Connex3 3D printer from Stratasys has the ability to print out in numerous materials and mixtures of materials, as well as the ability to mix three different colours to make hundreds of colours. A truly revolutionary moment within the industry. The Objet500 allows them to print our near exact 3D models of their vehicles, scaled down to 33%. From wheels, to emblems, to shifters, to tailpipes, the printer can produce extremely accurate models of them all. This allows designers to see exactly what a vehicle will look like before it is actually manufactured. They also use the printer to print out actual life sized models of parts for the vehicles as well. Nearly every part will be prototyped as scaled down versions, so that designers can assess their creations on an actual real world model. The accuracy of the Objet30 3D Printer enables Bentley to take a full-size part and scale it down to produce a one-tenth scale model. Once they have approval at this scale, they can move onto their larger Objet500 Connex 3D Printer to produce one-third scale models, full-sized parts as well as parts that combine different material properties without assembly. If you were to read the following statement from the early 20th century by W.O. Bentley, the company’s founder, the use of these printers would certainly make sense: The company’s objectives are to build a fast car, a good car, the best in its class. Maintaining this tradition for automotive excellence and prestige is a fundamental focus for Bentley as it combines innovative technologies with traditional craftsmanship at every stage of development and production. This is without a doubt the future of prototyping. The Objet500 by Stratasys allows Bentley, and will allow many other manufacturers to prototype using multiple materials within one print, […]

 A recent partnership between 3D systems and Hershey will make it easier to satisfy your strongest candy cravings. You don’t even need to leave the house. Hershey’s new chocolate 3D printer is a pretty sweet project (pun very much intended). The chocolate printer works the same as the other ones. 3D printers use specific materials like concrete, plastic, metal, and now, chocolate to build items layer by layer, following directions from a computer program. 3D Systems said that this deal with Hershey will allow 3D printing to become a more mainstream technology by giving people the opportunity to make their favourite candies as well as invent new designs. I’m not sure how this can be accomplished when the smaller printers for consumers start at $1000 a pop, but it’s a commendable idea to make this technology more attainable to regular folk. William Papa, head of research and development at Hershey, had this to say about the partnership: “Whether it’s creating a whole new form of candy or developing a new way to produce it, we embrace new technologies such as 3-D printing as a way to keep moving our timeless confectionery treats into the future.” 3D printing is definitely the way of the future. People are fascinated by 3D printing but may not have a use for a 3D-printed heart, prosthetic, or building. Candy seems like a good middle-ground to ease into this popular item that seems to be the hot new tech trend right now. Maybe, as it becomes more prevalent, the hefty price tag will go down so we can all play with our Easy Bake Oven for adults. Critics of the chocolate printer, and other 3D-printed endeavors, don’t see the merit in such advancements for consumers. It seems more like a fear of losing manufacturing profits than […]

A new catalytic converter that could cut fuel consumption and manufacturing costs has been designed by a scientist from Imperial College London. A catalytic converter is the component in a vehicle’s exhaust system that eliminates some harmful emissions. Tests suggest that the new prototype could reduce fuel consumption in a standard vehicle by up to three per cent. It could also deliver environmental benefits by reducing the amount of CO that each vehicle emits. The new design uses up to 80 per cent less rare metal, a development that could significantly reduce costs for vehicle manufacturers. Catalytic converters are expensive to manufacture because they use precious metals such as platinum to eliminate emissions. These metals currently account for up to 60 to 70 per cent of the cost of the component. The prototype is also predicted to perform better than existing models because the rare metal degrades less over the lifetime of the component. Laboratory tests suggest that it deteriorates by only four per cent over a distance of 100,000 kilometres, compared to 35 per cent for a standard catalytic converter. The inventor of the prototype device is Dr Benjamin Kingsbury. He is also a Research Associate in the Department of Chemical Engineering at Imperial College London. He says: “Catalytic converters are the most important component in a vehicle for controlling exhaust emissions. Yet their design has not changed since they were first developed in the 1940s. “The prototype I have developed could make cars cheaper to run because they use less fuel. It could potentially help manufacturers to reduce their costs. Drivers could also be a major beneficiary of this device, which could save on fuel costs and ultimately lead to reduced CO? emissions.” A conventional catalytic converter is a ceramic block, which is honeycombed with microscopic channels that […]

NASA is set to launch world’s first zero-G-ready 3D printer into space next year, during its resupply mission to the International Space Station, so that parts can be built on-demand in space. Space manufacturing company Made in Space’s customised 3D printer will be the first device to manufacture parts away from planet Earth, researchers said. The 3D Printing in Zero-G Experiment will validate the capability of additive manufacturing in zero-gravity.   “Imagine an astronaut needing to make a life-or-death repair on the International Space Station,” said Aaron Kemmer, CEO of Made in Space on the company’s website. “Rather than hoping that the necessary parts and tools are on the station already, what if the parts could be 3D printed when they needed them?” said Kemmer. All space missions today are completely dependent on Earth and the launch vehicles that send equipment to space. The greater the distance from Earth and the longer the duration, the more difficult it will be to resupply materials. “As NASA ventures further into space, whether redirecting an asteroid or sending humans to Mars, we will need transformative technology to reduce cargo weight and volume,” NASA Administrator Charles Bolden said during a recent tour of the agency’s Ames Research Center at Moffett Field. “In the future, perhaps astronauts will be able to print the tools or components they need while in space,” he said. The Made in Space and NASA team envisions a future where space missions can be virtually self-sufficient and manufacture most of what they need in space. This includes such things as consumables, common tools, and replacements for lost or broken parts and eventually even such things as CubeSats (small, deployable satellites). “The 3D printing experiment with NASA is a step towards the future. The ability to 3D print parts and tools on-demand […]