This white paper will cover ProfitTurning, a productive and secure cutting method that enables manufacturers to make more efficient cuts with consistent chip loads and cutting forces, thereby reducing tool wear and decreasing cycle time. This is achieved using a toolpath algorithm based on an engagement control strategy, which allows for consistent cutting forces universally, and achieves the highest level of productivity.

Topics discussed include:

• What is ProfitTurning?
• Comparison to traditional turning strategies
• Advantages and benefits of ProfitTurning
• Impact to cycle time, tool life, and productivity
• Test results and examples on actual turned parts

Your download is sponsored by Hexagon.

The post Engagement Control Strategies for Reducing Machine Cycle Time and Cost on CNC Lathes appeared first on Engineering.com.

In its latest update, CNC machining software SprutCAM X added an AI assistant based on OpenAI’s ChatGPT API. Its name is Éncy.

SprutCAM Tech, the Cyprus-based developer of SprutCAM X, says Éncy will help engineers with various aspects of the CAM workflow—and pretty much anything else.

“Hi, I’m Éncy, your SprutCAM X AI assistant. Ask away, and I’ll be happy to help!”

One of Éncy’s main features is the ability to explain G-code. Ask it to clarify any instruction and Éncy will describe its purpose in plain language. The AI assistant can comment on every single line in a G-code file if you ask it to.

Éncy explains a few lines of G-code. (Source: SprutCAM Tech.)

Éncy can also create G-code. Users give it a text description—“drill a 10 mm diameter hole at point (100, 25)”—and the AI assistant will program the operation based on the given CNC system. If you’re looking for reference information on a given CNC machine, such as its specs and limitations, Éncy can provide that too.

Engineers and manufacturers can also use Éncy as a Python programmer to create 2D and 3D models and write them to .dxf and .stl files, respectively, showing the results in real-time.

Éncy writes Python to generate a .dxf file. (Source: SprutCAM Tech.)

An all-purpose AI assistant for engineers

Éncy doesn’t stop at improving the CAM workflow. SprutCAM Tech says users can ask the bot about anything, from manufacturing tips to math questions and even how to explain to their spouse why they’re working late.

Éncy saves a marriage. (Source: SprutCAM Tech.)

“We are committed to creating software that enables our customers to seamlessly transition from CAD to finished parts with the fastest turnaround time in the industry. SprutCAM X with ChatGPT technologies will save you time, improve your productivity and enhance your creativity,” said Andrei Kharatsidi, co-founder of SprutCAM Tech, in a news release announcing the Éncy update.

For more on how ChatGPT is impacting engineers and manufacturers, read ChatGPT is Pushing Engineering Buttons.

The post ChatGPT Has Come for CAM Software appeared first on Engineering.com.

A 3D printed metal gear. (Image courtesy of Xometry.)

Choosing the right manufacturing method is essential to a product’s physical and economic performance.

Machining via computer numerical control (CNC) is the long-established standard, where a part is produced by removing metal from a workpiece according to a computer program. Metal 3D printing is the new technology on the block, where a machine builds up a part, layer by layer, using processes such as sintering, welding and melting.

While 3D printing is becoming increasingly popular, manufacturers need to consider carefully whether it offers sufficient advantages over conventional CNC production for their particular application.

Here are five things to keep in mind when deciding which process is right for you.

1) 3D Printing Is Not An “Easy Button”

“People think about metal 3D printing as that ‘easy’ button,” said Greg Paulsen, Director of Applications Engineering and Marketing at Xometry, a manufacturing-on-demand service provider. “That I used to get this component this way, and now maybe 3D printing is going to be cheaper or faster.”

Sometimes that’s a fair assessment, especially if the part has a lot of pocketing and is designed for 3D printing at its inception. If the component is designed to be produced via CNC, “you’re not getting the value add that metal 3D printing can really offer, where you’re designing with metal 3D printing in mind, which is a very different approach in manufacturing,” said Paulsen.

“Many people may not be aware that metal 3D printing comes with a number of challenges. This is because, unlike traditional machining methods where you carve out a piece from a larger block of material, metal 3D printing involves building a part from scratch, layer by layer, using a series of micro welds.” said Tommy Lynch, Senior Applications Engineer for additive at Xometry.

Parts built with metal 3D printing typically see a significant amount of internal stress after the metal powder melts and then resolidifies as it cools. The rapid change in temperature causes each layer to try to curl upward during build—which is why the build relies on support structures to keep the product anchored to the build plate. When the build is completed, those supports need to be removed, which comes with the risk of damaging critical features in the process.

It’s rarely as simple as pushing a button to start the printer and then unloading a completely finished part.

2) 3D Printing and CNC Machining Have Different Strengths and Weaknesses

Producing a part through CNC machining is a vastly different process than producing it with a 3D printer—and the nature of the part has a significant influence over which method is better for producing it.

CNC machining is a subtractive manufacturing method: material is removed from a solid block using a variety of cutting tools to produce the part based on a CAD model. The more complex the part, the more time it takes to produce: a shaft with threading can be created on a basic turning machine, while a blisk requires a full 5-axis mill. The material also makes a big difference, with harder metals requiring more specialized cutting tools.

In contrast, 3D printing involves “growing” a part on a blank baseplate, creating it by adding material one layer at a time. In this case, the complexity of the part and the material from which it’s made make much less of a difference to the cycle time.

“The second you have a profile that has a spline or keyway, or curvature—a manifold design, for example—3D printing becomes a lot more value added,” said Paulsen. “With additive manufacturing, less is more. With CNC machining, the work is removing the material, so you have different cost drivers on it.”

3) Designing for 3D Printing Requires Different Considerations

Just as these two manufacturing methods differ in process, they also differ in how engineers should approach part design.

With 3D printing, the part needs to be designed to factor in a set build orientation; ideally it would be designed to optimize and minimize the need to use supporting structures. “The role of the supporting structures is to win the battle of the part versus the build plate,” said Paulsen. “It’s like a tug of war…you start with about an inch and a half of a steel build plate, and you’re fusing your first layers down to that, and then every subsequent layer is fused on top of either the part structure itself or the supporting structures underneath.”

According to Paulsen, it is similar to coral on a reef: it’s mounted to a structure and grows out of it, and the shape of the organism (or part) depends on the support structures available to it. In any 3D printing process, the design needs to factor in the bottom-to-top fixed orientation as well as the intended function of the component itself. Because the supporting structures are also metal, they increase material consumption, build time and post-processing labor to remove.  

“Ask yourself, how can I get my core functionality out of my design, and design it in a way where you either mitigate or remove the need for supports,” he said. “Designers have to really understand that process to unlock the true value of metal additive.”

Selective laser sintering in 3D printing. (Video courtesy of Xometry.)

4) Converting Parts from CNC to 3D Printing Can Be Challenging

Paulsen and his team at Xometry have found that companies exploring 3D printing as a replacement for CNC often look at the components they already produce using traditional manufacturing methods and study the costs of producing the same part with a printer. But this decision is more complex than just swapping out equipment.

CNC machining is an established method that has been around for decades, and the CNC-produced part has likely gone through many optimizations already. Many of the assumptions made in the CNC process are taken for granted because of years and years of best practices. “A lot of that has to be rediscovered or substituted and validated in a 3D printing world,” said Paulsen. These necessary steps tend to create more complexities in the product design and approvals processes. In some cases, it’s like reinventing the wheel.

“It doesn’t always make sense in terms of price because milling or turning could be cheaper,” said Lynch. “And if you’re really going to volume production into the hundreds, then traditional machining will almost always win.”

Cracking and warping are the most common problems encountered when trying to 3D print parts designed for CNC, particularly for pieces that are either chunky or very thin. When hundreds or thousands of welds are stacked on top of each other it generates a tremendous amount of stress, potentially to a point where the component will either crack, flex or break away from the build plate, resulting in build failure.

These technical challenges can engender a broader reluctance to adopt metal 3D printing, due to the cost of failed builds. Unlike 3D printing plastics, where the material costs are much lower, the stakes are higher in metal. With a premium on pricing, equipment and post-processing, a failed metal print could cost thousands of dollars in wasted powder and lost productivity. In many cases: it’s not always clear if a part is successful until the build is complete.

“The designer is at somewhat of a disadvantage because if the part is not designed within a certain level of confidence of build success, then most service bureaus are hesitant to take a risk  on unproven designs with a high likelihood of failure,” said Lynch. “It is not beneficial to the customer or the manufacturer to  push the limits of the technology only to demonstrate why parts need optimization. Metal printing can be highly collaborative, and we try to guide customers down the path of success on the first try.”

5) You Can Access 3D Printing Services Without a 3D Printer

Some companies may find that it is worth the price to incorporate 3D printing into their operations, but don’t have the budget to buy a metal 3D printer of their own. A viable option for them could be 3D printing service bureaus such as Xometry.

Xometry, for example, is a digital manufacturing marketplace that connects the people who need a part printed with the suppliers that make the part through an integrated platform. A company using Xometry could upload a file, get a price and lead time estimates from suppliers who have already been vetted by Xometry, and make their purchase decision then and there.

“A service like Xometry gives you access to millions of dollars of industrial equipment. You upload the 3D file and you’re essentially reserving and renting space on the machine just for that print,” said Paulsen. “You don’t just have a metal 3D printer, you have a machine shop beside you that’s supporting your needs.”

While metal 3D printing may not be the “easy” button manufacturers have been hoping for, it still has the potential to significantly increase productivity and help a company’s bottom line—as long as the engineers do their homework to determine whether it’s the right call over conventional CNC production.

Get an Instant Quote on 3D printing and more at Xometry.

The post 5 Considerations When Deciding Between Metal 3D Printing and CNC Machining appeared first on Engineering.com.

(Image courtesy of EMAG.)

For all the hype about the factory of the future and advanced manufacturing technologies, most machine shops and factories in America count on older legacy machines to get the job done. Whether it’s the Bridgeport knee mill still being used for quick-turn jobs and repairs, or a heat-treat oven that may have seen the Eisenhower administration, these tried-and-true machines are still dependable. New machines are efficient and come with plenty of new capabilities, but many plant managers take a pragmatic approach to capital equipment: if a machine still runs and still produces quality parts, why spend the money to replace it?  

One process that often sees companies still counting on older machines is gear hobbing. Traditional gear hobbing machines typically had a closed gear train between the main spindle and hob head, meaning that operators need to change the ratio between the two spindles to produce different gears with different numbers of teeth. Operators need to manipulate change gears to obtain the exact ratio needed.

While these traditional machines may be deeply rooted in your shop floor, today’s gear hobbing machines offer benefits that are leaps and bounds beyond the capabilities of this legacy equipment, and as older equipment reaches the end of its useful life, it’s time to consider the fast ROI that new gear hobbing machines can bring.

What is Gear Hobbing?

Gear hobbing is the machining process by which gear teeth are cut into blanks. While gear blanks can be made by a variety of processes including casting, forging, sintering or even 3D printing, precise teeth are cut into the gears on a gear hobber, which uses a cutting tool called a hob. A hob is a cylindrical tool with many teeth designed to cut the precise tooth profile.

Gear teeth can also be precisely shaped by other processes including shaping, power skiving and grinding. Because of the surface finish and precision required for gears to mesh efficiently and quietly, gear hobbing may require additional grinding processes to reach the final part requirements.

New Gear Hobbing Machines vs. Legacy Equipment

Having to manage change gears is one of the most important differences between legacy machines and today’s machines.

“Nowadays, we have high performance, water cooled, direct drives for the work piece spindle, meaning the C axis, and for the hob head. So we have direct driven, high performance drive and we make sure you have the right ratio by means of an electronic gear box,” explained Joerg Lohmann, director of technology and product management at EMAG Koepfer GmbH.

Rather than work with change gears, operators now follow software prompts to program the machine. The software asks for input such as the module, the pressure angle, the number of teeth, the width of the gear, the helix angle, as well as data for the hob, and the machine generates its own CNC program. “It’s very easy to program such a complicated machine, which can have up to 15 axes,” said Lohmann. Typically, CNC programming is a complex task that requires manually typing in G-code commands or using computer aided machining (CAM) software to create a program.

In addition, newer CNC gear hobbing machines offer more functionality than traditional, single-purpose hobbing equipment. According to Lohmann, EMAG machines come with NC-controlled auxiliary tools, including sensors and tools for deburring and skiving. For example, sensor tools can be set up to orient a blank to a feature such as a keyway or a blind hole. EMAG can equip a machine to load a blank using a gantry loader, orient it using the spindle based on the sensor data, then cut the teeth with the correct angular position to the feature.

Extensive Automation

Today’s CNC machine tools, including gear hobbers, can be set up with complete process automation including part loading and unloading for lights-out operation. Lohmann explained the details of EMAG’s automation features for gear hobbing machines, beyond a gantry loader as mentioned above:

“It’s not just the gantry loader, it’s also the workpiece magazine that plays an important role. Gears usually roll by gravity. We offer very simple chute magazines where the workpieces roll down on multiple rows, so up to six rows are possible. And, accordingly, we have a higher autonomy,” he explained.

An automated solution could build on this six-row chute magazine with a distributor that picks up the workpiece and passes it to the gantry loader, which exchanges the blanks with finished parts in the work area. Finished parts would be deposited on a belt and transferred out of the machine. “This is our standard automation,” said Lohmann. “But for other customer workpieces such as a gear or shaft that does not roll, for example, we may even replace our magazines with a robotic cell made by EMAG for full realization of lights-out capability.”

When it comes to the automation possibilities available with the latest gear manufacturing technology, the sky is the limit.

One key difference between a piece of legacy equipment and new equipment is the service and support offered. Legacy equipment may have reached its end of life for service and parts, or the OEM may no longer even be in business. With new technology from OEMs like EMAG or many others, service and support are key differentiators for buyers. It’s wise to choose an OEM that has a business entity or division located in the same region where you plan to operate the machine. The costs of downtime from waiting for a part or service call from overseas can far outweigh any upfront cost savings when the equipment is purchased.

Many OEMs, such as EMAG, offer a package deal that is solution-focused. Before selling a machine to a customer, EMAG can begin with the drawings of the gear parts an engineer needs, then specify the machine, the hobs, the workholding fixtures and the automation cell to provide a complete solution from the design stage, then integrate it professionally on the shop floor. Procuring a unified solution, rather than a machine on its own, helps customers start making parts and accelerate ROI on the machine.

(Image courtesy of EMAG.)

EMAG’s K 160 Long Bed is an example of the functionality gained when investing in the latest gear hobbing machines.

Features:

• Machines shafts up to 1000 mm (39.5 inches) long
• Maximum workpiece weight – for autoloading – is 25 kgs (55 lbs)
• Capable of Hobbing multiple gears on one shaft
• Up to four gear or spline sections with up to three different hobs are possible
• Orientation of the gear to a keyway or pin hole(s) are possible
• Alignment of up to three gears/splines
• Automated loading and unloading

Possible Applications:

• Long shafts for motors and gear boxes of lifting and rigging devices (cranes in manufacturing buildings, freight railway stations and harbors)
• Rotor shafts for E-Mobility applications
• Aerospace shafts with multiple gears and alignment requirements
• Steering pinions for cars and transport vehicles (Hydraulic Power Steering)
• Gears, pinions and worms for fractional horsepower and worm gearboxes

Ready to replace your old hobber? Request a consultation with EMAG.

The post Replacement Options for Legacy Gear Hobbers appeared first on Engineering.com.

The brothers who invented the world’s first compact loader, which later became known across North America as the Bobcat skid-steer loader, have been selected as 2023 inductees for the National Inventors Hall of Fame (NIHF).  

In the 1950s, brothers Cyril and Louis Keller ran a small machine and fabrication shop building and repairing machinery for local farmers in Minnesota. A local farmer came to them with a problem—he needed a self-propelled loader light enough to be lifted to the second floor of a turkey barn and small enough to clean around the barn’s upright poles. In 1957, the Kellers built a three-wheeled loader with two drive wheels in front and a caster wheel in the rear. This was the precursor to the modern skid-steer loader. 

Melroe Manufacturing Co. In Gwinner, N.D. (now Bobcat Co.) took note of the development and invited the Kellers to show their invention in their booth at the Minnesota State Fair in 1958. The brothers later awarded Melroe the exclusive manufacturing rights to the machine on a royalty basis. The company hired the Keller brothers to refine their design and put the machine into production. 

The M440 prototype, invented in 1962. (Image Source: Bobcat Co.)

The second-generation loader—named the M400 and developed in 1960—included a second set of drive wheels added to the back of the machine, making it a true four-wheel drive and becoming the world’s first skid-steer loader. Skid-steer describes the steering system which enables the machine to turn within its own length. Later, it was renamed the Bobcat because of the machine’s toughness, quickness and agility. 

“We are proud of our inventors’ spirit of innovation, and while we remain grounded in our humble roots, we continue to push the boundaries to offer customers increased choice, improved performance and advanced technology to work smarter,” said Mike Ballweber, president, Bobcat Co. North America. 

2023 marks the 50th anniversary of NIHF’s founding, when Thomas Edison was the sole inductee. 

Acknowledging the award on behalf of his father Louis and uncle Cyrill, Joe Keller said, “This recognition is a great honor to dad and Cyril’s families, but it is not just for us. It is a recognition for all of the early and current Bobcat employees who have helped bring our little ‘Keller loader’ to be the Bobcat machine it is today. It has been a great honor to have had a front-row seat watching this invention revolutionize the way work gets done around the world.”  

Now headquartered in West Fargo, N.D., Bobcat Co. has grown to manufacture many pieces of compact equipment, including loaders, excavators, compact tractors, utility products, telehandlers, mowers, attachments, implements, parts, and services.  

Founded in 1973 in partnership with the United States Patent and Trademark Office, the National Inventors Hall of Fame (NIHF) is a U.S. nonprofit organization that recognizes inventors and inventions and provides a national, hands-on educational programming and collegiate competitions focused on the exploration of science, technology, engineering and mathematics.

The post Inventors of Iconic Bobcat tractor Inducted into National Inventors Hall of Fame appeared first on Engineering.com.

The post Use 3D machine simulation to enhance skills, efficiency and quality appeared first on Engineering.com.

Industrial additive manufacturing (AM) technology company EOS has launched a contract manufacturing network to connect end customers with established AM parts producers. 

The network will initially be launched in Europe with seven companies taking part as network partners. Those companies are: FKM, Erpro, Volum-E, Pankl, Materialise, Oerlikon, Hasenauer & Hesser. Eos says the plan is to expand the network globally, with more partners joining over the coming months. 

The new Contract Manufacturing Network builds on EOS’ offerings in its existing partner networks. Companies searching for an additive manufacturing partner to produce their parts, rather than manufacturing in-house, can approach the network for support with projects including rapid prototyping up to small series volumes of 1,000 parts. 

“When outsourcing their AM production to a partner from the contract manufacturing network, small series customers will get the same EOS quality and industry expertise all our customers are used to. Our network partners are also able to act as pilot users for new technology developments at EOS, giving us valuable input and together developing the innovations that will shape the future of [additive manufacturing]” said Markus Glasser, senior vice-president for EMEA at EOS. 

Criteria to become a network partner  

Companies that want to become a partner must be able to serve customers across Europe, the Middle east and Africa (EMEA). They must have a minimum of five EOS systems installed from the latest generation of machines, which are regularly maintained and inspected. EOS offers all the tools needed to ensure remote service as part of a preventive maintenance program. 

Additionally, Contract Manufacturer Network partners must use either EOS or EOS ecosystem powder. 

To ensure high quality standards, the partner must have a proven quality management system that complies with ISO 9001 and meet defined KPIs (key performance indicators) in customer satisfaction, scrap rates, and on-time delivery. 

EOS Contract Manufacturing Network partners will be included in the MakerVerse partner hub, an EOS branded platform on MakerVerse. This expands their reach to potential end-customers while making the ordering process less complicated.

The post EOS launches European partner network appeared first on Engineering.com.

Unless you’re a well-funded startup, chances are you’ve got machines on your factory floor from older generations—maybe even older than the Internet itself. But with global trends towards digitally enhanced manufacturing, companies with these “legacy” assets are asking themselves: do we want to connect these machines to digital platforms? And how do we do it? 

Here are two reasons why companies should, and two ways to go about bringing their machines into the digital world. 

Two Reasons Why 

Extend usefulness of legacy machines

Unlike modern technologies like laptops which are intended to be regularly swapped out for more powerful versions, legacy machines are long-term investments meant to perform for years and even decades. They might be the result of millions in capital expenditures, years of planning, and additional investments in supply chain management, process overhaul, safety protocols and operator training. These machines were built to perform specific functions well and last a long time—and from a business perspective, they can be depreciated over their useful lives. 

As the Internet of Things (IoT) becomes more and more widely adopted, it would be advantageous for companies to be able to use digital platforms to collect more data and improve efficiencies—while getting full value for the significant investments made in their legacy machines. In fact, capturing and interpreting data from these machines could help a company predict and avoid failures, make its operation more efficient and ultimately extend the capabilities and lifetime of the machine. 

Harnessing data to become more competitive

Speaking of data, a digitized factory not only generates data about machine performance—it harnesses data that enables a company to take action on its biggest needs. 

Many manufacturing sites still use a pencil and paper to capture data. Stacks of handwritten notes may often be laboriously transposed into an electronic spreadsheet for analysis. The process takes a lot of time and effort and still results in delayed, inconsistent and error-prone results that can have significant negative effects on business strategic planning. 

Because legacy machines were created to perform a certain function rather than generate data, its operators can spend considerable amounts of time looking for that data. This pulls engineers away from performing higher-value strategic and problem-solving tasks. 

An IoT-enabled factory floor provides continuous, real-time data from many different data sources: a typical production line could have five to 15 machines, often from different vendors with different protocols. This data is filtered, analyzed and reported by dynamic and accurate reporting tools that can perform instant calculations. 

That data could be integrated with business data from other sources such as customer demands, supply chain logistics, traceability data and increasing demand for product customization. Generating data from legacy equipment facilitates a manufacturer to solve existing problems faster—even those problems it hadn’t been able to take care of before—and make its operations more efficient, responsive to the market and profitable. 

In fact, according to McKinsey, companies that adopt digital manufacturing see increases in productivity (three to five percent) and forecasting accuracy (more than 85 percent), while reducing machine downtime (30 to 50 percent), maintenance costs (10 to 40 percent) and time to market (five to 20 percent). 

Two Ways to Do It

Retrofit Legacy Equipment

Also known as a best-of-breed or wrap-and extend-solution, under this approach a business could bring in a third-party vendor to connect legacy machines to a digital platform. Technologies such as IoT platforms, IoT gateways and high-tech sensors could help enhance the productivity of these machines and generate new and valuable data. 

There are definite benefits to this approach. Out-of-the-box connectivity solutions can be installed with minimal down time, and many are created to work with a variety of legacy protocols. IoT-enabled sensors are designed to be easy and quick to install and operate. In addition, the vendor’s system integrators will have the expertise and familiarity with a range of legacy systems to help advise on and implement a solution. 

Also, these solutions are by nature adaptable and customizable. For example, sensors can be tailored to provide targeted information an organization needs most, and IoT gateways can be fine-tuned so that the company only pays for the functionality it needs. In fact, an IoT-enabled retrofit that provides the right kind of data can help inform business decision-making at all levels of the enterprise, not just the operation of the legacy machines themselves. 

There are drawbacks to a third-party retrofit, however. These solutions can be quite data-hungry, requiring additional bandwidth and wireless investments. Edge-based processing, where a device uses analytics to process raw data at the source before sending to an IoT-enabled technology, can mitigate these costs somewhat. Another potential complication is the potential for increased system maintenance costs: a sensor network will require upkeep just as the legacy machines do, and this factor can be multiplied if several third-party vendor systems are deployed. 

In-House Solutions

If a third-party vendor isn’t the right fit, the best approach might be to develop a solution in-house, using the personnel and technical resources that are already in the company to create a solution tailored to the needs of the enterprise. 

One of the benefits of this approach—also one of the most appealing reasons—is that the solution is custom-made to meet the organization’s specific objectives and needs. Internal IT and operations staff would work together to create practical solutions that extract and use the data most crucial for the organization to run. 

Another benefit, particularly to small and medium-sized enterprises, is that the solutions can be created on a small scale first, enabling the company to test out and improve its solutions before rolling them out across production lines and other machines on the shop floor. 

A third advantage is improved installation speed and return on investment: a team can be put together to plan, develop, test and implement the solution while the larger enterprise continues doing business. However, while there may be less down time during implementation, it can take months to get the solution to that point and train employees on new technologies. 

There are, of course, some disadvantages to taking the in-house route. It can be difficult, time-consuming and expensive to find and train the staff on the bespoke system so that they can fully capture, interpret and display the new data it unleashes. The custom-made solution may also require a lot of maintenance to keep it going, and expertise to adapt the system to new and innovative uses—as soon as an IoT solution is proven useful, staff will invariably want to try to do new things with it. 

An in-house solution can ensure that a company is using a system that meets its needs and goals, using resources that the company already has. However, this system could lead to long-term pressures on the system’s operating staff to respond to increasing bug fixes, troubleshooting, testing improvements and maintenance—which could result in more costs down the road. 

Engineering.com’s Jim Anderton discusses how to connect older industrial equipment to the cloud. 

In order to remain in business, companies that use legacy machines—and there are many of them—need to be able to take advantage of the efficiencies of an IoT-connected factory without letting their legacy machine investments go to waste. The good news is, it is often possible to bring those legacy assets into the digital factory floor. 

According to McKinsey, the potential economic value that IoT could bring to the global market ranges from $5.5 trillion to $12.6 trillion by 2030—and a significant chunk of that value, about 26 percent, could originate on the factory floor. What part will your company, and its legacy assets, play in that growth?

The post Connecting Legacy Machines to Digital Platforms—Two Reasons Why and Two Ways How appeared first on Engineering.com.

Based on Siemens Xcelerator business platform, the collaboration shows the potential for optimization as a fundamental part of design and engineering in manufacturing, combining new and traditional technologies to reduce waste and maximize resource use when designing and manufacturing a steering knuckle for Siemens’ eRod electric vehicle. 

NX CAM G-Code driven simulation of the 3D printed steering knuckles (Image Source: Siemens)

The digital thread demonstrated in this collaboration uses technologies from all four companies, starting with Siemens NX to generate the initial design. In this instance, the partners take operating parameters of an electric vehicle and use them for optimal part design, using integrated generative engineering tools like design space exploration.  

A simulation of the topology optimized steering knuckle assembly installed on the eRod (Image Source: Siemens)

The next phase—Process Planning—shows how comprehensive manufacturing plans are developed with Teamcenter and Opcenter software. This helps manufacturers automate programming by applying their own standard CNC programming, inspection path methods, tools and program templates. It also ensures that correct revisions are programmed and measured on the shop floor, creating a single source of data for the entire digital manufacturing process.   

3D printing the steering knuckles on a DMG MORI LASERTEC 30 DUAL SLM (Image Source: Siemens)

The knuckle was then ready for production using Ti6Al4V titanium powder on a DMG MORI LASERTEC 30 DUAL SLM Selective Laser Melting machine. Final tolerances and surface finishing was done with DMG MORI’s DMU 85 monoBLOCK five-axis machining center equipped with the SINUMERIK 840D sl CNC system for a two-step machining process. The machine was equipped with Walter tooling for both the finishing and cut-off operations.  

Machining the 3D printed steering knuckles on a DMG MORI monoBLOCK 85 (Image Source: Siemens)

When evaluating the entire assembly, the design team found that certain components could still be manufactured more efficiently using traditional  processes. Specifically, the spindle lends itself to CNC turning. To make this change, the engineers used Run MyVirtual Machine—the digital twin of the CNC control—to add a TRAK Machine Tools TC820si turning center to the digital manufacturing process. The spindle was virtually programmed in the SINUMERIK ONE control with ShopTurn conversational programming and then validated with the TC820si’s 3D twin. 

The wheel knuckle spindles were a perfect fit for traditional turning operations (Image Source: Siemens)

The post This digital thread uses DFM to combine 3D printing with traditional machining appeared first on Engineering.com.

While craftspeople pride themselves on using traditional methods to create unique items and products, many have seen the benefits of incorporating digital technologies. Unfortunately, much of the time is still spent in the design phase instead of the actual creation. Shaper Tools, a San Francisco-based woodworking and robotics company, recently launched Shaper Studio to help change that.

“Studio is perfect for the traditional woodworker who is familiar with analog making techniques but has no idea where to start with digital design and fabrication,” said Joe Hebenstreit, Shaper Tools CEO in a press release. “It is also a great tool for the modern maker and Etsy crafter who use digital fabrication tools but want to take their designs to the next level.”

Shaper Studio is a 2D design tool that is pared down to the basics, eliminating unnecessary features often found in universal software available that often slow down the process. Like having CAD software accessible from a pocket without having to know CAD, Shaper Studio can be used on smartphones, laptops and tablets. Once the design is complete, it can be exported to Shaper Origin or as a .SVG to other design fabrication tools.

“One of the biggest challenges for craftspeople looking to work with digital tools like a laser cutter, 3D printer or CNC machine, is creating the digital files these tools rely on,” Hebenstreit said. “What may be a simple sketch of an idea with pencil and paper can require hours or days of work to transfer to a sophisticated CAD program.”

With Shaper Studio, users have access to more than 3 million basic designs that can be combined to make unique creations at scale and with real-world units. During the design process, paths can be fine-tuned thanks to the ability to adjust bit diameter and offsets. This allows users to visualize the design and make necessary changes before cutting begins.

For people who already own a Shaper Origin, the first handheld CNC router released in 2018, the company also recently released Shaper Plate, which can be used with Shaper Studio. Shaper Plate is a universal fixture and template designed to make connecting physical pieces and digital designs easier.

Shaper Plate uses Shaper’s Hardware Catalog, which features an array of digital hardware templates, to speed up the process of installing hardware, such as a hinge or door pull. It also features ShaperTape, which eliminates the time spent on installing engravings, corner rounding, etc.

A yearly Shaper Studio subscription is $99. This subscription provides users unlimited access to the millions of pre-made designs, fonts and ShapeShifter tool, which is an intuitive shape combination tool created to speed up the design process. The company offers a 14-day trial of the full subscription. For craftspeople looking for the bare minimum, Studio Lite is available for free. It provides users with basic shapes and limited fonts and pre-made designs. Shaper Plate is available for $375.

The post First Look at Shaper Studio: An Easy, Simplified CAD for Craftspeople appeared first on Engineering.com.