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New work materials are developed continually to improve the capabilities of finished parts, making them lighter and stronger, among other properties. When these materials catch on, cutting tools must adapt to their often challenging properties.

The ongoing digital transformation of manufacturing comes baked-in with many uncertainties, and the automotive business is no exception.

Challenged by an increasingly niche-oriented automotive market, The Chrysler Group (Auburn Hills, MI) must increase the number of models it offers while decreasing its capital investment. The company plans to offer 50% more models in 2009 compared to 2004, according to John Felice, VP of manufacturing, technology and global enterprise for Chrysler.

Automation in manufacturing is more important than ever, reducing costs and improving quality. While it is important in assembling cars, machining engines, or drilling holes in airframes, is it important to metrology operations as well? “Absolutely,” explained Michael Kleemann, engineering manager VRSI (Plymouth, MI).

With larger turbine components, compared to automotive and aerospace, plus assembly challenges, new machining technologies are gaining popularity. The conventional milling and broaching techniques in turbine blade machining, with the high tooling costs and abrasive flow issues, are fast fading, as modern assembly methods continue to drive machining tolerances to new heights

Step inside Pride Solutions LLC’s bustling shop floor in Hutchinson, MN, and you’ll see a shiny new CNC lathe turning out tube after tube of aluminum. While Pride’s machinists do more important things, a Universal Robot model UR10 collaborative robot (cobot) does the grunt work, loading and unloading the machine to keep up with high-volume orders.

Although drivers may not know it, cable connections for the airbags and seatbelt buckle systems in their vehicle simply would not work without components manufactured by ODW-Elektrik. A development partner and supplier for high-quality cabling, solenoids and mechatronic systems used in vehicles around the world, ODW-Elektrik supplies most of its products to Bosch, Autoliv, Brose, VW, and ZF.

From cutting various thicknesses of sheet metal and metal plate or different widths of tubing to navigating intricate materials or process issues, some of the laser industry’s leading suppliers have weighed in with tips and insights into their novel solutions.

The Fabricating & Lasers pavilion of IMTS shows how makers of machine tools have to keep improving their product lineup. For one thing, customer expectations continue to rise.

Manufacturers face the ongoing challenges of managing exponential product complexity, staying competitive, and avoiding disruption. For many of them that leads to the notion of digital transformation, but they are not always sure how to get started.