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Demand for machining titanium for aerospace applications won’t abate any time soon. It is driving OEMs and the supply chain in the commercial airplane market to find ways to dramatically increase machining output. Whatever date you pick from now until 2030, there’s a sufficient backlog of commercial airliners for both structural and jet engine applications to keep spindles humming around the clock cutting titanium.

“Metrology and its relationship to manufacturing is rapidly evolving,” Ken Woodbine, president, Wilcox Associates, a brand of Hexagon Metrology (North Kingstown, RI), recently observed. “We are seeing larger quantities and faster speeds of measurement data collection. The next challenge is what to do with all that data.”

To run factories at optimal efficiency, plant managers need to mine real-time shop-floor operational data as fast as possible, to quickly determine where and when any manufacturing process bottlenecks occur. With today’s shop-floor data management software and related hardware solutions, manufacturers can leverage more key production performance data than ever in order to fine-tune their manufacturing processes.

Even though it’s been around since the 1950s, when engineering-grade resins were first introduced, many manufacturers still are not familiar with the many benefits that metal-to-plastic conversion provides.

The latest statistical process control software offers manufacturers easy-to-use and effective real-time process quality control

The classic manufacturing conundrum is how to make products quicker, cheaper, and better.

Today’s products require high finishes, burr-free edges, freedom from contamination, and often close tolerances. Electropolishing provides all of those conditions and more in a matter of seconds for many metal parts. It is a process that has been used for more than a hundred years. It is widely known and the science is widely discussed, but its ability to run job shop lots and high-precision high-volume parts in the same equipment makes it a bit unique.

When you walk into the Redeye On Demand facility in Eden Prairie, MN, you enter into one version of the factory of the future. There you will see a bank of 100 high-end Fortus fused-deposition modeling (FDM) machines from Stratasys that provide the capacity to build real, functional parts with production-grade thermoplastics directly from CAD data.

All fixtures are designed to hold a workpiece in position firmly and accurately during a manufacturing process.

Overall, there are two overriding customer needs: reducing cycle time and machine downtime. They want higher feed rates and depth of cut for greater metal removal.