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It’s been almost two decades since the C5 Corvette hit the streets with its groundbreaking chassis built around hydroformed steel bumper-to-bumper frame rails. The technology gave engineers a chance to create components that were both lighter and stiffer than traditional stamped and welded assemblies.

Additive manufacturing lets companies think “outside the box.” Engineers can now start to look at a part without restrictions on size, shape or material. Instead of taking 15 different CNC milled parts and brazing them together, these companies have reimagined the part entirely—to be built as one part.

“Five years ago, our fit and finish was below average,” said Dr. Raj Kawlra, director of dimensional strategy and management of Chrysler Group (Auburn Hills, MI). “To be the future world-leaders, we knew that we had to focus on all aspects of quality … vehicles that look good, feel good, sound good, and are reliable.”

It’s getting harder to imagine any market that isn’t benefiting from the latest developments in parts manufactured from advanced composites. “Advanced composites will arguably dominate consumer and production products, especially in the near future,” says Bert Erdel, industry consultant and executive technology advisor, Morris Group Inc. (Windsor, CT), “as they have begun to gain wide acceptance in solving energy-related issues.”

The machining challenges for two of the most advanced concepts in cutting tool materials are pretty well known. Cubic boron nitride (CBN) tools of varying designs are being used to cut hardened ferrous metals with or without interrupted cuts, as well as welded and clad metals.

Off-line programming software tools for CMMs allow manufacturers to increase measurement capacity and throughput by programming CMMs, probes, and fixtures before parts are made.

NORTHBROOK, IL, Dec. 19, 2017 – UL, a global safety science company, and Tooling U-SME, a leader in manufacturing workforce and education development, announce the signing of a Letter of Intent (LOI) focused on a new collaboration to enhance workforce training and development efforts for manufacturers wanting to increase their capabilities in additive manufacturing.

Data mining and Big Data are hot topics. Your company develops process mining software; how does it differ from data mining?

Researchers at Penn State University (University Park, PA) have devised a novel method for sintering, a widely used manufacturing process for powdered materials. The new process, which uses much less time and energy than current approaches, could have global implications on manufacturing and energy savings and pave the way for new discoveries.

How do manufacturers love additive manufacturing (AM)? Bianca Lankford, a mechanical engineer at Northrop Grumman, can count the ways: antennas, brackets, clamps, coldplates, ducts, plenums and test fixtures.