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Entrepreneurs and existing manufacturers are making 3D printers that automate production of composite parts, and are unique in their design.

The simple proposition that no two automation solutions using robotics are alike because no two manufacturing processes are identical presented a major challenge to Daniel Drennen of Deshazo LLC (Alabaster, AL).

Daimler may be the first vehicle maker to offer 3D-printed replacement parts, but racing enthusiasts and car collectors like Jay Leno have been using additive manufacturing and 3D scanning for many years to replace worn-out parts or to enhance their rides.

The Fourth Industrial Revolution has begun, and there is wide agreement this revolution will involve cyber-physical systems with human-machine interaction and lots of data. But many still wonder what the revolution is about and what to expect as consumers and manufacturers.

Process improvement encompasses a wide range of tools, techniques and strategies. When properly deployed, shop-floor data collection and monitoring systems can help factory-floor managers leverage key data metrics including overall equipment effectiveness (OEE) and total effective equipment performance (TEEP) that measure machine uptime and pinpoint bottlenecks or other problems in order to improve machining performance.

Machining composites presents unique challenges compared to metals. Reinforcement fibers are abrasive, shortening tool life. The plastic matrix carries away little heat, unlike metal chips, and overheating can melt the matrix.

Taiichi Ohno is often quoted as declaring: “Without a standard, there can be no improvement.” The principles of lean do not work well when everyone is allowed to choose their own work method or work sequence in which to do a job: the outcome is unpredictable; flow and pull are impossible. This reduces throughput and the carefully crafted process develops unanticipated outcomes.

The growing need for nano and micro components in the medical industries is challenging manufacturers to continually improve upon their manufacturing processes and take a scientific approach to injection molding and tooling.

The issues around OEE are not its utility but the ease and credibility of the data used to calculate it

A recent effort by the Norton Advanced Applications Engineering Group demonstrates that for difficult-to-machine materials, grinding can be an economical alternative to other machining processes.