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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.

In conventional metal (material) removal processes like milling, turning, drilling, boring, and grinding, the challenge is always to hold the tool securely and rigidly against a fixtured workpiece without interfering with the process.

When GE decided that additive manufacturing was the way to go for making metal fuel nozzles for its new LEAP engine, the company touched off interest in other shops to move 3D printers from the design studio to the factory floor. It also stepped up the focus on safety standards for metal AM.

That huge backlog of aircraft being recorded by the global giants Boeing and Airbus, along with a lengthening list of regional aircraft, is stretching the supply chain’s capabilities to machine the newest difficult-to-machine materials.

To compete in the fast-paced world of manufacturing, machinists look for no-compromise machine controls offering fast, precision programming of machine tools. The latest CNC systems from machine control developers include a new dual-function milling and turning control and several updated controls with embedded software routines that can significantly speed up CNC programming.

High-pressure water can simultaneously clean and deburr a workpiece, and hybrid systems can include mechanical deburring in the process.

Cutting tool developments are a key driving force in manufacturing productivity, accuracy, and quality. At Sandvik Coromant (Fairlawn, NJ) one of the main trends influencing cutting tool design is developing cutting tools for small-part manufacturing, particularly the medical industry, which is seeing a phenomenal growth of 10 – 20% annually.

More than 4,600 cutting tools items from M.A. Ford (Davenport, IA) are listed on MachiningCloud (Camarillo, CA), with more to come. M.A. Ford manufactures standard, high performance and custom cutting tools with worldwide manufacturing and distribution facilities. MachiningCloud is a product data provider for cutting tools, CNC machines and workholding.

Vericut 8.1 includes a new additive manufacturing [AM] module that simulates additive and hybrid machining processes used in any order, and on any brand NC machine. AM has reached a maturity level and has proven to be a valuable addition to manufacturing strategies.

One of the “dirty secrets” of 3D printing is the universal need to take additional steps to render the output usable, including removing the part from its support, curing the part, or improving the surface. Aside from additional cycle time and cost, these steps often require or emit toxic chemicals, necessitating special ventilation and making them unsuitable for a standard office environment. For example, parts built with fused deposition modeling (FDM) must spend about four to eight hours in a heated, agitated sodium hydroxide bath.