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Additive Manufacturing (AM) machines making metal parts have been out there for a dozen years. The machines have improved since the initial offerings and the number of companies that now produce them have increased exponentially. Many companies are now ready to invest in this maturing technology, and there are many more companies with machines that vary in technology and materials. Even the experts in AM are having difficulty keeping track of all of the new offerings.

Researchers from the Georgia Institute of Technology (Atlanta) and two other institutions have developed a new 3D printing method to create objects that can permanently transform into a range of different shapes in response to heat.

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.

In what shouldn’t be too much of a surprise, challenges for advanced grinding technology from high tech industries range from handling the most difficult-to-machine materials for aerospace jet engine turbines to series production on automotive drive train lines.

Tool life, geometry, and stability largely depend on proper edge preparation. Tool Flo, located in Houston, TX, is a manufacturer of carbide cutting tools such as inserts for threading, turning, and milling. The company uses optical 3D measurement systems from Alicona Corp. (Bartlett, IL) in the quality assurance of inserts.

The pace of 3D printing adoption will accelerate, a General Electric Co. executive said during an address at RAPID + TCT today.

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.

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.

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.

Smarter factory systems connected via the cloud are the grand vision offered for the future factories that will fully leverage the best available tools from automation, software and machine tool builders.