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Heading to Mars? Pack a 3D Printer!

If NASA’s Journey to Mars project succeeds, the astronauts who make the 140 million-mile (225 million-km) trip to the Red Planet in the 2030s will need someplace to stay. The space agency is looking at 3D printing, using on-site materials, to manufacture humanity’s first deep space home.

New Materials Revolutionize Part Manufacturing

New materials for additive manufacturing are used for a diverse range of applications, including 3D paints for making human tissue-like cells; a hardenable stainless steel powder for surgical instruments; and a sustainable composite reinforced with bamboo fibers that resembles wood when printed.

Cryo cooling improves machining of super-hard materials, gummy polymers

If you’re trying to optimize metalcutting speeds, especially in difficult-to-machine materials, “Heat transfer is the name of the game.” That’s the summary offered up by Ranajit Ghosh, manager of applications R&D and growth for Air Products (Allentown, PA). “Most heat from a machining operation exits through the chip, but some transfers to the cutting tool, toolholder, machine spindle and workpiece. Heat buildup in the cutting tool causes thermal softening of the edge, which is why we often have to employ coolant.”

Smart Tools’ Target: Data Analysis, Not Paralysis

The road to manufacturing success today runs through the mountain of data that tools are generating in metalcutting applications, and most importantly communicating and reacting to in real time on the shop floor.

New Automation Makes EDMs Faster, More Efficient

While EDMs offer the benefits of holding tight tolerances, working on nearly any metal, and being well suited for delicate or fragile parts, knowledgeable operators for the machines are increasingly hard to find and robots can’t always fill the gap. Automated processes in the machines, newer designs and features of Industry 4.0 are helping to solve the problem.