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The bane of modern engineering is complexity. One promise of artificial intelligence and machine learning is helping engineers to use complex tools and harness vast data sets effectively.

As additive manufacturing (AM) moves from prototypes to mass production, manufacturers are setting their sights on the holy grails—the products and processes that will be game-changers. Many game-changers are already in play.

As with any digital transformation process, the devil is in the details, and there are many potential pitfalls that can derail projects.

The U.S. auto industry has been automated for decades. Production of cars and trucks is associated with large, hulking robots fenced off from human employees. Inside those fenced off areas, tasks such as welding are performed. The industry, though, is advancing on the automation front.

The U.S. Department of Defense (DoD) is set to award $10 million in funding this year to the Digital Manufacturing and Design Innovation Institute (DMDII) here, UI Labs CEO Caralynn Nowinski Collens, said this morning. UI Labs is DMDII’s parent organization.

Horizontal machining centers (HMCs) are versatile four-axis and, increasingly, five-axis machine platforms that maximize processing of multi-sided large parts by minimizing part handling.

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It’s a sad fact of practically all metal removal operations that, no matter how sharp the tool or free-machining the material, there are going to be burrs, hanging chads, ragged corners, and other edge quality issues that must be dealt with before calling the workpiece complete.

In my capacity as the Chair of the Council of the Manufacturing USA institute directors, I often get asked about trends in U.S. advanced manufacturing.

Manufacturers who have deployed the digital or smart factory have put down their pencils, found new uses for their clipboards and closed their spreadsheet programs in favor of using real-time data gleaned from condition monitoring of their machinery.