AMT FEB/MAR 2020

FEB MAR 2020

Cable-less Data Collection

U-WAVE resolves measuring process issues!

・ ・ ・ ・

NEW FRONTIERS: SPACE RACE 2.0 TAKES OFF

Receiver Digimatic gage

Up to 99 gages can be connected to 1 receiver

AEROSPACE & DEFENCE Industry 4.0 State Spotlight: Tasmania

After introducing the World-Renowned Absolute System to Digimatic Calipers, Mitutoyo now announces a further major breakthrough in electronic Caliper Design.

The New COOLANT PROOF Caliper achieves an Ultimate Dust/Water/Coolant protection level.

The COOLANT PROOF Caliper can be used in tough workshop conditions where at present only a mechanical Vernier Caliper can be used.

M.T.I. QUALOS PTY. LTD. MELBOURNE 55 Northern Road, West Heidelberg, Vic. 3081.

Phone (03) 9450 1900 Fax (03) 9458 3217 Web: www.mtiqualos.com.au e-mail: sales@mtiqualos.com.au

FEB MAR 2020

NEW FRONTIERS: SPACE RACE 2.0 TAKES OFF

AEROSPACE & DEFENCE Industry 4.0 State Spotlight: Tasmania

WATERJET CUTTING The JEKRAN XM series Waterjet is rich with technology but at the same time extremely user friendly, The X-MW series machines are equipped with many standard features such as built-in material databases, variable soft piercing function for brittle materials, auto garnet delivery system and laser light sheet positioning assistance to name a few.

The powerhouse of the X-MW machine is the German built direct drive pump which outputs 3,800bar / 55,000psi at 100% duty cycle whilst maintaining unrivalled energy savings. These machines are manufactured in Europe and are unbelievably good value.

High Pressure Pump

The heart of the system is the highly advanced German built variable speed direct drive pump, creating up to 3800bar / 55000psi pressure at 100% duty cycle using the standard 0.35mm orifice. The pump boasts a unique filtering system making it suitable for tap water quality saving you money on additional reverse osmosis equipment and maintenance costs.

Bulk Garnet Delivery System

Equipped with a PLC controlled automatic bulk garnet feeding system the machine utilises unique technology which allows you to fill the bulk hopper without stopping the cutting process, combined with a garnet low-level sensor maximum production efficiency is achieved. The hopper capacity is 80L / 180kg.

Available at

www.machineryhouse.com.au Specifications are subject to change without notice.

All prices exclude GST and are valid until 31-03-20

01_AMTIL_010220

QUALITY & PERFORMANCE CNC Control

The CNC controller is a 15” Industrial Touch panel which has been ergonomically designed for users in both standing and sitting positions.

Using large icon based intuitive CNC software, most operators can be well conversant in using the machine with a single day of training.

The CNC and accompanying offline software accept DXF, SVG, HPGL, Vector files as well as G-Code files. Auto nesting of parts can be achieved for material sheet utilisation.

HEADING MADE IN

EUROPE

Energy Efficiency

The variable speed directly driven pumps on the X-MW series distinguish themselves in comparison to intensifier pumps with a much higher degree of power efficiency of up to 30% more efficient than intensifier pumps.

Material Database

The material database makes the machine suitable for any user.

Cutting parameters are all stored in the CNC and loaded accordingly.

This means that correct parameters and cutting configuration is always set and an optimum cut is guaranteed.

Frame / Chassis

The chassis is fully welded to improve strength and rigidity, making the whole composition robust. This is especially important after prolonged cutting times when heat can distort the construction.

X-MW 44 1250 x 1250mm cutting capacity

X-MW 84 2450 x 1250mm cutting capacity

X-MW 105 3050 x 1550mm cutting capacity

X-MW 107 3050 x 2150mm cutting capacity

X-MW 125 3650 x 1550mm cutting capacity

$129,850 ex GST

$135,000 ex GST

$142,750 ex GST

POA

$153,000 ex GST

NSW

(02) 9890 9111

1/2 Windsor Rd, Northmead

QLD

(07) 3715 2200

625 Boundary Rd, Coopers Plains

VIC

(03) 9212 4422

4 Abbotts Rd, Dandenong

WA

(08) 9373 9999

11 Valentine St, Kewdale 01_AMTIL_010220

The world’s most reliable sheet metal machinery since 1916

PUNCHING MACHINES Part Picking

MURATEC WAS THE FIRST COMPANY TO INVENT THE HIGH SPEED SERVO ELECTRIC RAM

 FG2512T

 MOTORUM M3048 TG

PRESSBRAKES BB SERIES: FULL ELECTRIC, 1.3 – 2m, 40-60 TON BH SERIES: HYBRID ELECTRIC / HYDRAULIC, 2.5-4m, 85-250 TON

 BH13530 Videre Projection System Model: BH13530

Australia New Zealand SYDNEY MELBOURNE AUCKLAND

Phone: +61 2 8012 9602 Phone: +61 9 532 9344

www.amtronics.com.au www.amtronics.co.nz

80 years of system innovation that increases production and peace of mind. That’s reliability by design.

Made in Japan

FIBRE LASERS HIGH ACCURACY FIBER LASER WITH DEDICATED FRAME DESIGN FOR HIGH SPEED

Automation

ď ž FG3015TL

ď ž FIBER LASER LS3015GC

m ac hi n

e

CAD/CAM that speaks your language MBend

MRobot

Offline 3D Bending

Simulating & Programming Robotic Bending Cells

TM

Fully Integrated Manufacturing Solutions from per month*

Autonest Seemless Multi Part Multi Sheet Nesting

Cnckad 2D CAD/CAM

Mtube Ultimate Tube Design

$150

*Terms & Conditions Apply

Punchtech Australia (Pty) Ltd Phone: +61 3 9768 3745 www.punchtech.com.au Subscriptions Available. Call Punchtech for sales, training and support.

008

CONTENTS

Volume 20 Number 01 DEC/JAN 2020 ISSN 1832-6080

FEATURES AEROSPACE & DEFENCE New frontiers for Australian manufacturers Corrosion consequences on the high seas A path to certification: AM & aerospace Why SMEs are crucial to the defence sector’s future Australia set to build its first research submarine Metal 3D-printed suppressors for military, police

44 50 52 55 56 58

ADDITIVE MANUFACTURING AM Hub – Lessons from Germany Selective laser melting for aerospace Thermwood introduces new LSAM model AM in acoustic research and new development US researchers: record-throughput 3D printer New AM technique produces ‘living’ 4D materials

60 62 64 66 68 69

INDUSTRY 4.0 Triangle gains in smaller footprint with Balluff The promise of Industry 4.0 in Oz manufacturing Industry 4.0: A revolution from edge-to-edge High IQ tools optimise metalworking for digital MATERIAL REMOVAL

72 74 76 77

Automatic tool changing maximises spindle Benefits of automating material removal The key to Plastool’s success Precision packed into a small footprint

81 82 83 84

CUTTING TOOLS Reducing tool costs – Solutions for automotive Sutton Tools: Key trends in automotive & aero Unique products to meet rail demands

86 88 90

QUALITY & INSPECTION Quality revolution for busbar manufacturer

92

FORMING & FABRICATION Applied/Yawei partnership at KNS Metals

94

STATE SPOTLIGHT – TASMANIA Maltec Engineering – Chasing other fish Wider application of Segnut technology

100 101

ADVANCED MATERIALS & COMPOSITES IMCRC: commercialising zeolite process Potential new composite applications New robot to detect carbon fibre defects 1

102 102 03

SOFTWARE Rubrik cloud expansion drives Dunlop productivity Nearly 90% of Australian companies set sights on AI RoboHelix revolutionises auger flight Australia’s digital competitiveness is slipping

104 105 106 107

New Frontiers: Space Race 2.0 takes off While aviation remains rich with potential for Australian manufacturers, a growing number are setting their sights on the fast-evolving space sector.

60 Additive Manufacturing Hub – Lessons from Germany Last November, the AM Hub and AMTIL led an Australian delegation on a tour of manufacturing sites in Germany utilising additive manufacturing.

78 One-on-One

REGULARS From the Editor From the CEO From the Ministry From the Industry From the Union

10 12 14 16 18

INDUSTRY NEWS – Current news from the Industry

20

VOICEBOX Opinions from across the manufacturing industry

30

PRODUCT NEW – New and interesting products

36

ONE ON ONE Dr Christopher Hegarty CEO of the ANCA Group

78

COMPANY FOCUS Ignite Digi – Combining artistry with engineering

44

Dr Christopher Hegarty has been CEO of the ANCA Group since July 2018. He spoke to AMT.

96

96

AMTIL FORUMS

108

Ignite Digi – Combining artistry with engineering

AMTIL INSIDE – The latest news from AMTIL

112

MANUFACTURING HISTORY – A look back in time

118

Tasmanian company Ignite Digi designs and manufactures camera accessories for clients such as Apple, Sony, Uber and Tesla.

AMT FEB/MAR 2020

HEADING

GENOS M460V-5AX

5-Axis Machining Powerhouse ROBUST PERFORMANCE SMALL FOOTPRINT The next generation GENOS M460V-5AX, 5-axis vertical machining centre made in Japan, is specifically designed to manufacture high precision parts and deliver impressive metal removal rates in a compact design. Its solid double-column structure, full 5-axis simultaneous control and thermal stability performance give it the ability to easily cut a variety of materials.

Using a hypoid gear drive, the GENOS M460V-5AX features trunnion construction that offers exceptional accuracy, rigidity and table rotation speed.

HIGH POWER INTEGRAL MOTOR The spindle produces less vibration and power loss at the tool tip for outstanding surface finishes and metal removal rates.

This affordable, 5-axis machine, provides high productivity and profitability in a small footprint.

MODEL Travels (X-Y-Z) Table Spindle Speed Tool Storage Floor Space

GENOS M460V-5AX 762 x 460 x 460 mm ø400 mm 15,000 min-1 48 tools 2160 x 2810 mm

010

FROM THE EDITOR WILLIAM POOLE

Beyond business as usual It’s an occasional tradition for the first AMT of each year to start this column by wishing all readers a Happy New Year, and then to immediately acknowledge it’s a bit late since a whole month of 2020 has passed when this magazine comes out. February already. Where’s the year gone?

And a new decade as well. Where’s the century gone, for that matter?

Still, it’s never too late to pause and reflect, to contemplate the course we’re on.

So, as we race into the third decade of this still seemingly new millennium, where is manufacturing going?

New research by Western Sydney University (WSU) and the University of Newcastle has sought to address that question. Funded by the Australian Research Council, the Reconfiguring the Enterprise: Shifting Manufacturing Culture in Australia report identifies examples of a sustainable culture of manufacturing in Australia. It examines what kind of future exists for Australian manufacturing and how it can address challenges such as inequality, social exclusion and environmental degradation.

The findings are the result of three years of in-depth research with 10 manufacturers who are committed to responsible manufacturing of products including fabricated metal, furniture, mattresses and mattress recycling, carpet tiles, electronics repair and refurbishment, fashion, packaging, and food products. Companies that participated included the likes of Varley Group, Norco and AH Beard.

According to lead researcher - Professor Katherine Gibson - manufacturing in Australia must move ‘beyond business as usual’ to overcome current and future challenges. She said: “Our research has found convincing evidence that a successful future is possible for Australian manufacturing when shaped by a culture that maintains a firm’s viability while providing decent jobs in an inclusive society, and producing with a smaller ecological footprint. This manufacturing culture is making a vital contribution to Australia, but it is not well-known or publicly visible. Policy must change to strengthen and support this just and sustainable approach.”

The report recommends a number of policy changes aimed at safeguarding the manufacturing sector’s future, including: • Increase the profile of just, sustainable manufacturers through education and certification programs.

• Provide employment opportunities for people from diverse backgrounds through the development of partnerships with social enterprises and organisations who support them.

• Encourage the creation of high-quality, durable and environmentally-responsible products through customer education and the development of guidelines, standards and full cost accounting methods for product design and production.

• Undertake research & development into technologies for waste recycling or reuse, and incorporate new technologies to facilitate the tracking of products throughout their lifecycle.

• Develop incentives for voluntary and industry-led stewardship schemes and introduce levies on products to cover the cost of responsible waste management at end of life.

Professor Gibson added that it is more important than ever to support manufacturers with commitment, integrity, problem-solving capabilities and future orientation: “Australian manufacturing is at a crossroads and many question its relevance to the economy, but our research with innovative manufacturing firms shows that a positive change is already underway, and that Australian manufacturing can adapt to, and be successful in, the 21st century.”

By February, most of us have already abandoned some – if not all – of our New Year’s resolutions. But there’s never a wrong time to make a few more.

YOUR INDUSTRY. YOUR MAGAZINE.

AUSTRALIAN MANUFACTURING TECHNOLOGY

Editor William Poole wpoole@amtil.com.au Contributors Dee Rudebeck Sales Manager Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed in Australia using FSC® mix of paper from responsible sources FSC® C007821 Contact Details AMT Magazine AMTIL Suite 1, 673 Boronia Rd Wantirna VIC 3152 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright © Australian Manufacturing Technology (AMT).

All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher.

Contained specifications and claims are those supplied by the manufacturer (contributor)

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes.

AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published bi-monthly.

Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $175 (ex GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

1484AMTFEB/MAR2020

AMT FEB/MAR 2020

TAILORED SOLUTIONS DELIVERS TOTAL CUSTOMER SATISFACTION. For over 30 years, DDM Laser has been offering high-quality laser cutting systems. We provide customer tailored solutions to suit individual requirements. Our factory-trained service technicians are skilled in both Fiber and CO2 laser systems. Manufactured in Europe to the most stringent procedures, TCI Cutting are unequalled in value for money. Talk to us about our preventative maintenance programs, breakdown interventions and whole machine repairs and refurbishments.

LASER CUTTING • CONSUMABLES • SOFTWARE

AUSTRALIA’S NUMBER 1

SUPPLIER

SMARTLINE FIBER

1.0 kW – 10.0 kW ; 3.0 x 1.5 / 4.0 x 2.0 Smartline Fiber, unbeatable productivity with excellent cutting quality.

31-33 SULLIVAN STREET MOORABBIN, VICTORIA 3189 AUSTRALIA T: +61 3 9555 5525 • E: sales@ddmlaser.com.au www.ddmlaser.com.au

HIGH-QUALITY AFTERMARKET CONSUMABLES & SPARE PARTS AMADA • TRUMPF • PRIMA POWER • LVD • BYSTRONIC • MAZAK • MITSUBISHI • RAYTOOLS plus more…

DDM•AMTDECJAN20

E: sales@laserconsumables.com.au • www.laserconsumables.com.au

012

FROM THE CEO SHANE INFANTI – Chief Executive Officer AMTIL

Rail & Haulage Hub to drive export activity AMTIL has established an Export Hub in partnership with AusIndustry (through the Federal Government’s SME Export Hubs Grant Program) to help local companies in the rail and road, passenger and freight supply chains find new customers and new export markets. The AMTIL Export Hub will help local manufacturers build their export capabilities, discover export opportunities and showcase their products, technologies and services to international audiences.

The AMTIL Export Hub is a vibrant community of SMEs in the Australian rail, road passenger and freight supply chain (encompassing trams, trains, trucks and buses). The Export Hub will enable participating small and medium enterprises (SMEs) to collaborate on projects and address specific supply chain gaps identified by OEMs and work together to lift the capability and performance of their businesses and provide a path to global markets.

The Export Hub will enable SMEs to: • Collaborate to leverage individual business strengths, assets and resources.

• Share resources that an individual SME cannot access alone.

• Improve local supply chain capability and competitiveness.

• Develop new technologies and service offerings.

• Leverage collective strengths and capabilities in supplying to a low-volume, high-quality, customised vehicle design and assembly customer base.

• Work with Australia’s research & development community on industry innovation.

Export Capability Audit Each Export Hub Participant will be required to undertake an export readiness audit. This audit may be a self-assessment audit through Austrade, an Entrepreneurs’ Programme audit or an Export Capability Audit through partners such as the Export Council of Australia. The outcome of the audit will be to assess the participant’s export capability level and identify improvements required for them to collaborate with consortia members and become export-ready.

Export-ready improvement Each participant will be provided with a personalised assessment and a tailored approach to building capacity and capability through training, facilitation, and engagement with other group members.

The Export Hub will engage specialist providers of consortia development services for each participant. These programs will help participants develop the knowledge, capability and capacity to successfully collaborate and export their products and services.

Participant Export Plan Each participant will engage in a process to deliver a Participant Export Plan. This will contain a tailored approach including product strategy, foreign marketplace analysis, entry strategies, international law, financial analysis, risk management, external assistance requirements and implementation schedules.

Export hub activity Each participant will be invited to join Hub and consortia activities including facilitated member meetings, networking and engagement events, planned workshops, one on one mentoring sessions, plant visits, business breakfasts and progress reviews.

Trade missions Trade mission activity is dependent on the outcomes from the export research phase and the specific participant opportunities identified in their individual export plan. However, initial plans include

AMT FEB/MAR 2020

a rail- and urban transport-focused trade mission to InnoTrans, the world’s largest trade fair focused on the rail transport industry, in Berlin, Germany, in September 2020.

Marketing/collateral Each participant will have access to AMTIL’s marketing, communications and graphic design team to develop material that will assist in the promotion and marketing of the participants in export activities. In addition, “team approach” marketing material will also be developed to showcase the capabilities of the consortia as an entity.

Participant contribution Each participating SME will be asked for a contribution of $20,000 per financial year (pro-rata), to cover Export Hub activities.

Benefits of Export Hub participation include: • Export readiness audit.

• Subsidised business improvement training, consortia and export plan development and mentoring by specialist providers.

• Journey to export – Export Hub networking events and seminars.

• Market opportunity study – conducted by Austrade (or equivalent) for participant’s priority market.

• Subsidised trade mission and business matching at relevant trade shows.

• Development of marketing collateral for Export Hub consortia.

• Access to advice regarding export grants, Export Finance Australia, market entry strategies.

If your company is interested in participating in the Export Hub program or would like further information, please contact Phil Bourke, Export Hub Manager, at pbourke@amtil.com.au or on 0411 773 243.

The Australian Manufacturing Technology Institute Limited (AMTIL) is a not-for-profit national industry association, based in Melbourne, which represents the interests of manufacturing technology suppliers and users within the precision engineering and advanced manufacturing sector. www.amtil.com.au

Cable-less Data Collection

Promotes Smart Factory by Collecting and Managing Measurement Data Advantages of Introducing U-WAVE Centralized Data Management

Higher Efficiency Data can be input by single button operation! Since there is no need for manual input misinput does not occur.

Efficiency is greatly improved!

Cost Reduction Effect

Measurement data can be managed centrally! “Visualization of quality” helps prevent the generation of defective products!

Easily connected to the Digimatic gage* currently in use! A system configuration reducing the initial and running cost is possible. * Some models of U-WAVE-TM/TC are not applicable.

U-WAVE resolves measuring process issues!

Up to 99 gages can be connected to 1 receiver

・ ・ ・ ・

Receiver Digimatic gage

M.T.I. Qualos Pty Ltd 55 Northern Road, West Heidelberg VIC 3081 Ph: 03 9450 1900 sales@mtiqualos.com.au www.mtiqualos.com.au

014

FROM THE MINISTRY THE HON KAREN ANDREWS MP – Minister for Industry, Science and Technology

Delivering ongoing support to our automotive industry One of the most significant changes to the Australian manufacturing sector in recent times has been the end of passenger vehicle production. But the closure of the Ford, GM Holden and Toyota manufacturing plants in 2016 and 2017 did not bring an end to our automotive industry – far from it.

Australia still has a thriving auto component manufacturing sector and we punch above our weight in global vehicle design. Ford, Holden and Toyota continue to maintain a strong presence in Australia, providing employment opportunities in engineering, research & development, design, sales, marketing and corporate roles.

Australia’s motor vehicle and part manufacturing sector is worth more than $4bn a year and employs 38,000 people.

Exports of parts and accessories for motor vehicles is at a 15-year high, worth more than $930m annually as at October 2019.

Prime Minister Scott Morrison’s Government has strongly backed the sector during its transition and is continuing to do so. We have a strong set of policies and programs to encourage all manufacturers to embrace new technologies, especially in cases of industry transition.

Government support includes the $4.5m Automotive Innovation Lab Access Grants (AILAG) program. Applications are open now for the second round of this program and close on 24 February. Businesses across Australia can receive up to $200,000 in matched funding for eligible project costs. These include design, prototype and testing activities at established commercial and research facilities and Automotive Innovation Labs.

This helps businesses advance their technical capabilities and get products to market sooner, enabling them to grow and create new jobs. In such a fast-paced global market, it only takes a small innovation from an Australian business to generate a huge opportunity in international supply chains.

Skilled automotive engineers are in demand and we are helping to train them.

Grants totalling almost $5m are supporting more than 100 post-graduate engineers in industry engineering projects. This is through the Automotive Engineering Graduate Program, a competitive and merit-based program delivering grants to tertiary institutions from Victoria, Western Australia and Queensland. The program will develop job-ready graduate engineers with skills and experience that match automotive industry requirements.

And with Government assistance, the Australian Automotive Aftermarket Association (AAAA) recently opened the

AMT FEB/MAR 2020

Victorian Innovation Lab (Auto Innovation Centre). It is part-funded through a $3m Government grant. The Auto Innovation Centre is a cutting-edge facility that will increase the capability of companies and support new product development for local and export markets. It will use the latest technology and equipment to provide data and testing services. This includes 3D scanning to obtain vehicle data, 3D printing, and state-of-the-art robotic equipment for vehicle testing. This will boost our industry capability to manufacture products for global markets that comply with local and international standards.

Both the AILAG program and Government grant support to the Auto Innovation Centre are part of the $10m Automotive Innovation Labs initiative, which along with the graduate program, are key components of the Government’s $100m Advanced Manufacturing Fund.

Creating jobs and helping provide opportunities for workers who have lost their jobs is a priority for the Government.

The recently launched Skills Match tool, hosted on Job Outlook, helps jobseekers, including those in the automotive industry, to identify skills that are transferable to other industries and careers.

As detailed in the recent Transition of the Australian Car Manufacturing Sector: Outcomes & Best Practice Summary Report, more than 80% of workers retrenched when passenger vehicle production ceased, are now back in employment. The Australian Government, with Victorian and South Australian Governments, worked closely with the major car companies to provide assistance to workers and supply chain firms during

the transition. We have ensured support for many businesses in the supply chain affected by passenger vehicle production closures and helped many to diversify and pursue new advanced manufacturing opportunities. A separate report, by my department, The Australian Automotive Industry – Transition following the end of Australian motor vehicle production, has found that about 75% of supply chain companies remain in business following the closure of car manufacturing plants.

Locally owned businesses that made early efforts to draw on existing skills to diversify achieved the best results when looking to enter new export markets, and this increased their sales and created jobs.

The most success was seen when supply chain businesses diversified into similar sectors such as truck and bus manufacturing; however, we also saw diversification into newer sectors such medical technologies.

Electric vehicles also offer significant opportunities for businesses to participate in global supply chains.

Australia also has strengths in emerging areas such as critical minerals and hydrogen, lightweight components, battery recharging and cooling, and autonomous vehicle technologies. The Government’s National Electric Vehicle Strategy, due to be released this year, will have more to say about this.

The Morrison Government will continue to strongly support our automotive and advanced manufacturing sectors in our ongoing efforts to strengthen our industries, boost export opportunities and create jobs for Australians.

Materials Services

Reducing material cost through waterjet technology

Waterjet technology Waterjet cutting is a process of precision cutting that utilises high pressure water.

We can process a wide array of materials. Heavy gauge plate, thin sheet stock and composite materials (i.e. carbon fibre, phenolics etc.).

It is not uncommon for 6+ inch aluminium and titanium to be cut on waterjets to near final shapes.

Edge quality of the parts can vary depending on customer requirements.

We can process anything from a very rough cut for hog-outs, to a very fine edge for precision, finished parts:

Cut up to 6 m x 3 m (20 ft x 10 ft) Thickness up to 254 mm (10 in)

Improved yield and less waste material Supplied close to net shape reducing customer machine time Shorter lead times Zero heat effected zone Processing of customer supplied materials

Contact thyssenkrupp Materials Australia Pty Ltd Unit 2, 7−10 Denoci Close Wetherill Park, NSW 2164, Australia

T: +61 2 9757 7777 F: +61 2 9757 7700 sales.tkmaterials.au@thyssenkrupp.com www.thyssenkrupp-materials-australia.com

016

FROM THE INDUSTRY INNES WILLOX – Chief Executive Australian Industry Group

Shining a light on mental health in the workplace Among the variety of concerns raised by Australia’s devastating bushfires, the mental health of the families who have suffered directly and of the firefighters and others involved in responding has received considerable attention.

In part this reflects the greater openness about mental health issues across the community, and greater recognition of the need to build understanding and awareness of how mental health issues can be managed. As part of this society-wide change, employers are increasingly recognising that mental health issues cannot be ignored and while their origin is more often than not from factors outside work, they frequently manifest themselves inside workplaces.

• A clear business case for mental health support.

In looking at the Productivity Commission’s 2019 Inquiry into Mental Health it was clear to me that there was little research on the experience of Australian workplaces in dealing with mental health issues. What was needed was a deep-dive, not just into theoretical factors at play with mental health and work, but in what was actually happening on the ground in real workplaces.

Almost universally, stigma was cited as the greatest barrier to engaging with mental health initiatives within organisations. This strongly correlates with other studies on mental health.

Ai Group commissioned Griffith University to undertake this research to help fill that void. In particular we wanted to shine a light on the reasons some local workplaces have taken initiatives on mental health, the nature of those initiatives, the barriers they encounter along the way and the results they see.

• A lack of engagement by individual employees or groups of employees with the organisation and/or mental health activities.

The study reveals a very human core to the efforts of these organisations to grapple with difficult issues, quite apart from the benefits in terms of productivity, absenteeism and staff turnover. The findings will be valuable for employers who want some guidance on what they might be doing, and as a benchmark for businesses who already have mental health initiatives in place.

The first part of the study consisted of searching current academic research for evidence of what workplaces are doing about mental health. This review revealed a focus to date on establishing mental health as a workplace issue.

The second component of the research involved six case studies of organisations from various industry sectors, including large and small businesses, all of whom had indicated they had taken some initiatives on mental health. The case studies were drawn from interviews with management in these businesses to identify the triggers for them taking action on mental health issues, the scope of initiatives undertaken, the results, any barriers to doing more and plans for further action.

One of the key findings of the research was that there are a wide range of initiatives being undertaken by the studied businesses, with each implementing an average of seven separate initiatives. The most common initiatives included: • Employee Assistance Programs (EAPs).

• Mental health awareness day (for example, RUOK? Day).

• Organisational-wide meetings that included discussion of mental health issues.

Factors that facilitated the introduction of employee mental health initiatives included: • The personal commitment of an organisational leader to improving the organisation’s response to mental health.

This can stem from direct or indirect personal experience with mental health challenges.

AMT FEB/MAR 2020

Image by Gerd Altmann from Pixabay.

• Mental health first-aid training.

• An organisational culture that is aligned with or fits mental health activities.

• Activities to develop leaders who know their people and so can identify any mental health issues that develop.

• A budget for activities to address employee mental health.

Beyond this, other barriers organisations encountered included: • Managerial reluctance in dealing with employee mental health issues.

• Understanding how to access mental health assistance beyond an EAP. • A lack of internal capability and knowledge on mental health.

• Within diverse workforces, differing cultural attitudes to talking about mental health.

A significant – but hardly surprising – finding was that some regionally-based businesses reported that mental health issues in their workplaces were driven by social issues such as high unemployment and substance abuse in the surrounding community.

In fact, there was strong feeling among all the businesses studied that many of the mental health issues were generated externally to the workplace, either by community or individual factors. However, managers also understood that internal factors can cause or exacerbate mental health conditions.

Finally, businesses indicated a clear preference to improve their capability to understand and assist with mental health issues, particularly by raising awareness and reducing stigma. The larger organisations are looking at taking a strategic approach to mental health rather than implementing discrete initiatives. They are also keen to know how to better measure outcomes.

The managers reported they are conscious of the organisational context surrounding their efforts. There is no one-size-fits-all approach to supporting mental health in workplaces that emerges from this research. The managers reported intensively individual experiences in pursuing their initiatives, depending on the culture of the workplace, attitudes and background of management and the employees and, as mentioned, even the local community.

There is clearly increasing awareness and interest within Australian workplaces of mental health issues.

As well as helping companies benchmark against the experience of their peers, this report will also inform the growing debate of what policy action is appropriate and help ensure policymakers understand the extent, quality and complex context of the actions businesses are already taking.

Think Laser. Think Industrial Laser.

Full range of lasers, systems and automation for OEM’s and end users

21 YEARS OF TRUSTED INDUSTRY EXPERIENCE P Series 3kW Fiber laser – twin 3m x 1.5m table

$225,000 + GST installed BEST PRODUCT RANGE • BEST PERFORMANCE • BEST PRICES BEST SERVICE • BEST SOLUTIONS EXCLUSIVE AUSTRALIAN AGENT

Agents for: IPG, Precitec, Cincinnati, Sisma, Bodor, Ophir, Primes Cutting • Welding • Marking • Cladding • Laser Metal Fusion • 3D • Scientific • Military Laser spares & consumables

For more information contact Richard at Industrial Laser on +61 (0)3 9796 3055.

E: sales@industriallaser.com.au • www.industriallaser.com.au

AMTFEBMAR20

Demonstration Centre: Unit 20, 17-23 Keppel Drive, Hallam, Victoria Service Centre: Unit 8, 17-23 Keppel Drive, Hallam, Victoria

018

FROM THE UNION PAUL BASTIAN – National Secretary Australian Manufacturing Workers Union

Superannuation – Time to raise contributions The best time to increase superannuation contributions was in 1996, when they were stopped by then-Prime Minister John Howard. The second-best time was in 2014 when Tony Abbott delayed future superannuation increases. The third-best time to increase superannuation contributions is right now.

That decision by Howard cost the average Australian worker $250,000 in accumulated superannuation contributions over their working lives, the delay by Abbott cost them $100,000. The wavering from our current Prime Minister Scott Morrison about future increases to superannuation could have a disastrous effect on the retirement incomes for Australian workers.

In 2018, public policy thinktank the Grattan Institute released a report Money in Retirement: More Than Enough, which argued against a proposed increase in superannuation. They claim that a one percentage point increase in the superannuation contribution rate would lead to a one percentage point reduction in nominal wage growth. These arguments about the wage-suppressing impact of superannuation contributions have been made by employers since superannuation was first inserted into Award back in the 1970s.

Luckily, the McKell Institute had a look at the evidence, looking at the times at which superannuation contributions went up and the impact on wage growth. They find no evidence to support the constant claims that superannuation increases harm wage growth. This is exactly what effective wage theory would suggest: that an increase in wages above equilibrium would ultimately increase labour productivity. Then, as businesses enjoy the benefits of increased productivity, they are able to absorb parts of the increases in labour costs.

Given how little of the productivity improvements in recent years has gone back to workers, rather than to shareholders, locking in increased superannuation contributions is one of the few ways that workers will be able to enjoy the fruits of their (increasingly efficient) labour.

The Grattan Institute further argued that increasing the superannuation guarantee (SG) to 12% would cost the average worker $30,000 over their lifetime and lower their pension payments in the future.

As a result, this scheme would only be benefitting the rich yet would make middleincome earners poorer.

This has been criticised by Industry Super Australia deputy chief executive Matthew Linden, who said it is incorrect to imply that the rises will penetrate evenly across the workforce. He estimated that only 57% of

AMT FEB/MAR 2020

workers would be likely to receive a direct increase in their contributions when the mandatory rate increases. In reality, those that sit at either end of the spectrum – i.e. those who are currently paying above the minimum superannuation contribution level or those whose employers are currently (illegally) paying less than 9.5% – will mostly not be affected by the changes.

The recent formation of a Retirement Income Review by the Treasurer provides an opportunity for an in-depth look at the entire retirement income system and the important role that superannuation plays in it. That is why we’re concerned with the appointment of review members who are on the public record opposing the universal nature of superannuation.

Linden also pointed out the fact that about two million people are already enjoying superannuation contributions above 12%. These include public servants and academics whose super contribution rate is as high as 15.4% and 17% respectively. Among those two million workers are our federal politicians, who already benefit from increased contributions, while actively working to prevent working men and women in Australia from enjoying the same benefits.

Dr Deborah Ralston, who was until recently the chair of the Self Managed Super Fund Association, has called for superannuation to be voluntary for low-income workers.

This change would fundamentally alter the nature of superannuation as a guaranteed workplace right and a universal retirement savings scheme into a wealth management and tax avoidance scheme for the wealthy.

There is a real risk that further delays will damage Australia’s world-leading superannuation system. Even the former Premier of Victoria Jeff Kennett, not someone with a great track record for standing up for workers, supports the increase in superannuation contribution.

He noted that changing demographics and an aging population will make it harder for the federal budget to provide the quality of retirement that working Australians deserve in the future.

The changes suggested by Dr Ralston would mean low-paid workers will pay higher taxes and be left with less money in retirement.

Superannuation is one of the key pillars to Australia’s retirement system. It was set up to ensure that all working people in Australia, regardless of their income, could enjoy dignity in retirement. An increase in the mandatory superannuation contribution to 12% for all Australian workers will enable more workers to enjoy a comfortable retirement.

Combi Genius CG Complete flexibility within one machine

LASER CUTTING, PUNCHING, MARKING, FORMING, TAPPING IN ONE MACHINE! CNC programmable SERVO-ELECTRIC axes, including the ram axis Lowest overall power usage available on the market Very large tooling capacity, up to 384 tools in the turret in one setup Small footprint even with automation options Capable of up to 1000 hits per minute with up to 30t of punching force Prima Power CF solid state diode laser, 3kW or 4kW Capable of punching and cutting up to 8mm mild steel 3 table sizes available ( 2500mm x 1250mm, 3000mm x 1500mm or 4000mm x 1500mm )

TECHICNAL EXCELLENCE INNOVATIVE PRODUCTS

IMTS Machinery www.imts.com.au +61 9314 9888 sales@imts.com.au

020

INDUSTRY NEWS

Auto Innovation Centre opens to serve the automotive industry The Australian Automotive Aftermarket Association (AAAA) opens the Melbourne-based Auto Innovation Centre (AIC).

The establishment of two Auto Innovation Centres, in Victoria and South Australia, has been a highly anticipated addition to support automotive parts manufacturing in Australia. The state-of-the-art facility in Mulgrave, south-east Melbourne, will assist Australian manufacturers in continuing to develop their world-class products.

On 12 December, Senator Rex Patrick cut the ribbon to open the AIC facility in front of around 200 industry representatives, sponsors, dignitaries and media. Senator Patrick spoke to the assembled audience on the importance of a facility like the AIC, which will support the Australian automotive and manufacturing sector and the aftermarket companies contributing in a meaningful way to the Australian economy.

Joining the Senator in welcoming those in attendance and speaking of the vision of the AIC was Luke Truskinger, AIC Managing Director, and Stuart Charity, CEO of the AAAA. “The Auto Innovation Centre was the fruition of over five years work by the Australian Automotive Aftermarket Association and

was modelled on the SEMA Garage in the US,” said Charity. “With thanks to both the Federal and Victorian Governments, their investment has assisted in bringing this incredible facility to reality, and now it is up and running it will enable the industry to utilise the technologies, services and training and development opportunities for their direct benefit.”

The AIC offers a mix of key services to the automotive industry. State-of-the-art robotic equipment is already delivering premium vehicle testing services for product manufacturers, including Sine-withDwell testing (ADR35/88) to validate ESC performance, as well as brake performance testing (ADR31/35).

With access to key new target vehicles, the AIC will obtain important vehicle data, use 3D scanning to assist aftermarket companies’ product development, and allow developers to get ‘hands on’ with these vehicles. The advanced workshop equipment and technology will be accessible to the industry, and this includes the AIC’s investment into additive manufacturing

through 3D printing equipment and training modules.

The Centre of Excellence will be a hub for automotive training and education, playing a key role in inspiring the next generation of automotive industry workers. There are multiple meeting and training rooms open to industry to book and utilise within the facility, with a dedicated 100-person capacity training room overlooking the AIC workshop space. The AIC offers the perfect venue to ensure industry personnel can maximise their potential.

“This is a fantastic new facility for the industry, so we welcome companies contacting us to discuss how the centre can directly assist their business,” said Truskinger.

Research finds Australians prefer Australian Made Consumer research from Roy Morgan shows Australians prefer Australian Made products across a wide range of products categories.

The research found that 80% of Australians have a preference for Australian Made food & beverages; 77% for Australian Made agricultural and gardening products; 73% for children and baby care products; while 72% prefer animals, pet and pet care; and 65% in building and renovation materials.

Roy Morgan Chief Executive Officer Michele Levine explained: “The preference for Australian-made products has been long-standing and backed up by years of research conducted

by Roy Morgan which consistently shows Australians favour locally made goods in a range of product categories.

Unsurprisingly, Australian-made food & beverages are preferred by a large majority of Australians (80%), but these goods are closely followed by a range of manufactured goods from a broad range of Australian industries.

“This important study found that the most important reasons for buying Australian Made products are: better quality;

AMT FEB/MAR 2020

supporting local businesses/communities; and supporting local job creation.”

Ben Lazzaro, Chief Executive of the Australian Made Campaign, explained that Roy Morgan’s latest research highlights the importance that Australian’s place on locally manufactured products, and shows the increasing demand for authentic Aussie brands.

“The demand for authentic Aussie products is growing continuously,” said Lazzaro.

“When you buy Australia Made, Australian Grown products, you know what you are getting—products made to the highest of manufacturing standards and grown in our clean, green environment. At the same time, you are helping to support local industry. The best way to identify genuine Aussie products is to look for the famous green and gold Australian Made logo.”

Almost all Australians (99%) indicated that they were aware of the Australian Made logo, with the vast majority of those (84%) associating the logo with supporting local

jobs and employment. Over half of Australians also associate the Australian Made Logo with products that are of high quality (58%) and are produced using ethical labour (57%). Sustainable, environmentally friendly and clean and green attributes were similarly top of mind, with around half of Australians (49%) connecting them with the Australian Made logo.

Lazzaro added: “These environmental considerations, which are intrinsically linked to many Australian products, are continuing to be important to consumers when making purchasing decisions.”

Trust in the Australian Made logo remains strong, with 88% Australians confident that products displaying the logo had been manufactured or grown within Australia. Young Australians were among the most confident, with an enormous 94% of those between 25-34 years certain that products carrying the iconic green and gold kangaroo logo were authentically Australian.

INDUSTRY NEWS

BDO Australia: Middle-market remains engine room of Australian economy Australia’s middle-market – comprising organisations with annual revenues above $10m and up to $1bn – is a significant contributor to the economy, according to professional services firm BDO Australia.

Research findings from BDO show that mid-market businesses are a minority in number – comprising approximately 2.1% of all registered Australian taxpaying business – yet they contribute in excess of 20% of net corporate tax revenues for all business types, driving business growth and employment substantively.

One notable finding was that Manufacturing, along with Wholesale, were the two largest sectors in the Australian middle-market by volume.

According to BDO, as manufacturers look to adopt advanced technologies and innovate, there are still many opportunities to experience strong growth and profit. Manufacturers who invest in technology and research & development will be able to deliver more premium products with greater international success.

Grant Saxon, a Managing Partner for BDO Australia, said there is new evidence that demonstrates the mid-market segment is growing, both in size and relevance to the economy.

The report found that 82% of middlemarket businesses are based on the east coast of Australia and they achieved profit margins of 13.7%.

“The middle market punches significant above its weight, is achieving consistent growth, and driving employment in Australian businesses,” said Saxon.

“Although small in number, the mid-market employs around 20% of the Australian workforce and produces just under a quarter of Australia’s total revenue.

“For a long time now, the middle market has been overlooked when it comes to policies, business analysis and its contribution to the health of the Australian economy,” Saxon added.

“Middle-market businesses are often combined with the ‘small-to-medium’ segment – yet, they offer characteristics that make them distinctively unique.

“Mid-market businesses are unique in that they are large enough to invest and make a meaningful impact on the economy, yet small enough to be entrepreneurial and nimble, often with a clear market niche.

Whilst there is plenty of innovation occurring in the start-up community, innovation is commercialised in the mid-market.”

“Middle-market businesses are unique in their make-up, often starting as family-run, private businesses that grow organically. And as our client relationships tell us, they all have a different growth story and a number of distinct perspectives that nourish the Australian economy.”

Marand honoured at the 57th Australian Export Awards AMTIL member Marand Precision Engineering has been recognised for its outstanding export achievements at the 57th Australian Export Awards, where it won in the category of Manufacturing and Advanced Materials.

Birmingham presented the Manufacturing and Advanced Materials Award to Marand’s CEO, Rohan Stocker, in the Great Hall at Parliament House Canberra.

Based in Moorrabin, Victoria, Marand is a leading global supplier of precision engineered solutions to the defence, aerospace, rail, automotive and mining sectors. The company is the largest Australian supplier on the F-35 Lightning II Joint Strike Fighter (JSF) program. It is responsible for building 722 vertical tail sets for the JSF program, and is the global sole source provider of the F-35 engine removal and installation trailer.

The Australian Export Awards is a national program that recognises remarkable Australian companies that are engaged in international business and have achieved sustainable growth through innovation and commitment. The Awards measure businesses against their peers based on the strength of their international growth, marketing and financial strategies.

The event was hosted by Senator Simon Birmingham, the Federal Minister for Trade, Tourism and Investment. Thirteen businesses from around Australia were awarded for their export achievements.

Birmingham said the awards recognised

“This is wonderful recognition for many years of hard work,” said Stocker. “Our company is a proud engineering, manufacturing and sustainment business. We love exporting and connecting internationally to great companies like Lockheed Martin and BAE Systems. We also enjoy being an enabler for export, developing technology and engineering solutions for the likes of Boeing, Rio Tinto, BHP, and Carbon Revolution.”

Melissa Price, Federal Minister for Defence Industry, said: “This is a very, very welldeserved recognition for an Australian business that is a real shining star in our defence industry.”

Marand CEO Rohan Stocker accepting the company’s Award.

the enormous contribution exporters make to Australia, with the 94 finalists employing more than 34,000 Australians generating more than $7.8bn in export sales.

Marand was acquired by funds managed

by CPE Capital in June 2019. CPE Capital, alongside Marand, is building an integrated precision engineered products, solutions and sustainment company to support the Australian aerospace and defence industry and to better service global customers.

AMT FEB/MAR 2020

021

022

INDUSTRY NEWS

3D printing company Amaero lists on ASX Melbourne-based 3D printing business Amaero International has listed on the Australian Securities Exchange (ASX).

AMTIL member Amaero raised $8m at 20c a share in its initial public offering (IPO), valuing the company at almost $35m on a market capitalisation basis.

Established in 2013 through the Monash University Centre for Additive Manufacturing (MCAM), Amaero has grown to become a significant global player in 3D printing services, in particular for the aviation and defence sectors. Amaero is chaired by David Hanna, who is also Monash University’s Director of Business Strategy, with Barrie Finnin continuing in the role as CEO. “The use of metal 3D printing is growing rapidly in the aerospace, defence, and industrial sectors with manufacturers competing to secure the latest technology to improve their product capabilities,” Hanna said. “The value of additive manufacturing is expected to jump from $8.5bn in 2015, to $34.4bn by 2025 and I am confident that Amaero will more than play its part.”

The majority of the company’s operations are based in Melbourne’s Notting Hill, adjacent to MCAM, with which Amaero has a research services agreement. The ongoing relationship with MCAM, under the direction of one of the world’s leading researchers in additive manufacturing, Professor Xinhua Wu, will continue to give Amaero a significant edge in this rapidly developing field.

Amaero also has a manufacturing facility in Adelaide through a strategic partnership with the University of Adelaide. Additionally, via its US subsidiary AM Aero, Amaero recently established a US facility in El Segundo, Los Angeles, providing direct access to the world’s leading aerospace, defence and industrial customers.

“Amaero’s presence in North America enables it to exploit its capabilities with direct line of sight to its defence and aerospace customers, as well as on-shoring tooling manufacturing,” Finnin said. Amaero is not only a proven producer of complex, large format components; in October 2019, the company secured licensing rights from Monash for two new super materials (patents pending) – a high-strength titanium alloy and a new aluminium-scandium alloy.

It also has an exclusive USA distribution agreement for the world’s fastest laser-based power bed 3D printer.

Professor Margaret Gardner AO, President and Vice-Chancellor of Monash University, said that as one of the world’s top 100 universities, Monash continues to work with industry partners and support enterprising opportunities to drive change.

“Amaero’s listing on the ASX is a remarkable achievement for a company that developed from research application in the Monash University Centre for Additive Manufacturing just six years ago,” Professor Gardner said. “With extensive experience in additive manufacturing, backed by cutting-edge research at Monash University, Amaero has the potential, with the right partners, to deliver world-class, transformational solutions to the aviation and defence sectors.”

New taskforce addresses gender disparity in engineering A new national taskforce to tackle the deficit in numbers of women studying engineering, the Engineering for Australia Taskforce, launched a report on 21 January which identifies a need to change the perception of engineering in society and schools if gender diversity in engineering is to improve.

The Engineering for Australia Taskforce was created by the Deans of Engineering at Monash University, the Australian National University (ANU) and the University of New South Wales (UNSW Sydney) to address the gender disparity in applicants for university engineering programs by tackling the barriers to girls’ participation in engineering. The Taskforce’s first action was to commission a report, titled ‘Barriers to participation in engineering and the value of interventions to improve diversity’, authored by Professor Deborah Corrigan and Dr Kathleen Aikens from Monash University.

• Evaluate engineering intervention programs to map the landscape and build the evidence base of impact.

The report explores the factors which affect girls’ participation in STEM and engineering and looks at 115 international peerreviewed research articles to identify key considerations when creating programs to attract girls to engineering. It recommends three actions to improve engagement with engineering:

The Taskforce agreed that more needs to be done to encourage young people, especially girls, to study STEM subjects in school, drawing upon best practice scenarios from across the world.

• Create an inclusive vision for STEM and engineering to address persistent stereotypes, which invites and welcomes excluded groups to see engineering careers as real possibilities.

• Work with the education sector to create a STEM and engineering identity in schools, by making engineering activities prominent, positive and relevant.

AMT FEB/MAR 2020

Professor Corrigan, Director of Monash’s Education Futures, said: “The opportunities to impact the lives of so many through STEM is a real possibility that is not well understood. There is widespread, cross-national evidence that girls experience lower levels of confidence and higher levels of anxiety with respect to STEM subjects. We have to first focus on wider STEM interventions as a start, while raising the profile of engineering which is silent within the school curriculum.”

Professor Mark Hoffman, Dean of Engineering at UNSW, said: “Engineering needs the profession’s makeup to reflect the society it serves, and that means we need more women gaining confidence at school to join engineering programs at university.”

Professor Elanor Huntington, Dean of the College of Engineering & Computer Science at the ANU, added: “Engineers make our world, and we should be making a world that we all want to live in. Highlighting and then removing the current barriers to participation in engineering and evaluating possible interventions to increase diversity, will be invaluable to that vision.”

NEW YEAR

NEW BEGINNINGS

Complete Machine Tools are proud to now offer the full range of Accurl sheet metal machinery in Australia under the name AccurlCMT. This cooperation brings quality machinery with a high technology content to the Australian market at competitive pricing. Think sheetmetal machinery, think

Press Brakes

Turrret Punches

Guillotines

Watet Jet

Complete Machine Tools, Your Partner in Innovation T - 07 3279 3344 E - sales@completemachinetools.com.au W - www.completemachinetools.com.au

024

INDUSTRY NEWS

Brendan Nelson to head up Boeing’s Oceania operations The Boeing Company has appointed Dr Brendan Nelson AO as the next president of Boeing Australia, New Zealand and South Pacific.

Effective 11 February, Nelson will become chairman of the board for Boeing Australia Holdings and the company’s senior leader for its 3,800 employees working across commercial airplane manufacturing, defence systems, services, research and development and autonomous systems. Maureen Dougherty, who has served as the company’s president for the Oceania region since 2014, will retire in March after a transition with Nelson.

“Boeing is proud to have Brendan join our team after his many years of outstanding public and private sector service,” said Sir Michael Arthur, president of Boeing International. “His proven ability to understand and manage complex situations – first as a medical doctor, later as a government leader and diplomat – will be put to good use as he leads Boeing Australia, the company’s largest presence outside the US and home to a large engineering and technical staff.

“Brendan takes up the mantle from Maureen Dougherty, who has done a superb job over the past six years leading our regional efforts, growing our relationships with customers and other stakeholders, and ensuring that Boeing in Australia thrives for many years ahead.”

He later served as Ambassador to Belgium, Luxembourg, the EU and NATO until 2012. Most recently, Nelson served as the director of the Australian War Memorial in Canberra.

Nelson began his career in 1985 as a medical practitioner before going on to lead the Australian Medical Association (AMA). In 1996, he was elected to the Federal Parliament where he served five years as Minister for Education, Science and Training, followed by two years as Minister for Defence. He was elected leader of the Liberal Party of Australia in 2007 and led them in Opposition until 2008.

“It is an honour to join a global company like Boeing whose proud legacy here in Australia dates back more than 90 years to the earliest days of Australian aircraft manufacturing,” said Nelson.

“Today, Boeing Australia employees are working across the country in high-tech jobs that help define and deliver the future of aviation and defence – not just for Australian customers but for the world.”

Naval deployment for SPEE3D The Federal Government has announced a $1.5m investment into a two-year pilot of SPEE3D technology for the Royal Australian Navy (RAN), including the deployment of a WarpSPEE3D 3D metal printer.

Cold spray 3D printing technology developed by SPEE3D will be deployed by the Royal Australian Navy in a world-first trial that will streamline the maintenance of patrol vessels. SPEE3D partnered with the Advanced Manufacturing Alliance (AMA) and Charles Darwin University (CDU) to deliver the program. The company had also collaborated with CDU to form AMA in 2017, an initiative that is now recognised as a global centre of excellence for real-world applications of 3D printing technology.

“We’re excited to be working with the Royal Australian Navy and the Additive Manufacturing Alliance on this program,” commented SPEE3D CEO Byron Kennedy. “Having the capability to produce high-quality metal parts on-demand, in the field or at sea will be groundbreaking for the Australian Defence Force.”

Originally unveiled at Formnext 2017, SPEE3D’s supersonic 3D printing technology has always been targeted at final part production, leveraging metal cold spray technology to produce industrial quality metal parts in just minutes, rather than days or weeks. This process harnesses the power of kinetic energy, rather than relying on high-power lasers and expensive gasses, allowing 3D metal printing in the field or at sea, at affordable costs. The program aims to significantly increase parts available to the Navy compared to what the regular supply chain can provide.

“This high-tech machinery enables metal components to be produced quickly and efficiently, meaning our ships can get back on the water without delay,” said Federal Minister for Defence Industry Melissa Price. “Benefiting both the Navy and industry, the knowledge transfer gained using this capability also positions the Advanced Manufacturing Alliance to pursue further opportunities.

AMT FEB/MAR 2020

“This capability is a prime example of Australian innovation at its best and supports the Government’s unprecedented shipbuilding and sustainment plans.”

CoroDrill® DS20

What innovation looks like After years of R&D and customer testing, we are convinced – CoroDrill® DS20 is truly the best indexable short hole drill on the market.

The concept consists of new designs for both drill body and inserts. It offers superior reliability and predictability with outstanding penetration rates for your 4–7×DC drilling operations. CoroDrill® DS20 is the first indexable drill to reach hole depths up to 7×DC – with no need for pilot drilling – reducing your cycle time and cost per hole.

We proudly welcome you to discover the new benchmark for indexable drilling – CoroDrill® DS20. www.sandvik.coromant.com/corodrillds20

026

INDUSTRY NEWS

CECIMO elects Hans-Martin Schneeberger as new President CECIMO has announced the election of Dr Hans-Martin Schneeberger as its new President, for a period of two years.

CECIMO is the European Association of the Machine Tool Industries and related Manufacturing Technologies. Succeeding Dr Roland Feichtl in the role, Schneeberger’s term as President will focus on the setting of global standards and the uptake of artificial intelligence (AI). “The machine tool sector can contribute to the health of the European industry by shaping the next EU regulatory initiatives and policies,” said Schneeberger. “Europe must lead the race on global standards at the international level, so that our regulations set the example for others to come”.

On the issue of AI, Schneeberger added that it was important that reglulators see the value of different perspectives, not just those of the big tech companies: “In many cases, these companies are suppliers to our industry, while we are the customers and therefore users.” CECIMO brings together 15 national associations of machine tool builders, which represent approximately 1,500 industrial enterprises in Europe, more than 80% of which are SMEs. CECIMO covers 98% of the total machine tool production in Europe and about 35% worldwide. It accounts for more than 150,000 employees and a turnover of nearly €28bn in 2018. More than three-quarters of CECIMO production is shipped abroad, whereas half of it is exported outside Europe.

Schneeberger has been serving as Chairman of Schneeberger Holding since 2003, having worked with the company since 1988. Prior to that, he was and Account and Project Manager for a European management consulting firm. He was a member of the board of Swissmem, the Swiss association of mechanical and electrical engineering industries, and has been a delegate to CECIMO for several years.

Electrons ‘firing’ at opening of Deakin’s hi-tech energy storage centre A hi-tech energy storage centre that will develop solutions to Australia’s future energy needs and places the Victorian workforce at the centre of scientific innovation is now officially open.

The new $6m-plus StorEnergy centre – supported with a $4.4m Federal Government grant – will produce materials on a commercial scale for electrolytes and high-energy density electrodes; and is also an energy training hub with regular private sector interface.

On 13 December, Deakin Vice-Chancellor Professor Iain Martin supported Senator Sarah Henderson in officially launching the ARC Centre for Future Energy Storage Technologies at Deakin’s Waurn Ponds campus.

“What we are celebrating today is the start of an exciting collaboration between leaders in academia, government and industry to increase our domestic knowledge and drive innovative solutions to Australia’s energy needs,” said Martin. “StorEnergy symbolises the type of partnership that Deakin is prioritising, and we believe this is the future of innovation in Australia. Continued advancement in clean energy technologies, including generation, storage, and secure systems management, will be fundamental to Australia’s efforts to reduce greenhouse gas emissions, combat climate change and address increasing demands for energy.”

Professor Maria Forsyth, Director of the new Centre, confirmed that by working closely with industry partners, researchers will design and manufacture new energy storage devices and components, including advanced Li-ion, super capacitors, and solid state Li and Na batteries, with improved rate capability, capacity and safety.

Partner organisations include Boron Molecular, CSIRO, DST Group, SupraG Energy, Calix, Sensorplex, Ionic Industries, Ciditec, Sentek, M Brodribb, and Raedyne Systems. Deakin’s StorEnergy operations will also utilise the expertise of higher education partners Monash University, Melbourne University, Queensland University of Technology and University of South Australia.

AMT FEB/MAR 2020

From left: StorEnergy director Professor Maria Forsyth, Deakin University Vice-Chancellor Professor Iain Martin, and Victorian Senator Sarah Henderson at the opening of the StorEnergy centre at Deakin University.

Deakin expects the centre to unearth knowledge and create intellectual property in advanced energy materials, batteries and battery-control systems that will help small to medium-sized businesses play a world-leading role to advance and produce new storage technologies.

“The potential of this centre excites me as a scientist and the fact we will initially employ 15 PhD students, five research fellows and a research engineer makes me proud as this centre’s first Director,” said Forsyth. “The facilities, processes and partnerships we have in place will equip the next generation of researchers and the energy technology workforce with the skills needed to drive innovation, exploration and investigation.”

Advanced Manufacturing Expo

By National Manufacturing Week

A new revolution in manufacturing

130+

50+

6

Exhibitors

Industry Speakers

Product Zones

Free-to-attend expo & conference

REGISTER NOW advancedmanufacturingexpo.com.au

Organised by

028

GOVERNMENT NEWS

NSW aims to go Global The New South Wales (NSW) State Government has announced an ambitious new international investment strategy aimed at creating thousands of new jobs across industries of the future including advanced manufacturing, agribusiness and space.

Premier Gladys Berejiklian on 4 December launched Global NSW – a strategy to unlock international investment into the state.

“As Premier, I have worked hard to bring international investment into NSW, helping to secure 17 MOUs into our Western Sydney Aerotropolis,” Premier Berejiklian said. “This international investment will translate to high quality local jobs. Our new strategy takes this work to the next level. This is about expanding our key markets around the world and ensuring we take advantage of the incredible economic opportunities on our doorstep.”

Deputy Premier and Minister for Trade John Barilaro said under the strategy the number of trade and investment offices located overseas will grow from 11 to 21.

“NSW has successfully marketed itself globally as a ‘bucket list’ tourism destination for decades and it’s time to take that up a notch and highlight our State as this region’s centre of excellence for business, industry and innovation,” Barilaro said.

As part of the strategy, revamping the NSW trade and investment network will include the appointments of an Agent General in London, and five Senior NSW Commissioners in Mumbai, New York, Shanghai, Singapore and Tokyo. The new strategy will focus on key growth industries, including: health; defence and aerospace; agribusiness and food; resources; and infrastructure.

Treasurer Dominic Perrottet said a key part of ensuring the State’s economic future was making more of expanding markets in China, South-East Asia and India, as well as diversifying exports in established markets like Japan, the US and Europe.

“NSW has always been a leader, not a follower, and as part of this Strategy we will target growth in sectors such as medtech, cybersecurity, space, advanced manufacturing, quantum computing and blockchain,” Perrottet said.

To view the Global NSW Strategy visit: global.nsw.gov.au

New help for Australian Victoria – Planning business begins for engineers’ defence The Federal Government has unveiled measures to help businesses invest in Australia’s defence industry, registration scheme small with the release of the first two of its Sovereign Industrial Work is underway on the planning for a new registration scheme for professional engineers.

The new Professional Engineers Registration Act 2019 will initially require structural, civil, mechanical, electrical and fire safety engineers to be registered. The scheme is due to commence from 1 July 2021 and has been designed to include other engineering disciplines over time. The scheme recognises the important role engineers have in ensuring public safety in a wide range of areas and will ensure formal registration against internationally recognised professional benchmarks.

Public consultation is occurring via Engage Victoria, the Victorian Government’s Online Consultation platform, in the first half of 2020, with feedback received during the consultation used by the Department of Justice & Community Safety to help draft the Regulations and supporting Regulatory Impact Statement.

An information stakeholder forum was held on 2 December to update engineers on the scheme. Director of Consumer Affairs Victoria, Sam Jenkin, said the forum and the upcoming consultation is an important opportunity for everyone to have their say on how the new scheme can be successfully implemented. “The Department of Justice and Community Safety thanks the engineering community for their willingness to engage next year.”

The co-regulatory scheme includes assessment entities approved by the Business Licensing Authority (BLA). Consumer Affairs Victoria and the Victorian Building Authority will support the BLA to register engineers.

Updates on the professional engineers registration scheme, as well as proposed timelines, can be found at: engage.vic.gov.au/engineers-registration

AMT FEB/MAR 2020

Capability Priority Implementation Plans.

The Government’s Defence Industrial Capability Plan introduced 10 initial Sovereign Industrial Capability Priorities (the Priorities), and noted Defence would develop Implementation Plans for each Priority. These Implementation Plans outline critical industrial capabilities for each Priority, describe the existing Australian defence industry sector, and outline the actions to be taken by Government to support the development of each Priority.

Melissa Price, the Federal Minister for Defence Industry, on 19 December released the first tranche of Implementation Plans, covering the following Priorities: • Combat clothing survivability and signature reduction technologies.

• Munitions and small arms research, design, development and manufacture.

Minister Price said the Plans provided information and set key priorities on how the Government would work with defence industry to build and grow sovereign industrial capabilities.

“They provide a useful roadmap to help current and aspiring defence industry businesses understand the capability priorities of the Australian Defence Force, now and into the future,” Minister Price said. “They also include detailed information to guide companies already involved in, or looking to contribute to our record $200bn build-up of defence capability. Giving small business the tools and support they need to be involved in our defence industry, and grow their businesses to the point they’re ready to enter global markets is my number one priority.”

Implementation and Industry Plans for the remaining Priorities will be released throughout 2020.

The Implementation Plans are available at: www.defence.gov. au/SPI/Industry/CapabilityPlan/ImplementationPlans.asp

Every business has different needs.

Accelerating Commercialisation The Entrepreneurs’ Programme (EP) is a Commonwealth Government flagship initiative focused on raising the competitiveness and productivity of eligible companies at an individual level. The EP service offering Accelerating Commercialisation helps entrepreneurs, businesses and researchers to address the challenges of bringing their products, processes and services to market. Without the right advice and support this can be a very difficult, frustrating and challenging process that is fraught with many dangers.

Accelerating Commercialisation offers: • Matched grants of up to $1 million to support entrepreneurs on their commercialisation journey.

•

Support and guidance from independent commercialisation advisers.

•

Introductions to influential business contacts and networks including investors, domain experts, entrepreneurs and strategic corporations.

•

Opportunities to join an exclusive portfolio of high-potential Australian businesses that are marketed to investors and multinational corporations

To find out what the Entrepreneurs’ Programme can do for you, contact Greg Chalker 03 9800 3666 or email gchalker@amtil.com.au

www.amtil.com.au Commonwealth Government Entrepreneurs’ Programme partnering with AMTIL

1465AMTILEPMC

Mal Clark (BSc(Hons), PhD, GAICD, DipBM, DipMR&D, MAIP, MInstP, CPhy, CEng) Entrepreneurs’ Programme Business Adviser

030

VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Manufacturing differently We are living in interesting times; the global economy seems to be facing an imminent slowdown and overcapacity in many industries. For manufacturers in Australia, management innovation is essential, writes Hendrik Lourens of the management consultancy Stratflow.

Professor Danny Samson, Director of the Master of Enterprise and Master of Supply Chain Management degrees at the University of Melbourne, published an article a few years ago titled ‘Megachallenges and executive strategies’. In it he wrote: “In Australia, we face a number of challenges. With the mining boom over and industries such as automotive and many services being offshored in an increasingly high-cost Australian economy, leaders in all sectors have a daunting task in planning and executing long-term paths to prosperity.”

Manufacturing as a share of the economy has been declining for many years, and even the recent weakening of the exchange rate has not had much of an effect yet.

Anecdotal evidence suggests that it is becoming ever more challenging to obtain the required skills at an acceptable cost.

Employee engagement in Australia is seemingly falling off a cliff, from 24% of employees highly engaged in 2013 to only 14% in 2017.

Productivity is not improving, despite the tremendous effort. Managers and employees are tired and suspicious of improvement efforts that often end up in cutting employee numbers.

In his article, Professor Samson recommends a number of strategic interventions to deal with these challenges, the first two of which are: • Strategy 1: Put the consumer/ customer at the centre of the business. Most global markets are in oversupply, so competing for the customer’s attention is getting harder, and only those who are fully customercentric will survive.

• Strategy 2: Pursue Lean operations and waste reduction in every corner of the organisation. Most organisations waste fully one-third of their resources, and big improvements are possible that flow straight to the bottom line.

These seem quite sensible, but manufacturers have been trying these strategies for years with little success.

Often the way companies pursue Strategy 2 not only works against Strategy 1, but causes the low productivity and employee engagement that we see in much of the Australian manufacturing industry. In trying to optimise all parts of the operation

AMT FEB/MAR 2020

using traditional Command-and-Control principles, we destabilise production flow, end up with unhappy customers and make it difficult for employees to be successful and engaged.

We are in desperate need of innovation, but not the kind that involves technology and products. Based on 20 years of experience in running manufacturing companies and consulting to the industry, we at Stratflow believe innovation in manufacturing management is the missing success ingredient. Without innovation here, employees and managers will be working harder and longer with ever-diminishing returns.

Our management paradigm At Stratflow, we are in agreement with Professor Samson that looking after the client better than your competitors do is crucial. Most manufacturing businesses have a marketing constraint; that is, they can produce more, but the market demand is not sufficient at the required margin.

To increase sales and margin they focus their efforts towards Strategy 2, trying to reduce costs through operational strategy.

This typically means trying to have just enough of everything and maximising the efficiency of all the parts. The inevitable outcome is balanced capacity across the manufacturing chain. We now have moving bottlenecks, long lead times and poor duedate performance, firefighting, managers that are under pressure, finger-pointing and

blame-shifting. Customers are unhappy, and sales personnel end up dealing with customer complaints instead of selling.

The belief that reducing costs everywhere is the solution leads managers to plan production with “just enough of everything”, using cost accounting principles that are unchanged from the early 1900s – a time when businesses operated in a very different way. In this way, managers hope that they will achieve high efficiency on all the parts and thus achieve the greatest productivity and lowest cost for the system.

This is a fundamental mistake, made worse by the continued (incorrect) application of Command-and-Control ideas first highlighted by FW Taylor over a century ago. Command-and-Control is valuable but takes the ability to fix the system away from workers. Workers become cogs in a machine, replaceable and required only to follow directions.

Changing the paradigm What we need is a production system that ensures the flow of the right amount of product, at the right time, all at a lower cost and with shorter lead times. Furthermore, we want to unleash the abilities of workers and managers to achieve this without losing command of the situation. How can we do this?

The most powerful management efforts focus on changing the accepted best practice management paradigms. The British occupational psychologist and

031

reduced down to two weeks; no stockouts occurred and there were almost no late deliveries. Sales personnel and customers started supporting the business again.

Margins quickly increased by 20%.

Three years later, margins had increased by 66%, a compound annual growth rate of 19%. Sales volume had increased by 69%.

Conclusion We believe that the obstacle to engaging workers and improving productivity is widespread “optimise everything” mental models in combination with excessive Command-and-Control activities. This leads to a focus on the performance of individual departments and employees at the expense of overall system performance. management guru John Seddon says: “Forget your people. Real leaders act on the system. Real leaders redesign the system to meet demand. When leaders act on the system, customers cheer, costs fall, and the culture change comes free.”

At Stratflow we have developed the Productivity Platform, based on principles of Theory of Constraints (TOC) and Dialogic Organisational Development, to make this possible.

The Productivity Platform makes the overall goal of the system clear – it identifies and communicates the role of each person and department in achieving that (by getting work to flow faster through bottleneck areas) and changes the management paradigm to one where we manage the overall system for greatest effectiveness and efficiency. The increased clarity of purpose, advance warning of problems, alignment and trust enables production flow to increase by 20% to 30%, using the same resources. This enables employees and managers to not only decrease lead time and increase volume, but also to ensure that the right product is available at the right time.

The Productivity Platform creates a platform where managers and employees can safely practice the new way of managing, without getting rid of the beneficial characteristics of Command-and-Control and Hierarchy. It reduces the levers to control to the absolute minimum and unshackles employees to do what needs to be done for the good of the whole. In this manner, the information overload that impedes many management teams is substantially reduced. It creates an environment where employees have a purpose, can achieve mastery and have more autonomy.

With a newly created optimised flow capability, it is now possible to satisfy the customer’s significant need more effectively

than any competitor. This need is typically for shorter lead times, full availability of items, or significantly improved due-date performance. The example below sets out a situation where optimised flow was used in synergy with a marketing strategy to simultaneously satisfy Professor Samson’s strategies. Productivity and employee engagement dramatically improved.

Case study: Polyester panel roof sheeting business A roof sheeting business was about to be closed down due to years of declining performance. Sales had been falling for five years. Lead times were six to seven weeks, but as long as ten weeks on some items.

Customers were desperately unhappy; their lead time preference was often less than three weeks.

Interdepartmental relationships were poor; the one thing everyone agreed on was that the Production Department was underperforming. Production morale and engagement was poor. The production planner had a nervous breakdown trying to manage orders under these conflicting requirements.

Intervention: After establishing the Productivity Platform and improving production flow, the sales quotation process was changed. The Theory of Constraints buffer replenishment system enabled all-round availability on selected Make to Stock (MTS) items; stock and capacity buffers ensured Make to Order (MTO) reliability. Marketing capitalised on the improved capability by offering industrial customers reliable two-week lead times, and for commercial customers availability and higher stock turns.

Results: Customers loved the new market offering; employee engagement improved noticeably; the planner became a different person. Lead times of six to 10 weeks were

In this manner, managers destabilise the flow of work and overload their cognitive abilities, since everything becomes important and in need of constant attention and adjustment. Work becomes difficult for them and their subordinates. The Theory of Constraints holds that expending time and resources on non-bottlenecks areas is unproductive and prevents breakthrough results from being achieved.

Manufacturing Differently is about embracing technology and process to enable humans, not the other way round.

Automation, data-driven supply chain and outsourcing can boost productivity and innovation. However, if you lead with classical management theory and treat people as replaceable cogs in a machine, the outcome will be troubled relationships with your employees, unhappy customers and lower margin.

By implementing a Productivity Platform we unshackle employees and managers from the worst consequences of Commandand-Control and improve psychological safety, trust and unity of purpose. The resultant reduction in lead time, improved due-date performance and lower costs make it possible to offer highly competitive terms to the market and to grow market share and margin. Now Strategy 1 and 2 can be executed synergistically, to the benefit of client and manufacturer. The joy that managers and workers experience from becoming successful ensures that we get culture change without the need for a culture change program.

Hendrik Lourens is a Sydney-based management consultant and owner of Stratflow. He has turned around manufacturers and improved the safety & productivity of mining and construction companies as well as published in various journals on efficiency and innovation. www.stratflow.com.au

AMT FEB/MAR 2020

032

VOICE BOX OPINIONS FROM ACROSS THE MANUFACTURING INDUSTRY

Work is a fundamental part of being human.

Robots won’t stop us doing it The impact of automation in an array of industrial sectors has prompted widespread speculation that human workers may become increasingly superfluous. However, these concerns may be overstated, writes Jean-Philippe Deranty.

Hardly a week goes by without a report announcing the end of work as we know it. In 2013, Oxford University academics Carl Frey and Michael Osborne were the first to capture this anxiety in a paper titled: “The Future of Employment: How susceptible are jobs to computerisation?” They concluded that 47% of US jobs were threatened by automation. Since then, Frey has taken multiple opportunities to repeat his predictions of major labour market disruptions due to automation.

In the face of threats to employment, some progressive thinkers advocate jettisoning our work ethic and buildi ng a world without work. If machines can do our work, why not reduce the working week drastically? We should be mature enough to decide what truly matters to us, without tying our identity to a job, or measuring happiness in dollars and professional status. Right?

Not quite.

The reality is that work is tied to our constitution as a species.

And this fact is too often overlooked in discussions about the future of work.

Work is a feature of the human species Recent studies have raised alarms that advances in automation and artificial intelligence (AI) will leave all sectors open to the threat of machines replacing human workers. The power of AI will supposedly, according to these studies, even make high-skilled specialists redundant – threatening medical practitioners, bank associates, and legal professionals.

Predictions about the rise of the robots either take a pessimistic stance, focusing on disruptions to economic organisations, or view “undoing work” as an opportunity to move to a fairer social model.

However, these views disregard the central role work has played in humanity’s development.

Working on environments Philosophers including Karl Marx, Henri Bergson, and John Dewey argued that working is a defining trait of humans. Findings over the past two decades have confirmed that features of modern Homo sapiens are directly tied to their tendency to work. Three basic ideas of the old philosophers are reaffirmed by contemporary research in archaeology, anthropology and genetics.

First, humans haven’t evolved to fit into their environments as seamlessly as other animals. Humans have had to compensate for a lack of fit. They did this by learning about the ecosystems around them, the plants and animals they could eat, and the natural processes they could use, or should avoid. This knowledge was applied to create instruments, tools and weapons.

Very early on, humans mobilised their knowledge and skills to shape their immediate surroundings and become the dominant animal. Knowledge of nature, technical skills and intervention in the environment are all characteristics of humans’ capacity to work. These allowed us to adapt to highly diverse geographies and climates.

AMT FEB/MAR 2020

Working on ourselves, and with others Each new generation has to learn the skills and knowledge that will enable it to sustain its particular mode of survival. Australian philosopher Kim Sterelny has shown in detail how evolution selected genetic traits that sustain humans’ capacity to learn, specifically by enhancing social behaviour and tolerance towards the young.

And as humans worked on nature, they also worked in ways that influenced their minds, and their bodies.

It has been demonstrated that co-operation in humans reaches a level unknown in other species. This co-operative capacity has its roots in each individual’s dependency on the knowledge, skills and efforts of others. No human is able to sustain themself on their own, and collaboration exceeds what each person can produce alone. Even the most brilliant astrophysicist calls the plumber to fix a broken toilet.

Humans have to work to survive, and this entails working with, and for, others.

The future of work Acknowledging the anthropological depth of work means admitting current scenarios advocating “the end of work” are not the right answer. They take an unrealistic view of who we are.

We need to recognise work as a human need. As Marx said: “…

Labour has become not only a means of life, but life’s prime want.”

The question should not be whether there’s room for human work in an automated future. The question should be: “how will human work find its place next to machines and robots?”

Even if automation becomes widespread, we’ll still apply our minds, bodies and hands to productive tasks. We’ll still experiment and learn from others.

If machines could truly do all human work, then they’d make humans redundant, as 2001: A Space Odyssey anticipated back in 1968. While this isn’t a pleasant scenario, it’s not a likely one either.

Automation might bring major social and economic disruptions in the short-term, but it won’t get rid of the need for humans to work.

Human needs are also infinitely complex. Nobody can foretell what new activities, techniques, and consequent modes of working will fulfil future needs. Even if we reject the modern work ethic, we’ll still find ways to learn through action and emulate experts.

Human intelligence is geared towards producing useful goods, so we’ll continue to look for purposeful activities, too. And we’ll seek collaboration with others for mutual benefit.

This is the influence of work on us. We are heir to thousands of years of evolution, and it would be pretentious to assume evolution could stop with us.

Jean-Philippe Deranty is a Professor at Macquarie University.

This article was originally published by The Conversation. www.theconversation.com www.mq.edu.au

1426AMTMTIQUALOS

Keeping me up to date with our industry As a member of AMTIL since its inception in 1999, M.T.I. Qualos appreciates AMTIL’s efforts in keeping the Australian manufacturing industry informed via AMT Magazine. This includes international news, the high levels of achievement of Australian manufacturers and initiatives to support our precision engineering sector. As a supplier of Precision Measuring Instruments, M.T.I. Qualos sees AMT magazine as an extremely valuable tool in reaching the key decision-makers. There isn’t a better or simpler way of reaching our target market.

Andrew Smith, General Manager M.T.I. QUALOS

APPROX

31,500

READERS AMT the No. 1 trusted industry publication.

For information or advertising rates visit www.amtil.com.au or contact Anne Samuelsson, Head of Partnerships & Sales on 03 9800 3666 or email asamuelsson@amtil.com.au AMT proudly owned and published by Australian Manufacturing Technology Institute Limited (AMTIL)

034

TECH NEWS

USA: 3D printer switches between multiple inks up to 50 times per second.

Most commercial 3D printers build objects from a single material at a time and inkjet printers capable of multimaterial printing are constrained by the physics of droplet formation. Now, a new technique called multimaterial multinozzle 3D (MM3D) printing has been developed which uses high-speed pressure valves to achieve rapid, continuous, and seamless switching between up to eight different printing materials, enabling the creation of complex shapes in a fraction of the time currently required. It uses printheads ranging from a single nozzle to large multinozzle arrays. Each nozzle is capable of switching materials at up to 50 times per second. The key to the speedy ink-switching is a series of Y-shaped junctions inside the printhead where multiple ink channels come together at a single output nozzle, precisely calculated and tuned so that the ink that flows down through that arm does not cause the static ink in the other arm to flow backwards. Adjustments can be made for materials’ different viscosities and yield stresses. Because objects can be produced so quickly, reactive materials whose properties change over time can be used. One can also readily integrate materials with disparate properties to create origamilike architectures or soft robots that contain both stiff and flexible elements. (Informative video clip at the Harvard.edu/news website.)

Wyss Institute at Harvard University

The more successful ones were kept and refined. The stem cells were separated into single cells, incubated, cut and joined according to the computer designs. Assembled into body forms never seen in nature, the cells worked together: The skin cells formed a more passive architecture, while the once-random contractions of heart muscle cells were put to work creating ordered forward motion.

Fully biodegradable, the Xenobots turn into dead skin cells after job completion. In a test, after being sliced almost in half, the Xenobot stitched itself back up and kept going. The bots promise advances from drug delivery to toxic waste clean-up.

University of Vermont

USA, Australia: Successful flight of world’s first commercial electric airplane Harbour Air and Australian electric motor manufacturer magniX (headquartered in Redmond, Washington) announced the inaugural flight of the world’s first commercial electric airplane. The ePlane is a six-passenger DHC-2 de Havilland Beaver retrofitted with an electric motor (a 750-horsepower 560 kW magni500 propulsion system). The flight occurred in Vancouver, Canada. Roei Ganzarski, CEO of magniX, said that the aviation industry in particular is “ripe for a massive disruption.” He added that this flight proves that “lowcost, environmentally friendly, commercial electric air travel” could be possible in the very near future.

Harbour Air Seaplanes and mixed.

USA: Making airplane parts minus the massive infrastructure Australia: Adding copper strengthens 3D-printed titanium Current titanium alloys used during the 3D printing process are prone to cracking/distortion. But now a new titanium alloy with copper appears to have solved this problem. This could kickstart a new range of high-performance alloys for medical device and aerospace applications. It was noted that the crystal grains had grown equally in all directions to form a strong bond, instead of in columns, which can lead to weak points liable to cracking. This finding suggests similar metal systems could be treated in the same way to improve their properties which could increase manufacturers’ production rates and allow for more complex parts to be manufactured.

RMIT

USA: Living robots built using frog cells For the first time, a team has repurposed living cells from frog embryos and assembled them into entirely new life-forms (Xenobots). The Deep Green supercomputer cluster reassembled a few hundred simulated cells into myriad forms and body shapes.

AMT FEB/MAR 2020

Carbon nanotube film has been used to produce aerospacegrade composites without the huge ovens and pressure vessels.

Instead of placing layers of material inside an oven to cure, they were essentially wrapped in an ultrathin film of carbon nanotubes (CNTs). When they applied an electric current to the film, the CNTs quickly generated heat, causing the materials within to cure and fuse together. With this out-of-oven (OoO) technique, the team was able to produce composites as strong as the materials made in conventional airplane manufacturing ovens, but using only 1% of the energy. The researchers next looked for ways to make highperformance composites without the use of large, high-pressure autoclaves. This involved developing nanoporous networks (ultrathin films) in place of giant autoclaves to squeeze out voids between two material layers, with surprisingly positive results.

MIT

International: “Aeroelastic” aircraft wings Last November, two 3.5m-long test-aircraft, with an “aeroelastic”, 7m-wingspan made successful test flights. The six-country collaborative effort known as FLEXOP was led by Germany’s TUM and DLR. The wings are wider in span and lighter than conventional

TECH HEADING NEWS wings, resulting in possibly increased fuel-efficiency. The aim is to develop wider and lighter wings which are not affected by the aerodynamic phenomenon known as flutter. One solution to flutter is to develop aeroelastic wings – capable of more movement in flight than conventional, more rigid, wings. One of the two test aircraft used carbon fibre. The fibres were aligned so that if the wing was bent by the force of the air, it would also twist to minimise the force upon it. The second wing is made of fiberglass. When flutter occurs, the outermost flaps are deployed, functioning as dampers.

These wings could save 7% of fuel.

compound called phenol, the researchers were able to create a lightweight, flexible material that is also durable enough to potentially protect the body of a rocket or jet from the intense heat it experiences. The buckypaper was better than control samples at dispersing heat and keeping it from reaching the base layer. It also stayed strong and flexible compared to control samples made without protective layers of nanotubes.

The Engineer

Researchers have created a new form of gold that weighs about five to 10 times less than traditional 18-carat gold. The conventional mixture is usually 3/4 gold and 1/4 copper, with a density of about 15 g/cm3. However, this new lightweight gold’s density is just 1.7 g/cm3, but is still 18-carat gold. It has material properties of plastic but it glimmers like metallic gold, and can be polished and worked.

Instead of a metal alloy element, the researchers used protein fibres and a polymer latex to form a matrix in which they embedded thin discs of gold nanocrystals. The hardness can be adjusted by changing the composition of the gold. The latex can also be replaced with other plastics such as polypropylene which can mimic the gold melting process, yet at much lower temperatures. The shape of the gold nanoparticle can change the material’s colour: typical shimmer or a violet hue. While the plastic gold will be in particular demand for watches and jewellery, it is also suitable for chemical catalysis, electronics applications or radiation shielding.

Switzerland: 3D-printed glass Producing glass objects using 3D printing is difficult. Molten glass has been used, which requires extremely high temperatures and heat-resistant equipment. Powdered ceramic particles have resulted in objects which are not very complex. However a new technique using a resin containing plastic and organic molecules to which glass precursors are bonded and then cured with UV light, has been produced. This has resulted in complex and highly porous glass objects. Wherever the UV light strikes the resin, it hardens because the light sensitive components of the polymer resin cross link at the exposed points. The plastic monomers combine to form a labyrinth-like structure, creating the polymer. The ceramic-bearing molecules fill the spaces. An object can thus be built up layer by layer. The parameters can be changed in each layer, including pore size. Complex objects can be made from different types of glass, or combined in the same object. During the firing process, the objects shrink significantly, but become transparent and hard like window glass.

ETH Zurich The blank (left) is fired at 600deg.C to eliminate the plastic framework.

In a second firing step, the object becomes glass (right).

Florida State University

Switzerland: Plastic gold

ETH Zurich

“Wouldn’t it be great, if Australia were to become the electronic VTOL manufacturing capital of the world”. David Taylor, Operations & Development Manager for Australian company, Macchina Volantis (Latin for “Flying Car”) which is developing a concept vehicle considered to be the flying car design most suitable as one of the world’s first vertical take-off and landing machines for urban use. “We want to build the prototype in Australia. Australia has plenty of capability in building these sorts of one-offs cost-effectively at small volumes. This country’s skills in exotic constructions are second to none.”

Stephen Fries, Designer. With support from Boeing, the Uni of Sydney and the Uni of Technology Sydney, the concept is in the final stages of pre-production. It is a five-seater with a carrying capacity of 25 kg of luggage per passenger.

USA: Lightweight heat shield protects superfast aircraft Aerospace increasingly relies on carbon fibre reinforced polymer composites to build the structures of satellites, rockets and jet aircraft. But the life of those materials is limited by how they handle heat. A team is developing a design for a heat shield that better protects these structures. The team used carbon nanotubes (or “buckypaper”) a material with incredible abilities to conduct heat and electricity. By soaking the buckypaper in a resin made of a

AMT FEB/MAR 2020

035

036

PRODUCT NEWS

Major efficiency gains made through machining insights Using digital solutions for monitoring of equipment utilisation makes workshops far more efficient and profitable than would otherwise have been possible, which is why Sandvik Coromant has introduced CoroPlus MachiningInsights.

More than a monitoring system, the solution gathers data, calls attention to issues, and provides the insights required to take action.

It is an easily attainable step for manufacturers that are looking to reduce waste in production and make a smooth transition into a digital way of working.

Sandvik Coromant strives to identify where improvements can be made, and this digital solution was developed in recognition that a machine that stands idle is not making money. For many manufacturers and workshops, knowing when a machine has stopped – and identifying the underlying reason for the stoppage – can be a major challenge and digital solutions are creating new possibilities to overcome this issue. Replacing the traditional ways of manual tracking, manual data aggregation and manual time studies, collecting data directly from a connected machine tool as well as from operators makes it possible to visualise the machineutilisation and even tool-utilisation levels and create improvements within the factory.

Manufacturers are able to make substantial efficiency gains from this digital solution through the ability to analyse equipment utilisation and act to optimise production processes. The analysis itself is facilitated by digital connectivity and by adding the capability of operator input into the system, Sandvik Coromant has ensured there are also opportunities for increased collaboration and greater efficiency by combining data from the operator with data from the machine.

Transparency is ensured through the visualisation being carried out online and, therefore, accessible by a web browser. This means there is no need for a complicated IT project to get up and running and there is a rapid and simple method of incorporating digital manufacturing intelligence into a production site to drive improvements. coroplus.sandvikcoromant

Kern EcoFlex – New entry-level large-format laser system Business owners looking to expand their laser services have previously had to compromise on either size, engraving speed or quality when it comes to laser cutting and engraving equipment.

Kern Laser has listened to customers’ needs for an entry-level laser system that does not compromise on quality, speed or size – and comes at an economic price-point. The EcoFlex is Kern’s entrylevel large format model. Available in two generous table sizes (1.2m x 1.3m, and 2.5m x 1.3m) and a range of wattages (100W, 150W, 200W and 250W), the EcoFlex is an ideal laser solution for any business looking at starting large-format or high-volume laser engraving and cutting.

parts to be easily removed at all sides of the machine.

The moving gantry features high-speed servo motors and a flying optics beam delivery providing consistent beam power and quality over the entire work area.

The EcoFlex’s large-format work area expands work opportunities to include large-format products and high-volume projects. A wraparound gantry traverses over the cutting bed allowing for finished

Its US-made laser source ensures high-quality, industrial grade cutting and engraving. Fast engraving speeds on such a large work area allow businesses to produce more in less time, as well as high-volume work.

The Kern EcoFlex is available in Australia exclusively through Kern Laser’s local partner Alfex Laser. Alfex can offer support on-site and over the phone for all Australian businesses, while its rent-to-buy financing means users can get an immediate return on investment, get their hands on the equipment immediately and generating income to offset the low monthy payments. www.alfexlaser.com.au

AMT FEB/MAR 2020

PRODUCT NEWS

OnRobot launches VGC10 compact, customisable gripper

DI N G V TAN AL

EX

TS

UE

OU

P R OC ES

E ACCUR EM A TR

CY

EED SP

G SIN

Based on the award-winning OnRobot VG10 electric vacuum gripper, the compact VGC10 is smaller and lighter than its larger cousin, making it ideal for constrained environments and smaller robot arms, while offering the same impressive payload of 15 kg.

The VGC10 provides fast out-of-the-box deployment but also offers unlimited customisation, with easily changeable suction cup options and the ability to add or replace arms to fit highly specific application needs. With this configurability, the VGC10 can grip and move a wide array of small, multi-dimensional, and heavy objects even with a lighter payload robot arm.

HIG H

Precision sheetmetal OnRobot has released the VGC10, a compact electric processing vacuum gripper that addresses customer demand for a small but powerful and highly configurable gripper for nearly any application.

THIS YAWEI LASER ISsolutions.

DESIGNED TO CUT That’s Applied ABOVE THE REST. thinking.

NOW THAT’S APPLIED THINKING. The VGC10 features two independently controlled air channels that allow it to act as a dual gripper with pick-up and release in the same action, further increasing efficiency and reducing cycle time. The gripper can also be used with a single air channel for higher gripping performance. With no compressor or air supply needed – eliminating the cost, noise, space, and maintenance of producing compressed air – this compact electrical gripper is easy to implement and move. Fully integrated software through OnRobot’s new One System Solution platform makes it quick to deploy and redeploy on any major collaborative or light industrial robot arm for greater production flexibility.

“We heard from customers that they loved the features of the VC10 gripper but sometimes needed a more configurable, compact version, so we delivered,” said Enrico Krog Iversen, CEO of OnRobot. “The VGC10 is another great example of OnRobot’s mission to be the one-stop-shop for innovative, collaborative endof-arm tooling that lets manufacturers focus on their application rather than the complexities of the robot.”

A study by Future Market Insights predicts that the global robotic gripper market will experience substantial growth over the next With10 its years, extreme accuracy, consistency of cut, driven by thespeed use ofand innovative solutions, thecombined rise in with very low operating costs, the new Yawei HLF fiber laser is the perfect way to take your business to the next level. applications as well as the growth in end-use industries. The market, valued at US$1bn in 2018, is projected to increase at a Dollar for dollar, the new HLF is in a league of its own, opening up possibilities for companies compound annual growthsector; rate of from 10% between 2019 and 2029. all across the laser cutting start-ups through to fullThe production, 3-shift growth is expected to be dominant in the automotive, electronics environments. and semiconductor industries and in Asia, specifically Asia Pacific, World class performance without the price tag. to the rapid growth of factoryauto-focus automation.cutting head, IPG laser source, Siemens Withowing a quality German built Precitec 840DSL controller and a fabricated, fully annealed James Taylor, General Manager -stress-relieved APAC at OnRobot, said: “The frame it really is a cut above the rest. roll-out of VGC10 is timely as Asia Pacific countries are embracing robotic automation at an impressive pace. Australia registered a density of 83 robots per 10,000 employees in 2018, above the Asian average of 63 units. The VGC10 continues our commitment to help Fiber Lasers • Tube Lasers • Turret Punch Presses • Pressbrakes • Guillotines For more information: local manufacturers embrace automation easily and enjoy quicker Call: 03 9706 8066 returns through its Email: sales@appliedmachinery.com.au Visit: flexible www.appliedmachinery.com.au and compact nature, speedy Connect with us socially deployment process appliedmachinery.com.au and increased power.” www.onrobot.com

APP054-Yawei-FPC-1.indd 1

22/12/16 9:27 am

Phone: 03 9706 8066 Email: sales@appliedmachinery.com.au

AMT FEB/MAR 2020

037

038

PRODUCT NEWS

Safe and sound: KEMPERbeats takes welding fume extraction to new level KEMPERbeats ensures employee motivation and health protection at the same time during welding. It not only makes it possible to listen to music, it also increases the degree of detection of hazardous substances during welding.

KEMPER has developed an extraction hood that sets new standards in welding fume extraction for the individual design of your personal workplace. Extraction hoods are the most frequently used technology worldwide for extracting harmful fumes, particles and vapours directly at their point of origin during welding. KEMPER has gone a step further with its new extraction hood.

“With our new development, we are thinking beyond pure extraction,” explained Björn Kemper, CEO of KEMPER. “KEMPERbeats creates a pleasant working atmosphere for welders, increases employee motivation and, ultimately, also productivity. The solution encourages the use of extraction technology, and companies send positive employer signals to their employees regarding the workplace design of the future.”

KEMPERbeats is an additional feature of the new KEMPER extraction hood. Behind it lies a special handle with Bluetooth loudspeaker. This allows employees to network the hood with any end device during their work and listen to their music even while the extraction system is running. Thanks to the individual music selection, welders can design their workplace according to their personal preferences. The loudspeakers are designed in such a way that employees at surrounding workplaces are not disturbed.

KEMPERbeats offers a further advantage: to ensure that their music always plays directly above the weld seam, welders must always reposition the extraction hood to the point where the welding fumes originate. The solution thus ensures optimum positioning and the capture rate increases, so that the hazardous substances can first be filtered.

The dimensioning of the new extraction hood also results in a higher capture rate and easier handling for welders. The increase in the hose diameter to 180mm increases the extraction performance by 30% and the capture rate by a further 20% compared to the previous KEMPER extraction hood. Due to its flange-shaped

design, this hood already achieved capture rates up to 40% higher than conventional solutions. Welders now have to reposition the new extraction hood even less frequently.

The new extraction hood can be rotated 360° and is easy to operate by hand, even with gloves on. Integrated above the extraction area rather than in the air flow, an energy-saving LED strip provides welders with an optimum view of the workpiece. The new bayonet lock for connecting the extraction hose ensures an effective seal and quick fitting. The new function of extraction volume measurement in the hood directly at the point of origin safeguards companies now for future legal standards. www.smenco.com.au

Sonatest WAVE – Ultrasonic flaw detector with interactive technology The WAVE Flaw detector from Sonatest employs interactive scan plan technology that allows you to map the geometry of the part and see the path of the ultrasonic beam through the material by overlaying it onto the scan plan.

All the useful parameters can be pre-set and recalled in two clicks.

The fact that the parameters can be set by supervisors over a wireless network and not altered by operators makes for good integrity of data, which is easily recalled and analysed.

Features include Gates, DAC/Split DAC, TCG, AVG/DGS, AWS, API, CSC, TKY & Complex Shapes (all as standard), as well as WiFi, Audio Recording and a 10-hour battery life. Unlike touchscreens used in older flaw detectors, the WAVE’s UTouch technology works well through rubber gloves and can even distinguish between a finger and couplant.

The IP67-rated WAVE weighs just 1.7kg with an 18cm, 1024x600 screen. The ability to track and show beam path is a great feature for training in ultrasonics so it is clear where the beam path is travelling. The unique Curved Surface Correction function makes this an impressive ultrasonic set in terms of functions and features. www.rfsales.com.au

AMT FEB/MAR 2020

PRODUCT NEWS

IMTS Machinery unveils new additive manufacturing range from Prima Additive IMTS Machinery has unveiled details of a full new range of additive manufacturing systems from Prima Additive, a division of the Prima Industrie SpA group of companies based in Italy.

IMTS has been offering the full range of Prima Power fabrication machinery, including laser cutters, turret punches, combination machines, press brakes and panel benders, for more than 15 years. Now it is diversifying into the additive manufacturing space with the arrival of the Prima Additive range of machinery.

as well as other exotic metals, which can be tested directly at the Prima headquarters when required by the customer.

Prima Additive is a leading specialist in additive manufacturing processes, systems and solutions. The manufacturer is unique worldwide in offering the full range of metallic laser additive manufacturing technologies – encompassing powder bed fusion and laser metal deposition processes – as well as delivering full application support and global service. Benefiting from Prima Industrie’s longstanding experience in laser machinery and services, Prima Additive provides strong support to its customers, developing innovative applications driven by the emerging needs and demands of the main industrial sectors where additive manufacturing is dynamically evolving – in particular aerospace, automotive and energy.

Prima Additive’s Print Sharp (powder bed ) and Laserdyne (laser deposition) machines are both capable of using many different types of powders including aluminium, nickel, steel and titanium,

Prima Additive has a customer-oriented approach that involves providing services that are tailored to each customer’s diverse needs, encompassing advanced training, consulting, technical service, process optimisation, machinery status monitoring and analysis, application development and certification. It is at the forefront in embracing Industry 4.0 developments to integrate additive manufacturing in the smart factory of the future.

IMTS and Prima Additive believe in long-term partnerships, and the key product they deliver to their customers is not just machines and applications, but the manufacturing capacity that can be achieved with advanced products and technology. According to IMTS, at the heart of the Prima Additive offering is a common goal shared with the customer: supporting, training, operating, and protecting output to guarantee performance. IMTS’ service covers the entire life-cycle of the system and technology in support of achieving one aim: to maximise the added value and profit for the customer. www.imts.com.au

2020: Start the new decade by getting on top of your legal requirements.

Get your commercial, employment and contractor contracts in order. A properly drafted set of contracts will allocate risk and responsibility appropriately, create commercial certainty and allow you to enforce your rights.

Now is the time to:

Use the Personal Property Securities Register to your advantage: failure to do so can result in dire consequences.

For more information contact Julia Cameron: jcameron@rigbycooke.com.au +61 421 285 104 | + 61 3 9321 7807 www.rigbycooke.com.au

Understand the Free Trade Agreements that will come into effect in January 2020.

Do you know how your business can benefit and what you need to do?

Protect your intellectual property (IP) and confidential information by using Confidentiality Agreements before disclosing valuable IP and, where applicable, registering your IP rights.

Mention your AMTIL membership to receive your member discount with us.

AMT FEB/MAR 2020

039

040

PRODUCT NEWS

Kaeser launches Secotec TG series refrigeration dryers Kaeser has extended its range of energy-saving refrigeration dryers with the introduction of the Secotec TG series.

Accommodating flow rates up to up to 98 cubic metres per minute, the new Secotec TG series of refrigeration dryers from Kaeser ensures stable pressure dew point performance even under the toughest of operating conditions, with maximum reliability and minimal life-cycle costs, and all within a compact footprint.

All Secotec TG series refrigeration dryers are equipped with the innovative Secopack LS heat exchanger system. Its latent heat thermal mass is composed of a phase change material.

Compressed air warms the material up to its melting point (thermal mass discharge), absorbing melt heat during the process. This is significantly more than the amount of heat that it can absorb based on its normal specific heat capacity (without the phase change properties). As a result, the latent heat thermal mass in the Secotec dryers has a dramatically higher thermal density than equivalent conventional systems. It is therefore capable of delivering the same performance using 98% less thermal mass material.

Each dryer also comes equipped with the Sigma Control Smart electronic controller. This provides intuitive operation and comprehensive information can be viewed at a glance from the colour display, such as current operating data, active messages, and a piping and instrumentation diagram (P&ID) diagram.

The high-performance thermal mass concept ensures stable pressure dew points and together with the network-capable Sigma Control Smart controller, it also guarantees long-lasting, energysaving operation in all load phases.

The air-cooled Secotec TG models additionally feature a brand new ventilation system with unique exhaust air control that sets new standards for operational safety and cost efficiency.

Thanks to the use of a radial fan, the exhaust air ducting can be directly connected to the refrigeration dryer. The radial fans are

powerful enough to blow the air out directly via the exhaust duct. Because they are frequencycontrolled they draw off only the exhaust heat needed to maintain stable pressure dew point performance. An auxiliary fan is no longer required.

With the air hood gone exhaust air flow is reduced, which means significantly smaller exhaust ducting can be used. Furthermore the independent exhaust air control allows the dryer to be connected directly to the collecting ducts. Less installation height is therefore required, simplifying system planning and assembly.

The Secotec TG series refrigeration dryers have been specifically designed for the use of R-513A refrigerant. Utilising this climate-friendly refrigerant will assist compressed air users in future-proofing their system as Australia transitions to low-GWP refrigerants as part of the Australian HFC phase-down. It also ensures maximum efficiency and reliability – even at the highest temperatures.

With a compact footprint, the Secotec TG series have only a minimum need for space. It is easy to install with excellent accessibility for service. When it comes to service, the requirements are minimal – only the service unit in the standard Eco-drain condensate drain needs replacing. Unlike typical axial fans, the radial fan in the Secotec TG series models are designed to last for the unit’s entire service life.

Equipped as standard with a Modbus TCP module, the Secotec TG series is Industry 4.0-ready. They can be connected to the Sigma Air Manager (SAM 4.0) master controller, which enables comprehensive monitoring and management of the entire compressed air station. The result is maximum air availability for minimal cost.

Kaeser’s Secotec TG series of energy-saving refrigeration dryers accommodate flow rates from 45 up to 98 cubic metres per minute and are available with a choice of air or water-cooling. au.kaeser.com

Kennametal makes turrets more flexible, collet chucks more capable Kennametal has announced an expansion of its turret adapted clamping units (TACU): ER-ready driven units in conjunction with a line of solid ER collets that are threaded to accept screw-on milling cutters.

Available in sizes ER25 through ER40 with thread sizes ranging from M08 through M16, this innovation provides machining centre-like capabilities to live tool lathes. The new products provide the flexibility to use standard ER collets with solid end mills, or the new solid ER collets together with screwon indexable milling cutters.

Sealed for through-the-tool coolant, there is a one-millimetre standoff for additional clearance on larger end mills with a precision-ground locating boss for minimal runout. This highly compact design reduces the chance of interference on smaller machines.

Compared to a standard spring-style ER collet, the new

AMT FEB/MAR 2020

products are very rigid, allowing users to take heavier cuts. The TACU offering can be used on seven leading brands of CNC lathes, both VDI and bolt-mounted turrets (BMT) with a variety of static and driven blocks. TACU’s are equipped for internal and external coolant, with up to 12,000rpm possible on specified driven tools.

“Together, the new TACU ER units and the solid ER collets are a great marriage of technology,” said Ronald West, Manager – Tooling Systems at Kennametal. “This addition greatly increases the capabilities of our TACU offering.” www.kennametal.com

PRODUCT NEWS

Datalogic Matrix 220 – Ultra-compact image-based scanner Datalogic has introduced to Australia and New Zealand an ultra-compact new image-based barcode reader designed for industry-leading levels of performance and flexibility for high-speed and direct part marking (DPM) applications.

Weighing just 173g, the palm-sized new Matrix 220 imager features rotating connectors for easy installation and integration into tight spaces encountered in industrial automation and highspeed applications. The extreme industrial-grade scanner can read barcodes in a wide variety of applications, including difficult lighting, at high speeds and in a large range of temperatures, making it an ideal industrial scanner for manufacturing, automotive, packaging, food & beverage, electrical or document handling, and a wide range of Industry 4.0 and automation-ready industries.

“The new Matrix 220 imager has been designed for industries needing a robust and reliable scanner that can support their digitalisation and automation growth,” said Morena Corradini, Identification Product Marketing Manager at Datalogic.

The Matrix 220 imager is designed for superior performance in rugged applications and harsh conditions. It features IP67 and IP65 industrial-grade ratings and can safely operate in temperatures between -10 and 50 degrees Celsius. The imager’s 1.2 Megapixel high-resolution sensor and a new multicore image processing platform offer outstanding performance and the ability to read up to 2 mils code resolution. (‘mils’ denotes the width, in thousands of an inch, of the narrowest element – bar or space – in a barcode.)

The Matrix 220 is the first stationary industrial scanner on the market supporting OPC UA (Open Platform Communications Unified

Architecture) protocol for Industry 4.0 communication and Digimarc Barcode technology for added value decoding applications. It is also the first reader of its market segment to embed High Dynamic Range (HDR) imaging. This improves image quality and contrast for higher code readability in applications with lower exposure time and faster line speeds.

The Matrix 220 is ideally equipped to read barcodes marked with DPM. Datalogic’s innovative lighting solutions and integrated flexible illumination system – in white and red models – allow the imager to solve various applications with outstanding performance. In a single model it offers polarised and diffused light options, resulting in optimal illumination on any type of surface. The electronic focus control allows easy remote job changing during assembly line reconfiguration with extreme reading flexibility.

To reduce the number of models, the Matrix 220 comes with a range of front cover accessories – including ESD (electrostatic discharge) and Anti-YAG (Yttrium Aluminium Garnet) protection – to enhance its flexibility and simplify stock management. The imager also offers cost-effective communication and connectivity options with Power over Ethernet (PoE) connectivity, onboard PROFINET/ IO and ETHERNET/IP industrial fieldbus. www.datalogic.com

MTI PE200 SWING DOORS The most robust solution for food industry, retail and logistics The new PE200 HDPE double acting impact traffic door, exclusively available from MTI See-Thru, offers the perfect solution for insulation, functionality and durability.

Benefits of the MTI PE200 Swing Door; • Made of solid polyethylene – non breakable • Hygienic (EU/FDA approved) • Maintenance-free • Made to measure • Short production time • Easy installation • Long service life • PVC finger protection • 10 year guarantee on door leaves • Stainless steel hinges

MTI PE200 AMT_HalfPage.indd 1

Trusted by food and retail companies worldwide;

Contact M.T.I. Qualos today to discuss your industrial door needs.

• Kraft Foods, Bahrain • Nestlé, Germany • Aldi, Ireland • Lidl , Germany, England • Edeka, Germany • Kaufland, Germany • IKEA, Turkey

INDUSTRIAL DOOR SOLUTIONS www.mtiqualos.com.au Free call: 1300 135 539 sales@mtiqualos.com.au AM AMT 25/10/2018 FEB/MAR10:55 2020

041

042

PRODUCT NEWS

Epson – Compact spectroscopic camera to automate colour inspections Epson has developed a compact, lightweight spectroscopic camera that can be integrated in manufacturing lines.

Differences in colour can occur between products in different production lots in ordinary manufacturing processes. A spectroscopic camera can be used by manufacturers to control these differences to a certain extent and ensure product quality by performing colour variation inspections and surface coating inspections.

The RGB cameras currently used in these inspections are unable to capture detailed colour information and are not always able to distinguish between subtle differences in colour. Consequently, most visual inspections relied on human colour perception. However, colour perception varies among individuals, and human error puts manufacturers at risk of shipping defective goods. Time and cost constraints make colour management an issue in many industries. Spectroscopic cameras have traditionally been large and expensive, and those equipped with line sensors may have to composite images after scanning, adding to the

time and expense. Epson has developed an optimal solution for colour management processes, with a compact, lightweight spectroscopic camera that can be integrated into manufacturing lines, can automate and quantify inspections, and can output images without the time and trouble of compositing.

This spectroscopic camera will enable manufacturers to manage colour in their manufacturing processes more easily than ever before.

At approximately the same compactness and weight as an RGB camera, the new Epson spectroscopic camera can be installed in manufacturing lines. Featuroing integral field spectroscopy, it can focus on an area, measure the colours, and distinguish colours of a target object within the visible light range.

Any image processing functions needed on manufacturing lines can be used along with spectral imaging functions. www.epson.com.au

Guhring raises standard with new drilling line Renowned for its expertise in drilling, Guhring has now developed its latest addition to the extensive holemaking portfolio - the new RT100XF. Providing unbridled power and outstanding results guaranteed, the holemaking benchmark has been taken to a new plateau with the RT100XF. Branded as ‘Extreme and Powerful’, the new RT100XF has been developed with all tool parameters optimised to generate outstanding feed rates and exceptional metal removal rates. Created to reduce cycle times for difficult-to-machine materials and special applications in series production, the extremely hard new drilling line is said to be extremely resilient to potential breakages.

This claim is based upon the new carbide grade developed by Guhring for the RT100XF, which performs a balancing act between hardness and toughness. The special structure of this Guhring created carbide grade has a resharpening effect, so breakages that normally accelerate tool wear no longer occur. This is supplemented by the proven nanoFire coating system, which has been created via a specially designed preand post-treatment that smooths the coating and makes it significantly more robust.

The design and geometry of the new RT100XF supports the robust performance of the carbide grade and surface treatment with an early double margin support that perfects the coaxiality to ensure perfect bore size and roundness. This makes the RT100XF

AMT FEB/MAR 2020

the drill of choice for precision, concentricity and performance for holemaking from 5xD upwards.

The new drill series also consists of support chamfers that ensure excellent running smoothness.

Furthermore, polished flutes reduce the heat input into the component, this also supports the fast evacuation of chips and thermal changes such as hardening are avoided. The point geometry is protected by a negative chamfer and this makes the cutting edge ultra-robust and durable.

The rounded edge preparation produces a stable and efficient cutting edge – this rounding is produced with to-the-micron precision. The new through-coolant drills are perfect for the drilling of structural and case-hardened steels, free-cutting and heattreated steels, nimonics, titanium, inconel and hastalloy, making the RT100XF the perfect complement for any machine shop. Available in 5XD and 7XD, the new drills can be purchased in diameters from 3mm to 20mm diameter with 0.1mm increments. The series is also available in all common imperial dimensions. www.guhring.com.au

Real Business Real People Real Members AMTIL is the pre-eminent body representing the Australian machine tools industry.

Relationships have been developed with the global equivalents throughout the World, thus enabling access to the very latest developments. AMTIL continues to lobby on behalf of members and the industry, particularly to Governments, unions and industry stake holders, not only in Australia but also to the wider machine tool industry globally. Strong linkages have also been forged with Australian and international universities, providing the technological and intellectual linkages to the world for our industry. The staff at AMTIL are always willing to assist the membership and the regular networking and awareness sessions on topics of current interest are informative and thought provoking. I can highly recommend AMTIL to industry participants as a dynamic forward thinking industry association.

Grant Anderson, ICN Victoria

Since 1999, AMTIL has been connecting business, informing of opportunities and growing the manufacturing community.

To be become an AMTIL member contact our Corporate Services Manager, Greg Chalker on 03 9800 3666 or email gchalker@amtil.com.au

amtil.com.au 1311AMTIL/GA

044

AEROSPACE & DEFENCE

While aviation – both civil and military – remains an area rich with potential for Australian manufacturers, a growing number of ambitious companies are setting their sights that little bit higher, targeting exciting opportunities in the fast-evolving space sector.

AMT FEB/MAR 2020

045

On 3 December 2019, the Australian Space Agency (ASA) signed a Statement of Strategic Intent and Co-operation with defence and space giant Thales, strengthening Australia’s international space connections to create new local jobs. Minister for Industry, Science and Technology Karen Andrews said the agreement was an important step in the Federal Government’s plan to create opportunities for Australian industry and new local jobs in the burgeoning space sector.

“Engaging with big international players like Thales will allow Australian businesses, including our advanced manufacturers, to carve out a place in the international space supply chain,” said Andrews. “Space is very much an international game and for Australia to succeed we need to play to our strengths and have our businesses and researchers working co-operatively. This statement is designed to mutually identify key areas of investment as well as potential research, development and commercial opportunities.”

The agreement with Thales was the latest in a string of recent announcements by Prime Minister Scott Morrison’s Government as it aims to triple the size of the Australian space sector by 2030, adding $12bn to the economy each year, and creating 20,000 new jobs. The establishment in May 2018 of the ASA was followed last April by the announcement of the Morrison Government’s Australian Civil Space Strategy, a 10-year plan to guide the growth of Australia’s space sector.

Dr Megan Clark AC, Head of the Australian Space Agency (ASA).

“Australia has a strong and dynamic space sector, with high ambitions, great potential characterised by creativity, entrepreneurship, and a sense of discovery,” said Dr Megan Clark AC, Head of the ASA. “This Strategy provides the certainty of a long-term framework around which the sector can plan its activities towards the long-term transformation and growth of the industry.”

It’s an ambitious plan, but already there are several innovative Australian companies moving ahead towards the launchpad and getting set for take-off.

Gilmour Space Technologies – Shooting for the stars Announced in Sydney in October, the Advance Awards celebrate the achievements of Australians living abroad, and of those who have returned home, across a range of sectors. In the Advance Manufacturing category, the award went to Adam Gilmour, CEO and co-founder of Gilmour Space Technologies. He received the award from Michael Sharpe, National Director of Industry at Advanced Manufacturing Growth Centre (AMGC), of which Gilmour Space is a member.

Continued next page

AMT FEB/MAR 2020

046

AEROSPACE & DEFENCE Gilmour Space Technologies specialises in the design and manufacture of launch vehicles for transporting small satellites into space.

Initially founded in Singapore in 2013, Gilmour Space is now headquartered in Helensvale, Queensland.

Contined from previous page

Founded by Adam and his brother James Gilmour in Singapore in 2013, Gilmour Space is now headquartered in Helensvale, Queensland. It has rapidly established itself as one of Australia’s leading space companies, pioneering innovative hybrid propulsion technologies with the goal of providing lower cost access to space.

“We are designing, developing and building a launch vehicle to take small satellites into space, and we are doing this in Australia,” Adam explains. “It has always been incredibly difficult and expensive to send anything into space, but thanks to the last decade of technology advancements, satellites that used to be the size of a fridge can now be made in the size of a microwave, with perhaps the same or better capability. According to Adam, recent rapid advances in technology have caught the industry by surprise. While many of the major aerospace companies are committed to building bigger and bigger rockets, Gilmour Space saw an opportunity to provide smaller launch vehicles to transport the new generation of smaller satellites to space.

“There is a lot of different technologies involved in building a rocket,” Ada explains. “It takes a long time to design, build, and manufacture all the components on your own, and we’ve been very pleasantly surprised to find adjunct industries that utilise similar or adaptable technologies for our rockets.

“To date, we’ve approached and partnered with several of such companies where we supply the requisite designs and they undertake parts of the manufacturing process on our behalf. These companies have decades of experience, which fast-tracks the process; they’ve all ‘seen the movie before’, so to speak.”

In addition to working with other industry players, Gilmour Space recently signed a strategic agreement with the University of Southern Queensland (USQ) to collaborate on advanced rocket technology research, testing and STEM initiatives.

“We have some exciting projects in the pipeline with USQ,” says James Gilmour, now the Chief Operating Officer (COO) of Gilmour Space. “Our initial focus for this Research Partnership will be to develop space-grade composite capabilities and to explore new rocket test facilities in Queensland.”

Adam is equally excited about the new partnership: “USQ has strong capabilities in composite technology. We are using composites for the structure of our vehicle: tanks, the fuselage, and many other parts of the rocket. So, we will be working with the university throughout the design and testing phases of these components.

We will also work with USQ to establish rocket engine test facilities in Toowoomba.”

AMT FEB/MAR 2020

Gilmour Space and USQ are no strangers to collaboration in space, having engaged with the US National Aeronautics and Space Administration (NASA), among others, on separate projects over the years. However, this local partnership will result in innovative space research & development (R&D) activities taking place in Queensland. Along with other national and international partners, USQ and Gilmour Space are developing STEM-related activities to encourage and train the next generation of space scientists and engineers. “We believe it’s important to provide more pathways for bright young minds to get involved locally in the global space industry without having to leave the country,” says James. “And we want to play our part in building this future-ready industry for Queensland and Australia.”

Adam adds: “We’re developing new propulsion technology that we think will produce world-beating rocket launch vehicles, and we’re hiring aggressively—both Australian and international rocket engineers, and university graduates. We’ve been pleasantly surprised at how collaborative organisations in Australia are, and how enthusiastic they are to help build our rockets.”

Titomic – Printing the world’s largest titanium rocket Gilmour Space recently signed an agreement with Melbournebased additive manufacturing specialists Titomic to produce high-performance rocket and aerospace components. Titomic specialises in digital manufacturing solutions for industrial-scale metal additive manufacturing (AM) using its patented Titomic Kinetic Fusion (TKF) technology.

In November Titomic unveiled the world’s largest 3D-printed titanium part, a 5.5m-long rocket at FormNext, the world’s premier AM trade show, in Frankfurt, Germany. The rocket was manufactured on the Titomic TKF 9000 system, the world’s largest and fastest metal AM system, at Titomic’s Production Bureau in Notting Hill, south-east Melbourne. The TKF 9000 has a build size of 40.5 cubic metres (9m x 3m x by 1.5m); utilising the company’s patented TKF technology, it is capable of build rates of up to 30kg per hour compared to many melt-based metal AM machines, which often print less than one kilogram per hour. Manufactured in just 27.6 hours using the TKF9000 system, Titomic’s 5.5m-long rocket is a smaller-scale version of the Gilmour Space ERIS-S rocket, which is 27m long and which will provide customers with reliable and cost-effective access to space. Titomic has the capability to build the full-scale ERIS-S rocket in just 165 hours with the TKF process, using its economical high-performance titanium and other super-alloy powders, which can also be applied to ballistic missiles for defence applications.

AEROSPACE & DEFENCE

(L to R)Jan-Erik Ronningen, Chief Engineer at Gilmour Space Technologies; Jeff Lang, Managing Director of Titomic; James Gilmour, Chief Operating Officer of Gilmour Space Technologies; and Nathanael Miller, Chief Technology Officer at Titomic.

Titomic recently unveiled the world’s largest additive manufactured titanium part, a 5.5m-long rocket at the FormNext 3D printing trade show in Frankfurt, Germany.

Titomic’s TKF 9000 system is the world’s largest and fastest metal additive manufacturing system.

Titomic’s Production Bureau in Clayton, south-east Melbourne.

Titanium is a highly desirable material in aerospace and defence industries due to superior mechanical properties such as light weight and high strength. However, availability of titanium currently remains limited, with Russia being the world’s major supplier. This, along with the difficulty of manufacturing titanium parts using traditional methods, mean the material has generally been too expensive to use. Many high-profile aerospace organisations, such as Elon Musk’s SpaceX, are forced to use less optimal materials like stainless steel 301, a material that offers a quarter of the strength of titanium, at twice the weight.

Myriota and Motherson – Partnership boosts SA space industry

Compared with stainless steel, titanium offers higher fatigue stength and tensile strength, with lower thermal expansion and specific heat capacity. Most importantly, titanium also holds nearly three times the thermal shock resistance in comparison to stainless steel, making it highly suitable for building rockets.

According to Titomic, titanium rockets made using TKF are half the weight of stainless-steel rockets made via traditional manufacturing processes, which allows for an increased payload mass and volume capability. This in turn opens new possibilities for more economic payload deliveries to space. TKF also allows very large seamless shapes to be produced, as advances of AM surpass traditional manufacturing methods in terms of productivity and affordability.

“Previously, titanium was more than twice the price of stainless steel,” says Jeff Lang, Managing Director of Titomic. “But now with our development of new titanium powder supply chains and Australia’s significant mineral sand resources of approximately 280m tons of titanium, Titomic is at the forefront of advancing technology to ensure the future sustainability of the Earth’s resources whilst reducing carbon emissions for global manufacturing.’’

Based in Adelaide, Myriota is a global leader in nanosatellite Internet of Things (IoT) connectivity. In October it entered into a partnership deal with global manufacturer Motherson to produce its Myriota Module – a cutting edge, low-powered device that securely transfers data to the Myriota Network of satellites from anywhere on the planet. Production is well underway, with Motherson already manufacturing tens of thousands of Myriota Modules at its South Australian design and manufacturing facility, for delivery across the globe. Myriota’s growing list of partners and customers include Optus, Amazon’s AWS and Boeing. It is the first partnership that Motherson has entered into with a space or IoT business within Australia, enabling Motherson to expand its business into these industries. Dr David Haley, Myriota’s co-founder and Chief Technical Officer, believes the collaboration shows that it’s possible to keep design and manufacturing within South Australia. “Myriota and Motherson are examples of two South Australian businesses excelling in their respective industries,” says Dr Haley . “Our partnership demonstrates that manufacturing capabilities in South Australia – which once primarily served the automotive industry – have diversified into new sectors, including Australia’s growing space sector.”

Sam Vial, Motherson’s Business Development Director for Asia Pacific, says the partnership is an important step in diversifying its business: “We’re thrilled to become Myriota’s manufacturing partner and expand our operations to include the space and IoT sectors. This partnership will help to sustain jobs in our South Australian facility, with products being both designed and manufactured locally.”

Continued next page

AMT FEB/MAR 2020

047

048

AEROSPACE & DEFENCE

Myriota co-founders, Dr David Haley (left), now the company’s CTO, and Dr Alex Grant, its CEO.

Black Sky Aerospace specialises in supplying responsive access to space, with a range of rockets capable of flights up to 300km.

Black Sky Aerospace – Cleared for launch The Northern Territory is also claiming a slice of the international space industry, with Equatorial Launch Australia (ELA) developing a commercial spaceport near Nhulunbuy in East Arnhem Land.

The Arnhem Space Centre will include multiple launch sites with various launch vehicles providing sub-orbital and orbital access for commercial, research and government organisations.

ELA recently signed an agreement with NASA for it to launch its sounding (research ) rocket program from the Arnhem Space Centre in 2020. The site will host a world first: NASA’s first-ever launch from a non-government-owned site. Meanwhile, Black Sky Aerospace (BSA) will become the first Australian rocket manufacturer to gain priority access to the space centre.

Production of Myriota Modules is already underway at Motherson’s South Australian design and manufacturing facility.

Continued from previous page

Motherson will be manufacturing millions of units of the Myriota Module in South Australia over the next five years. Built on an edge computing platform, the Myriota Module allows for thirdparty integration with a huge range of sensors and devices. These devices communicate directly with Myriota’s nanosatellites to provide sensor data updates on valuable resources to a wide range of businesses.

One of the first customers to benefit from the partnership is Zepiro.

The Australian business recently purchased its first order of Myriota Modules for use by clients in the mining sector, and Zepiro’s COO Damien Cox, says that they’re very excited about the potential.

“The Myriota Module provides a great market opportunity for our business in industries like mining and agriculture where longendurance remote resource monitoring is vital,” says Cox . “The low cost and robust nature of this technology allows us to economically retrieve critical telemetry from difficult to access locations.”

Steven Marshall , Premier of South Australia, was excited to see South Australian manufacturing being leveraged to grow the state’s space industry.

“This is yet another example of two companies collaborating across this exciting, high-growth industry in our state, creating the jobs of the future,” said Marshall. “Myriota is a proud South Australian company now making an impact on an international scale.

Partnerships like this bolster South Australia’s reputation as a global leader across the space sector, attracting even more national and international companies to invest in our state.”

AMT FEB/MAR 2020

“Increasing access to local vehicle manufacturers is an exciting option for the site,” said Carley Scott, CEO of ELA. “We are pleased to provide a launch platform that, we hope, will significantly enhance the growth of opportunities for BSA as a vehicle of choice here and abroad into the future.”

Blake Nikolic, CEO of BSA, added: “Launching from the ELA site in the near term will provide our customers with the benefits of being close to the equator. In the longer term, it allows us to continue developing nation-leading rocket technologies that can carry payloads to orbit and beyond using local expertise and our proven ability to create reliable vehicles.”

Based in Logan, Queensland, BSA specialises in supplying responsive access to space. The company has a range of sounding rockets capable of flights up to 300km, and designs and manufactures a range of propulsion systems for use in rockets and sub-orbital launch vehicle applications. BSA successfully launched Australia’s first commercial payloads in 2018. The company was recently given the green light by regulators to begin the process towards the manufacture of solid rocket motors (SRMs) in Logan.

SRMs are the preferred means of propulsion for many space launch companies due to their simplicity and cost-effectiveness. They are particularly useful because SRMs have a long shelf life and can be stockpiled with little upkeep, yet still be ready to use many months or years later. BSA will be the first manufacturer of its kind in Australia and will be able to provide access to solid fuels for orbital and sub-orbital launch vehicles.

“Our propulsion arm is integral to the bigger picture for us,” says Nikolic. “Without fuel, the industry stalls. Our SRM manufacturing provides industry with accessible rocket boosters, made right here in Queensland. This also allows us to continue with our testing and launch capabilities that we carry out at our facility in Goondiwindi.” space.gov.au www.amgc.org.au www.gspacetech.com www.titomic.com www.myriota.com www.motherson-innovations.com www.ela.space www.bsaero.space

050

AEROSPACE & DEFENCE

Corrosion consequences on the high seas When pursuing suspected smugglers through the waters off northern Australia or rushing humanitarian aid to a cyclone-ravaged Pacific island, the last thing the Commanding Officer of a naval ship needs to worry about is whether the hull will leak, or a critical system will fail, due to corrosion.

Australia’s maritime industry operates in a wide variety of open water and coastal environments ranging from hot, humid tropical, to windy, freezing sub-Antarctic. According to international standards, most of these are classified as having very high to extreme corrosion severity, containing high levels of salt-laden aerosols.

Adelaide-class guided missile frigates HMAS Newcastle and HMAS Melbourne. ©Defence Science & Technology

The Royal Australian Navy (RAN) has all its water-borne assets and most support infrastructure exposed to these environments. For the RAN, corrosion has consequences in addition to the economic ones faced by other organisations.

The RAN consists of approximately 50 warships including frigates, destroyers, amphibious landing ships, submarines and patrol boats.

It also operates minehunters, resupply vessels and hydrographic survey ships. In addition to its vessels, the RAN’s rotary wing aircraft are integral to its operations. Generally, warships can tolerate higher levels of corrosion causing structural damage than aircraft.

All of the RAN’s vessels, equipment and structures must be protected to minimise the impact of corrosion. Traditionally, naval maintenance was carried out on fixed-time schedules such as the rolling hull survey of RAN frigates. Such programs do not allow for the impact of the actual operating environment encountered by individual vessels and its impact on operational availability.

However, when an asset is managed effectively, the impact of corrosion can be minimised. According to a Department of Defence spokesperson, the RAN has implemented a “whole of life” management plan for its assets as recommended by government reviews carried out in 2008 and 2011.

“The plans factor the overall costs for maintenance into the acquisition process,” the spokesperson said. “A culture of accountability has also been instituted which considers the riskversus-cost benefits of deferring preventative maintenance.”

There are a number of ways to estimate the financial cost of corrosion of RAN assets, including scaling the costs of a foreign navy operating similar warships. According to the RAN spokesperson, the economic impact of corrosion and its degradation of naval assets and infrastructure is estimated to be between $135m and $650m annually, depending on the metric used to calculate the cost of maintenance and remedial repairs.

The RAN is now planning condition-based maintenance, which optimises maintenance costs by only intervening when a monitored system’s condition indicates a problem. Corrosion Prognostic Health Management (CPHM) uses these principles to predict current and future corrosion conditions based on platform usage in an operational environment. CPHM uses a combination of sensors and models to predict and plan future maintenance activities and operations. “Moving from a time-based to a condition-based maintenance system through use of environmental and corrosion sensors, allied with corrosion prognostics and modelling, should allow targeted maintenance and more efficient use of limited resources,” the RAN spokesperson added. “It will also allow improved scheduling of maintenance, resulting in optimum usage of platforms and equipment.”

Ship staff on a warship are directed to report changes in appearance or obvious signs of corrosion. If staff have the relevant training, they may apply corrective maintenance if it is safe and timely to do so. However, maintenance at sea or on operations is usually only carried out if it is high priority. The majority of maintenance is carried out while the ship is alongside or in dry-dock in accordance with the technical maintenance plan.

AMT FEB/MAR 2020

The RAN’s mission includes maintaining Australia’s sea lines of communication and defending Australia’s sovereign interests.

Additionally, it undertakes humanitarian missions around Australia and the Asia Pacific region. From a long-term perspective, corrosion shortens the “life of type” of vessels, which can create a capability gap as it may be several years before replacement vessels come into service and may have a large impact on the ongoing maintenance budget as the older vessels are kept for a longer time than planned.

It is important to manage corrosion in the defence industry using preventative measures over both short and long timescales.

Unidentified or untreated corrosion issues can lead to unplanned corrective maintenance that can affect availability, readiness, safety and capability of RAN vessels and rotary wing aircraft for operations, all of which result in significant costs.

Protective coatings are critical to mitigating corrosion as they form the barrier between the metal and the aggressive marine environment.

The RAN spokesperson stated that a paint specification document that details the coatings systems to be applied to every part of the ship, from underwater hulls, superstructure and decks to all internal areas, is prepared for each vessel prior to construction.

Safety-of-flight is paramount for the RAN’s air assets – this demands very strict inspection and maintenance programs to mitigate risk of failure. Failure of a key component in flight could result in accidents leading to loss of the helicopter and loss of life.

AEROSPACE & DEFENCE Areas of naval vessels subject to continuous water immersion, such as the underwater hull, bilges and tanks, are considered critical as these areas are more prone to coating failures and corrosion. Corrosion and loss of metal in tankage is a major factor in determining the life of commercial vessels. Freeboard areas, which are subject to continuous water spray while underway, and ship decks are also considered critical.

Research into the development of specialised protective coatings for military applications is supported by the Australasian Corrosion Association (ACA). The organisation works with private companies, not-for-profit bodies and academia to research all aspects of corrosion prevention and mitigations. The ACA provides an extensive knowledge base that supports best practice in corrosion management, thus ensuring all impacts of corrosion are responsibly managed, the environment is protected, public safety enhanced and economies improved.

Several ACA members are currently engaged in a range of Defencerelated projects. Professor Maria Forsyth, Chair in Electromaterials & Corrosion Sciences at Deakin University, and Senior Research Fellows Dr Katerina Lepkova and Dr Laura Machuca Suarez at Curtin University’s Western Australian School of Mines: Minerals, Energy & Chemical Engineering are investigating anti-corrosives such as lanthanide-based ones to mitigate microbially induced corrosion and special anti-corrosive pigments.

A related anti-corrosive pigment project is being undertaken by researchers Dr Sam Yang and Dr Tony Hughes at the CSIRO’s Materials Science & Engineering division, specifically looking at ways to transport these pigments to defect sites.

Associate Professor Scott Wade from Swinburne University’s Faculty of Science, Engineering & Technology is researching microbiologically influenced corrosion of piping materials and mitigation options, and high-velocity oxygen-fuelled (HVOF) coatings for marine hydraulic applications.

For many decades, the RAN employed solvent-based gloss alkyds as the topside coating for vessels, but these were not very durable, often failing in as few as six months. In the 1990s, a polyurethane coating was introduced but this has since been replaced by a Low Solar Absorbing (LSA) Polysiloxane coating, which has a colour-stable pigment that provides improved visible camouflage

in the waters around northern Australia. The polysiloxane also has improved thermal protection reducing the cost of cooling ships, where trials of patrol boats in norther Australian waters showed that the surface temperature of the polysiloxane coating could be as much as 15 degrees Celsius cooler than traditional coatings.

The development of rapid-cure, ultra-high solids, two-pack epoxy amine coatings technology offers potential advantages for the RAN, especially when dealing with complex internal surface geometries found inside sea water ballast tanks, which feature baffles with cut-outs between bays and numerous longitudinal and transverse stiffeners to provide requisite rigidity and strength. Historically, corrosion on these edges would appear after a period in service, largely as a result of the poor edge retention of conventional coatings that were used.

The latest epoxy amine coatings are applied using specialised plural component high-pressure spray equipment where the two components are mixed at, or close to, the tip of the spray gun and generally require each component to be pre-heated to reduce flow viscosity. The coatings can be spray-applied at high film build without sagging, have improved edge retention and produce very low emissions of volatile organic compounds. These coatings cure very quickly and can be walked on within a few hours, delivering a swift return to service.

The specification of high-performance coatings for RAN ships must be supported by rigorous quality assurance inspections.

It is imperative that coatings are applied as per specification or manufacturer’s recommendations, which is best achieved through the use of independent inspectors who are required to witness the condition of the substrate and undertake measurements, such as dry film thickness at key ‘hold points’, during the surface preparation and painting processes to ensure that the environmental conditions are suitable for painting. These include weather conditions, substrate temperatures, and dew point.

Other corrosion management technologies applicable to naval vessels and infrastructure include research into anti-corrosive coatings, for superstructure, underwater hull, tanks and bilges as well as cathodic protection of hulls, bilges, ballast tanks, seawater piping systems. www.corrosion.com.au

Queensland manufacturer lands Heathrow Airport export deal Queensland-based manufacturer National Plastics & Rubber has secured an export contract to supply specialised aircraft wheel chocks for London Heathrow International Airport in the UK. Based in Sumner Park, in Brisbane’s south-west suburbs, National Plastics & Rubber was established 22 years ago and remains privately owned by two families, employing a local team of 34 people. The company specialises in the design and manufacture of quality polyurethane, industrial plastic and rubber products, primarily manufacturing specialised products for the mining industry in Australia.

In recent years it has been gradually building its export business.

According to National Plastics & Rubber, the Aerochock product is the lightest specialised aircraft wheel chock on the market today, helping to reduce workplace injuries stemming from constant handling. It was designed utilising technology that National

Plastics & Rubber developed for the manufacture of chocks for the world’s largest mining trucks.

The Aerochock is already in use in countries such as Cambodia and New Zealand, as well as Australia. In securing the contract with Heathrow Airport, it saw off competition from rival products from around the world including the USA and Germany.

“We are very proud of our team in achieving an export order to Heathrow International Airport with locally designed and manufactured products,” said Peter Tulley, Director of National Plastics & Rubber. “Hopefully this win will inspire other manufacturing companies in Australia into realising they can do the same.” www.nationalplastics.net.au

AMT FEB/MAR 2020

051

052

AEROSPACE & DEFENCE

A path to certification: Additive manufacturing and aerospace The importance of additive manufacturing (AM) isn’t lost on the aerospace industry, with industry leaders like Boeing and Airbus long having adopted the technology to create parts. But it’s not just the giants that recognise the advantages: smaller, innovative companies like Aurora Flight Sciences also see the benefits.

Aurora developed and flew the first 3D-printed jet-powered unmanned aerial vehicle (UAV), capitalising on the strength of fused deposition modelling (FDM) ASA thermoplastic for the main wing and fuselage structures. The aircraft’s main purpose was to demonstrate the speed at which a design can go from concept to a flying aircraft. It also illustrates the validity of AM for flight-capable parts, beyond the traditional role of prototyping.

While AM methods and applications may differ among these companies, the reason they use it is common: it provides multiple benefits that collectively improve their bottom line. That might come in the form of meeting delivery schedules, improving performance, reducing waste, optimising the supply chain, or a combination of the above.

From rapid prototyping to flight parts Since its inception, a common use case for AM has been rapid prototyping, allowing aerospace companies to validate fit, form and function in addition to reducing product development time.

The next step is the production of flightworthy parts for use on certified aircraft. The reasons for this are obvious: AM helps aerospace companies attain important goals of reduced weight and lower buy-to-fly ratios (the ratio of procured material weight to the final part weight). For example, 3D printing allows the creation of organic shapes that aren’t otherwise possible with conventional manufacturing methods. This lets engineers design optimal strength-to-weight geometries, reducing weight by minimising the amount of material needed to carry the load. Aurora Flight Sciences used this approach on their UAV to achieve a stiff but lightweight structure, using material only where it was necessary.

This capability to apply material only where it’s needed also results in little to no scrap, unlike subtractive processes. AM thereby offers a much more favourable buy-to-fly ratio, using only what’s necessary to create the part. Buy-to­fly ratios for machined aircraft components can be in the range of 15-20, compared to close to one for AM parts, making material waste an important cost consideration.

Other benefits of AM include part count reduction by 3D printing multiple components as a single part. This results in fewer individual parts, less manufacturing and inventory, and reduced assembly

The jet-powered UAV developed by Aurora Flight Sciences is made with 34 parts; 26 of those are 3D printed.

AMT FEB/MAR 2020

labour. United Launch Alliance reduced the part count on an environmental control system duct for its Atlas V flight vehicle from more than 140 pieces to just 16 with ULTEM 9085 resin.

AM also enables creation of complex designs and intricate geometries without the time and cost penalty of traditional manufacturing methods. In some cases, it allows creation of parts that otherwise wouldn’t be possible. The fuel nozzle for the GE LEAP engine is a good example. The configuration engineers developed to meet restrictive performance requirements included intricate internal passages and geometries. The final design was ultimately not possible to manufacture with machine tools and could only be achieved with AM. From a supply chain perspective, the ability to economically produce parts on-demand gives manufacturers much greater flexibility to make and locate parts when and where they’re needed.

This alleviates the expensive process of producing and stocking sufficient spares to support demand scenarios that are difficult to predict. It also gives manufacturers the flexibility to overcome hiccups in the supply chain. Airbus used this strategy in producing the A350 XWB aircraft, 3D printing parts to maintain the aircraft delivery schedule.

Certification headwinds These are just a few examples of the merits of AM for end-use aircraft parts. But the challenge faced by aerospace companies in achieving these benefits lies with airworthiness certification.

Parts installed on aircraft must be certified flightworthy as part of the overall certification of the aircraft. For engineers wanting to design additively manufactured flight parts, that’s easier said than done, since unlike traditional materials and processes, there are no industry-standard “design allowables” to characterise the properties of AM materials.

Without this information, aerospace companies face either avoiding the use of AM flight parts altogether or developing the design allowable themselves. Depending on the application, the latter scenario probably requires expensive and lengthy testing. In the highly competitive aerospace industry, neither option is optimal.

AEROSPACE & DEFENCE

Nonetheless, some companies have done what it takes to qualify non-metallic materials, such as polymer-based composites, for use on aircraft. However, manufacturers that take this approach typically view the data as proprietary due to the cost and effort involved, and they don’t share it within the aerospace community.

This creates an “everyone­for-themselves” environment, resulting in a lack of industry-wide standards. While large companies may be able to justify the time and cost for this effort, it can be prohibitive for smaller companies without publicly funded support programs. At a practical level, requiring each manufacturer to duplicate the process for a material that another manufacturer has already evaluated is simply counterproductive, driving up industry costs and inhibiting innovation.

An industry solution A solution to this was indirectly borne out of an effort in the mid1990s to rejuvenate the general aviation market. The Advanced General Aviation Technology Experiments (AGATE) initiative involved the participation of NASA, the US Federal Aviation Administration (FAA), the aerospace industry and academia in the development of improved technologies and the standards and certification methods governing them. Part of this project involved the development of standards to qualify new materials and their production while abbreviating the certification timeline.

AGATE eventually evolved into a new process, named after the organisation that administers it: the National Centre for Advanced Materials Performance (NCAMP). The NCAMP process is now the established method for qualifying new material systems and developing a shared database of design allowables. The benefit for aerospace companies looking to certify their designs, beyond access to resultant material data, is that the certification authorities, the FAA and the EU Aviation Safety Agency (EASA) accept dataset and material process specifications for key components of the qualification process.

The initial focus of AGATE and the NCAMP process was qualification of polymer-based carbon-fibre composites, as composite technology offered benefits in the form of strong, lightweight structures. As a result, a number of different composite material systems have been qualified through the NCAMP process, providing a shared database of corresponding design allowables.

This has been a benefit to companies that want to use those materials on certified aircraft, while avoiding the long, expensive process of qualifying the material on their own. Instead, they must simply demonstrate “equivalency” – proving they can duplicate the material characteristics of the base qualification dataset, but on a smaller and less costly scale than a full qualification program.

Unfortunately, the same cannot be said for manufacturers looking to use AM parts on certified aircraft programs. Although aerospace companies have leveraged AM for more traditional benefits like faster prototyping and agile tooling, the barrier to certification endures due to the lack of a qualified AM material that is tested and validated using the NCAMP process. This prevents the aerospace community from fully benefitting from AM production parts, with real performance, supply and cost efficiencies.

The problem was taken up by America Makes, also known as the National Additive Manufacturing Innovation Institute, which chartered the initiative to qualify the first AM material for certification purposes using the NCAMP process. This qualification process is what ultimately results in the establishment of design allowables that companies can use to design aircraft parts, a major piece of the certification puzzle. ULTEM 9085 resin was chosen by an industry steering group as the first AM material for NCAMP qualification. The material and the FDM process were selected because of their wide acceptance and use within the aerospace community.

Material testing and qualification using the NCAMP process is performed by the National Institute for Aviation Research (NIAR) at Wichita State University. The process begins with the establishment of a material specification to control the material manufacturing and processing quality. Next, a process specification is developed to control the build process using that material. This is necessary to remove any process variability and establish a controlled means of production. These specifications exist because an important part of the certification process is the assurance that each manufacturer is making parts to the same standard. As Paul Jonas, Technology Development Director at NIAR, described it: “The first part you make has to be equivalent to the hundredth part, to the thousandth part, to the part you make ten years from now, to be good enough to be certified for the FAA.” Once the production method is established, any decision to create parts using another system, process or material requires a separate qualification process for that method or material. The specifications also include controls for ongoing process validation, to ensure standards are maintained.

After the process specification was established, the ULTEM 9085 resin material qualification plan began. Around 6,500 test coupons were evaluated for specific mechanical properties and exposed to fluids typically found in an aircraft operating environment like engine oil, hydraulic fluid and jet fuel. Test results are then analysed to determine the material characteristics and corresponding design allowable dataset.

This data is currently published on the NCAMP website and findings will be incorporated into CMH-17, the composite materials handbook that provides standardised engineering data on composite and other non-metallic materials.

The Stratasys solution The final step in the AM certification solution path involves the demonstration of equivalency to the NCAMP dataset. Companies that want to leverage the NCAMP process need to show that their AM process with ULTEM 9085 CG resin results in material properties statistically equivalent to the original data. But this is achieved with a much smaller sample size, drastically reducing the time and cost for qualification, with a ten-fold estimated cost savings. Once equivalency is achieved, manufacturers can leverage the NCAMP process for key components of the airworthiness qualification process, having established that their AM process is equivalent to the allowable database.

The equivalency process is reliant on two factors: use of a properly configured Fortus 900mc Production System, in conjunction with certified ULTEM 9085 CG material. Stratasys developed specific capabilities for the Fortus 900mc that include enhanced material deposition, ensuring consistent, repeatable build results to produce equivalency test coupons. An AIS Machine Readiness package is available to validate the proper set-up and operation of the AM system and demonstrate a means of compliance with the NCAMP process specification. ULTEM 9085 CG resin undergoes more testing than standard ULTEM 9085 material and is accompanied by documentation that gives manufacturers full traceability back to the raw material. The certified ULTEM 9085 CG resin, the configured Fortus 900mc, and the AIS Machine Readiness package are available as a comprehensive solution from Stratasys.

AM is no stranger to the aerospace industry. The next level of efficiency involves the manufacture of interior (or other non­flightcritical) components using the NCAMP-certified material and process – a major step in defining the roadmap toward using AM in aerospace production. The NCAMP process sets the precedent for the qualification of other AM materials, clearing the path for faster, broader use of AM in aerospace. www.objective3d.com.au

AMT FEB/MAR 2020

053

054

AEROSPACE & DEFENCE

Naval shipbuilders make pitch for industry talent Appropriately skilled and experienced naval architects and design engineers/drafters are priority employment targets today for Australia’s naval shipbuilding companies.

Market analysis undertaken by the Naval Shipbuilding College (NSC), in collaboration with Australia’s naval shipbuilding industry, identified experienced designers/drafters in particular as a critical job priority. Naval architects and associated designers/drafters are responsible for the creation of the highly sophisticated 3D designs, product models and schematics, required to design, build and sustain the Royal Australian Navy’s new submarines and warships.

NSC Chief Executive Ian Irving said the Federal Government’s $90bn National Naval Shipbuilding Enterprise provides an unparalleled career opportunity for naval architects and maritime designers/ drafters in this country.

“The opportunity to work on the world’s most technologically advanced projects, contributing to the design of some of the most sophisticated machines that are being creating anywhere in the world, and to be able to do this here in Australia, is very appealing to a potential workforce,” he said. “Naval architects and designers will be at the very heart of creating Australia’s new fleet. These are very important and coveted jobs that are in demand across the world today.”

The spearhead of Australia’s new fleet will include 12 Attack Class Submarines, 9 Hunter Class Frigates and 12 Arafura Class Offshore Patrol Vessels. Irving said the Government’s commitment to establish a sovereign shipbuilding capability means that naval shipbuilding is now a standout career of choice for many Australians, providing meaningful employment and ongoing career opportunities for the current workforce and future generations.

“With the emergence of the digital shipyard, next-generation maritime technologies, and the rapidly evolving Industry 4.0

transformation taking place in shipbuilding, workers who gain experience and expertise in these areas will quickly be considered among the leaders in their field, providing opportunities for a lifelong career,” he said. “They will be able to write their own ticket for their futures.

“Naval shipbuilding offers new opportunities that are not widely available across other industry sectors. That’s because we’re dealing with highly complex first-principles designs, on largely bespoke first-of-class solutions. It’s incredibly exciting work for our naval architects and designers.

“More broadly there will be thousands of jobs available within the wider Enterprise across Australia, providing rewarding and meaningful employment, with wide ranging career options including technical trades and professional roles.

“The College is focussed on helping industry realise their workforce goals and assisting Australians to secure their desired education and training qualifications to put them in a position to meet their employment goals through the Workforce Register, which is free to join. More than 2,000 candidates have already joined the Workforce Register and thousands more are expected to register in the months and years ahead.

“From experienced workers looking to upskill themselves or transition from other industry sectors, to secondary school students seeking advice on their technical learning and subjects they should study, we are helping them identify the next steps in their education or career pathways that can lead to a job within the Enterprise.” www.navalshipbuildingcollege.com.au

A job for life in a booming industry to cope with the tens of thousands of different parts that make up a modern submarine.

The lure of working with world-leading technology, in a booming industry that also offers long-term job security, was irresistible for new ASC designer and drafter, Richie Van Bochove.

After completing a four-year apprenticeship and then an advanced diploma (part-time over six years) with TAFE SA, Van Bochove quickly advanced to the role of Chief Mechanical Designer in the transport industry. When submarine builder ASC began advertising for designers and drafters, Van Bochove didn’t hesitate to apply.

“I had enjoyed my role with my previous employer and they were disappointed that I was moving on, but the opportunity to join the naval shipbuilding industry was too good to resist,” he said. “Naval shipbuilding is a booming industry and when I kept hearing about the contracts being signed by the Government, I knew this would be a job for life. There is a lot of work going on right now and it’s just going to keep growing.

“As far as I am concerned naval shipbuilding is the future for people in my line of work.”

The computer programs and technology used to work on the Collins Class Submarine sustainment are extremely advanced

AMT FEB/MAR 2020

“Working with these programs everyday is improving my skill set and something I will keep for life,” said Van Bochove.

“The opportunity to learn and work with these programs is unique within the defence industry. If people want to work with the best technology in the world, this is where they have to be.”

According to Van Bochove, the job requires constant attention-to-detail, which helps with the development of advanced skills and an understanding of best-practice design techniques.

“It was a little daunting after I finished school to navigate my tertiary education pathway, but I found my way through eventually,” he said. “If the NSC’s Workforce Register was around when I was trying to work out the best study and training options for me, I would have joined up in a flash.

“I think it provides a big advantage for people who want to get into the defence industry, either right now or down the track. For me, I’m really looking forward to new opportunities at work and just being a part of this evolving industry.” www.asc.com.au

AEROSPACE & DEFENCE

Why mid-sized manufacturers are crucial to the defence sector’s future The defence sector is an important contributor to the Australian economy and a huge employer, accounting for almost 30,000 jobs, half of them among 3,000 or so small-to-medium-sized businesses (SMBs). How can these SMBs transform themselves into firms that can bid for major defence contracts in partnership with or even against the Primes? By Rob Stummer.

Considering the concentration of SMBs in the Australian defence sector, to achieve the ambitious growth required, more emphasis needs to be placed on helping them enhance their capabilities in order to become long-term strategic suppliers to the Department of Defence (Defence). The Federal Government has already invested a record $200bn in Australia’s defence industry capabilities in order to encourage more innovation and growth.

How can SMBs win major defence contracts?

One of the challenges is that defence machinery and equipment can be in operation for up to 30 years, which is why Defence wants to see an iron-clad supply chain that will be around when the equipment is nearing the end of its life. The strategic suppliers to Defence need to prove that they have the necessary growth strategy, systems and resources to position their businesses to become major strategic suppliers that will still be operating in 30 years’ time.

It’s extremely tough for SMBs to win major defence contracts either direct with Defence or working with the Primes as a key part of their supply chain due to not having the right management structure in place. They also lack the knowledge, skills and experience needed to develop their businesses to the next level required to even be on the shortlist.

Government grants have gone some way to helping develop technical capabilities; however the problem is that if the most advanced defence equipment available was developed by a relatively small Australian company, they would need to demonstrate that they are structured for long-term growth and have the right strategy, systems and resources that will enable them to build the company in a sustainable way, which needs a lot of funding and investment.

Digital transformation In order to be suitable to win defence contracts, Australian defence suppliers not only need to get their strategy, management structure and capabilities right; they also need to demonstrate where they are in relation to digital transformation.

This will help them to identify if there are ways that they can optimise their manufacturing operations by creating flow, increasing efficiency, connecting their machines and reducing downtime.

The first step on this digital transformation journey for defence suppliers is to understand how the convergence of digitised machine parts, improved connectivity and emerging ‘Industry 4.0’ technologies, such as IIoT and AI, will help them to improve the productive time of their employees and equipment, as well as aiming to eliminate paper from the production environment.

Having real-time production data to hand 24/7 will allow defence suppliers to give defence customers realistic delivery dates, improve on-time deliveries, provide live job statuses and accuracy of job costing, minimise changeover time, measure performance and increase productivity by visualising loss.

How defence has adopted IIoT and AI The defence industry was among the first to realise the value of Industrial Internet of Things (IIoT) sensors in areas such as aircraft maintenance and health monitoring, real-time identification of quality issues, rapid delivery of software updates, and optimised tracking and traceability. It has also spearheaded the use of IIoT technologies to improve process and product efficiencies.

Military aircraft generate terabytes of digital data every day, but to date only a minute amount of that potentially invaluable information is being utilised. This presents an opportunity; the huge volumes of data will eventually yield profitable secrets, such as the identification of new manufacturing and service opportunities.

By embracing AI, defence manufacturers provide their enterprise resource planning (ERP) systems with the ability to mine and analyse immense amounts of data, along with the power to respond to surfaced insights with specific, automated tasks. For users across the business, AI can deliver real-time information with direct relevance to decision-making processes, encouraging the creation of agile, increasingly competitive cultures within defence sector SMBs.

A single source of truth In order to become a major defence supplier and remain competitive, a digitally advanced factory environment needs to be implemented with what we call a ‘Single Source of Truth (SSoT)’. This is a fully integrated approach to ERP that ensures error- and redundancy-free data. Combined with manufacturing operations management (MOM) software, an SSoT provides AI with accurate, real-time data from across the entire business and optimally, along its associated value chain.

Given the immense challenges facing defence suppliers – including global competitors, changing approaches to acquisition and sustainability, shifting economies and geopolitical instability – Australia’s SMB defence companies need to become more agile and forward-thinking than they’ve ever been before. Strategically utilised AI will be one of the keys to future success, helping these developing companies allocate capital and build differentiated skillsets. This will result in more opportunities for strategic defence contracts in Australia and internationally, resulting in bigger profits and more Australian jobs.

Rob Stummer is the CEO – Asia Pacific at Syspro. au.syspro.com

AMT FEB/MAR 2020

055

056

AEROSPACE & DEFENCE

Australia set to build its first research submarine A three-year project to design, manufacture and test Australia’s first yellow submarine is getting underway.

The fully reconfigurable Australian Research Experimental Submarine (ARES) will be used for hydrodynamic and crew efficiency testing of future submarine designs. The project is a collaboration between the University of Adelaide, University of South Australia, Flinders University, TAFE SA and the University of Tasmania’s Australian Maritime College with Defence support from DST Group. The four industry partners for the project are SAAB, ASC, Dassault Systemes and MOOG Australia.

ARES received $150,000 in Defence Innovation Partnership funding from the South Australian Government in December to boost a $350,000 in-kind contribution from participants to fund the project’s first year. An estimated $3m will be needed to complete the three-year project.

Project lead and University of Adelaide Director of the Shipbuilding Hub for Integrated Engineering and Local Design (SHIELD) Eric Fusil said the project would deliver Australia’s first reconfigurable research submarine. He said the autonomous submarine would be used to test hydrodynamics – how a submarine behaves underwater – to aid in the design and safe operation of new submarines globally.

“Because you can’t see on board a submarine and you don’t really know where you are going, you need to know that when you are pulling on the controls from inside the submarine that you are setting the control planes outside at a given angle,” Fusil explained.

“You need to know the effect of these angles for each given speed on the trajectory of the submarine – otherwise you are at risk of breaching the surface or diving too quickly.

“Despite all our best efforts worldwide we’re still at a point where we cannot use computers to predict all of that. You need to go to actual testing with small-scale submarines to be able to deliver a safe analysis of how present or future submarines are behaving underwater. These vehicles are often quite specific to a class of submarine, whereas our submarine will have the ability to be generic and to be adaptable to any kind of shape overall and also to any kind of location of contour plane.”

Early designs show the submarine to be about 7m long and up to 1.8m high. Its ‘golden wattle’ yellow colour will allow it to be easily observed during underwater tests. Initial testing will probably be done in lakes at a depth of 30 to 40m – deep enough to properly test the submarine’s hydrodynamics but shallow enough for it to be safely recovered by dive teams if it encounters problems.

AMT FEB/MAR 2020

While Australia has not previously had a research experimental submarine, several of its allies including the US, the UK, The Netherlands and France have used them extensively.

Fusil said the project would also help develop a skilled workforce that will go on to contribute to Australia’s future submarine program.

“The project is quite unique because in Australia so far we have taken products off the shelf and we have customised and adapted them to our Australian environment,” he said. “On this project we are starting pretty much from scratch but we have access to a very good technical support network including the UK, The Netherlands and potentially the French, so we will be able to feed on the lessons learned from these countries and take the best from all of them to build a successful model.”

The project will also enlist the help of several international ‘Grey Beards’, experienced industry experts who will mentor and guide the project. The first year of the project will mainly involve design work before procurement, manufacture and testing phases in years two and three.

South Australia is pivotal in Australia’s $50bn plan to regenerate the Royal Australian Navy (RAN), including 12 Attack Class submarines to be built at the Osborne Naval Shipyard in Adelaide, which is undergoing a $500m upgrade.

Dassault Systemes will provide its 3DExperience software platform, which is likely to be the environment in which Australia’s future submarines are developed. Fusil said the 3DExperience software would cover the full cycle of engineering and production from the very early stages of design through to the transition to procurement, manufacturing and testing.

“The 3DExperience will integrate Industry 4.0 aspects and enable us to cover the whole life-cycle from design to test and activation, and that’s a big challenge that nobody has done before,” he added.

“It is definitely the ambition – not just in defence but industry overall – to go fully digital and Dassault’s 3D Experience is a product that claims that to be completely possible.”

According to Fusil, DST Group – the Federal Government’s Defence Science Technology agency and one of the project’s major partners – would have the opportunity to use ARES to help develop the Attack Class submarine and also to validate other projects Australia is involved in with its allies.

AEROSPACE & DEFENCE

“Our aim – because we are universities with industries and DST – is to start with an unclassified submarine shape but we want that shape to be able to be used by our sponsors such as DST for classified testing if they elect that to be the case,” he said. “But we are also aware there is a niche market for these vehicles. Because submarines are being considered by many navies including in the South-East Asian region, there are a number of countries that are interested in accessing this kind of technology.

“We are applying this capability by connecting these researchers with our defence industry to accelerate development and build solutions to key projects for Australia,” said Price. “The importance of collaboration between defence industry and researchers cannot be understated; it is the foundation for success and key to solving increasingly complex Defence problems.”

According to Fusil, securing funding for years two and three was key to delivering the full project.

“We could export that vehicle because it is based on an unclassified “We need to prove to the stakeholders that we are serious and shape and it can be customised. We could sell this kind of freethat we are here to deliver. We’ve got interest from a number of running model to our neighbouring countries interested in having stakeholders – public and private – and we’re trying to find a model their own model to be used for analysis to develop their own where everybody is comfortable to contribute and will also be submarines.” The project is one of four South Australian projects happy with the outcomes.” funded through the latest round of the Defence Innovation www.adelaide.edu.au www.unisa.edu.au Partnership. Defence SA Chief Executive Richard Price said South www.flinders.edu.au www.tafesa.edu.au Australia’s three universities each had specific strengths in a range AMTIL-ADVERT-MAIN-2020-OUTLINED(FA).pdf 1 17/1/20 10:49 am of defence-relevant fields.

C

M

Y

CM

MY

CY

CMY

K

AMT FEB/MAR 2020

057

058

AEROSPACE & DEFENCE

The new normal – Metal 3D-printed suppressors for military, police New Zealand-based metal 3D printing outfit RAM3D has been scaling up its additive manufacturing production recently. By Gilly Hawker.

According to RAM3D, the world has, at long last, woken up to the benefits of additive manufacturing. For more than 10 years the company has been leading the way in metal 3D printing in the Southern Hemisphere, and prints parts for a range of industries worldwide. The sectors it serves include aerospace, defence, marine, food manufacturing, industrial and speciality.

Many of the industries that it engages with have Non-Disclosure Agreements in place, meaning RAM3D can’t usually talk about its clients or the parts that it prints for them.

However it has been allowed to discuss its working relationship with Oceania Defence.

An early adopter of additive manufacturing technology, Oceania Defence has been able to secure patents on firearms suppressors made using metal 3D printing.

The company supplies suppressors for defence and law enforcement clients all over the world. Health & safety regulations around the world are driving the demand for suppressors as regulators and firearm users look to reduce significant hearing risks to themselves and others.

Oceania Defence has been working in collaboration with RAM3D since 2012. The journey started with Bert Wilson, owner of Oceania Defence, sketching up some designs and deciding to try 3D printing the suppressors. RAM3D was able to develop strategies to overcome the challenges of making the very complex geometries involved, while at the same time Oceania Defence was learning what would offer the best outcome from a design perspective.

Together, after rigorous design, research and testing, they reached the most desired outcome: a suppressor that is highly efficient, lightweight, compact and most importantly, cost-effective. Military and police tactical groups put their suppressors through an extensive evaluation procedure, alongside manufacturers from Europe, USA and Australia, before awarding their contracts to Oceania Defence. The suppressors are for semi- and fully-automatic rifles.

So what does the military want in a suppressor?

• Keep the weight low.

• Keep the size small – minimal additional length.

• No change to bolt velocity.

• Hearing safe at the muzzle and shooter’s ear.

• Flash signature reduction.

AMT FEB/MAR 2020

It’s impossible to achieve everything on the wish list without jeopardising other factors, but it’s important to get as close to this list as possible. According to Wilson: “You can get really good in one area and make it really bad in another area.”

Oceania Defence prints its suppressors in both Inconel and titanium. Inconel retains its strength at red hot temperatures in extreme firing schedules, and is as strong as standard stainless steel at room temperature. This suits the defence sector which has a high rate of fire. On the other hand, titanium suppressors are very light and ideal for hunters, police and sport shooters. And why choose metal 3D printing over other traditional manufacturing techniques?

With conventional machining, the focus and cost are directly related to material removal.

The machinist spends time and money removing material from a blank to make a finished part. To make the part cheaper, the designer must leave as much material in the part as possible, so the machinist doesn’t have to remove it.

The reverse applies to 3D printing. The designer starts with nothing and spends time and money putting material where it’s

required without having to add it in places it’s not needed.

The potential of metal 3D printing RAM3D knows that metal 3D printing is a competitive production technology with unprecedented potential for industry. It works with companies to improve the design of production parts, and 3D printing them makes them more efficient and costeffective.

The diversity of parts that RAM3D manufactures ranges from titanium knives used by the Team NZ America’s Cup crew, to customised handlebar extensions for the New Zealand Olympics Cycling Team, as well as Oceania Defence’s Inconel and titanium suppressors.

Over the last three years, the company has seen a big shift from prototyping to full production work. To keep up with customer demand, it recently purchased two more Renishaw AM250 printing machines, commissioned in early January. RAM3D now has a total of seven printers in its growing facility. www.ram3d.co.nz www.oceania-defence.com

Explore your unlimited possibilities additively The Additive Manufacturing Hub is a $1.85m programme that will grow and develop additive manufacturing capability and investment in Victoria. The vision of the AM Hub is to provide an industry-driven network of users, suppliers and supporters that will foster and grow the use of Additive Manufacturing technology in Australia. + Promote and market additive manufacturing sector capabilities. + Expand the knowledge base of additive manufacturing technologies. + A grant programme for Victorian businesses to encourage adoption of additive manufacturing technologies. + Support the creation of high quality additive manufacturing jobs. + Be a voice to Government on additive manufacturing sector development.

Companies looking to explore the potential of additive manufacturing, or further expand their use of the technology should register interest via email at amhub@amtil.com.au

www.amhub.net.au 1407AMHUB

060

ADDITIVE MANUFACTURING

Additive Manufacturing Hub – Lessons from Germany Last November, the Additive Manufacturing Hub and AMTIL led an Australian delegation on a tour of various manufacturing sites in Germany that are utilising additive manufacturing in their processes, to complement the group’s attendance at the Formnext exhibition in Frankfurt. Among the delegates was Matthew Harbidge of Charles Darwin University; here Matthew shares his notes on what he saw on the tour.

The tour offered some excellent insights into the ways that others are engaging in the additive manufacturing (AM) industry, some of the general practices being implemented, and ideas regarding the future of the technology. We visited three sites: Bosch, FIT, and Toolcraft.

Bosch – Integrating 3D printing The Bosch facility was a modern mass production site that utilised CNC machines, robots, and people all working together to produce three main parts: high-pressure fuel pumps, gearbox solenoids, and driveby-wire throttle systems. Currently the facility only uses “digital twin” for very small production runs and compares the real run to the simulated production run. They do not digitally trace their production components.

Bosch uses three main pieces of software for monitoring and reporting of the facility – these are Nexeed MES, PowerBI, and Tableau. With these packages they can monitor machine outputs, variations and downtime, and plan maintenance. They are in the early stages of applying machine learning to solve production issues preemptively.

In the last three years Bosch has expanded its facility by adding in some AM machines: Dremel plastic printers, with Concept Laser and 3DS metal printers. All production line equipment was housed in plexiglass and aluminium extrusion frames. All parts are labelled internally with QR codes, and stations are set up around the facility that can scan or produce labels. The printer work area is fully enclosed for powder control, and they have a large amount of signage and labelling for personal protective equipment (PPE) and procedures. They currently outsource all their heat treatments except for aluminium.

The parts that they had on display were a mix of standard geometry test prints and actual Bosch parts. Our hosts mentioned some of the benefits of 3D printing and how they could be applied to some of their existing parts or be used to improve them. However, their main display part had no features that could not have been done with a CNC machine (curving internal geometries) and appeared to have a casting line. The facility itself was excellent, with a very high value placed on safety, and obvious knowledge of powder-handling standards. A lot of time and money has been spent to reach this level. However, from a production side it appears they are

AMT FEB/MAR 2020

still at the very early stages, and unsure of how AM will tackle any problems that they have.

FIT – One of the world’s largest printing bureaus FIT is one of - if not the largest - printing bureaus in the world for 3D printed components. They produce more than 400k unique parts every year, not including production runs of like parts. They’ve been in operation now for more than 25 years and produce plastic, metal, and other materials such as sand casts.

The opening presentation showed some of FIT’s print philosophies that they believe set them ahead of the crowd. They believe first in understanding the part function, translating this into a physical specification, not a design, then deciding what material and process should be used to create this part. They understand that AM isn’t the be-all-and-end-all of manufacturing, yet. FIT has developed their own in-house

monitoring software, which monitors their printers, part completion, and part layout in the machine, but does not individually monitor or track individual parts. They have a “booking” system used for allocation orders and times to equipment, but I couldn’t see what software it used.

Their manufacturing is split into two warehouses: one for plastics, one for metals. In the plastic warehouse they use a universal powder delivery system, connected to all the powder-based plastic printers, which reduces handling of loading machines. However, metal powder proved too variable or inconsistent to be delivered in this way. In the plastic area EOS powder transfer stations and in-house built stations were also used. For metal powder handling and transfer, all equipment is designated to a specific material to prevent crosscontamination. The metal warehouse was very clean. However, only one machine was running, which was quite odd given most of the prints would typically take several days.

ADDITIVE MANUFACTURING There were large, powered hexagonal workstations with tool cabinets located underneath. There was also a significant number of Hermle C30U and DMG MORI CNC machines.

Toolcraft is partnered with Trumpf, so it has several pieces of equipment provided

by Trumpf, including Trumark 7000 laser engraving machines, Truprint 3000 printers, TruCell LMD machines, and all Trumpf powder handling equipment. Toolcraft also has Concept Laser printers. It uses two types of co-ordinate measuring machines (CMMs), which are both used to ensure a part meets specifications: a Zeiss Accura CMM, equipped with a 1.5-ton granite block; and a DEA Global machine. All required parts are double-checked on the different machines.

FIT currently outsources most of its heat treating, though the recent installation of a new hot isostatic pressing (HIP) machine may change that.

The FIT team generally spend the day preparing the printers with powder, files, substrates, and processing printed parts.

At night the printers are preheated and begin their printing. They do not typically fill the print volume with parts. Instead they prefer to shorten part lead times, at the cost of additional labour per print. For example, if they have two different parts with five each to be made, they won’t put them together in a print; they’ll allocate them to different printers to reduce the turnaround time. FIT also prefers for at least 30% of its printers to be unloaded at any time, so that if it receives a large order that requires a short turnaround time, the team can process it.

The FIT team clearly knows how to produce parts for AM and have solidified the company’s place in the AM world as innovators who are ahead of the curve. I look forward to watching them grow and branch out in the future.

Toolcraft – Producing parts for multiple sectors Toolcraft is also approximately 25 years old and prides itself on making precision components for a variety of industries.

The company produces components for aerospace, medical, biomedical, turbines, and more. The team pride themselves on a sense of family and community, where every employee is given a key. The company has only recently begun adopting AM it has been engaged in advanced manufacturing since the beginning. It produced the first flying parts for Boeing, Airbus, and Pratt & Whitney.

The first port of call during our site tour included the apprentice’s station and several very large Seco/Warwick vacuum furnaces.

Toolcraft implements constant environmental monitoring and replacement of the air in the AM rooms. In the AM room, a portable workstation is used for each material, with the required PPE, a RuVac powder vacuum cleaner, and the print plans. Every tool and printer had an allocated material and serial number. There are individual powder handling rooms per material type, such as an Inconel room with both 718 and 625, a Ti room with 64 and CP, and an aluminium room. Each material has its own full handling system to prevent cross-contamination.

Toolcraft analyses both powder and part for grain sizes, composition, microstructure, and density, as well as static, dynamic, and fatigue-testing rigs for the components that they make. Unfortunately, we weren’t able to see this section. Coupons are printed with all parts for testing, and dye pen NDT is conducted on printed parts and all flying CNC parts.

3D Printing Functional

Metal Parts

Markforged combines Metal Injection Molding (MIM) technology with a unique 3D printing platform

Toolcraft also has a printer booking/job system displayed on a large TV on the wall.

It uses Mastercam and Siemens NX Cam for its CNC machines, as well as SAP ERP production and part tracking for all of its machines. It is not as automated as the Bosch site.

The Toolcraft facility was in my opinion by far the best site. They had combined procedures, powder handling, manufacturing together seamlessly to produce real parts that are designed for their task. Parts that benefitted from CNC machining would be machined; parts that benefitted from AM production would be produced via AM. Led by AMTIL, and generously supported by the Victorian Government, the Additive Manufacturing Hub has been established to grow and develop Additive Manufacturing capability. To find out more about the AM Hub, contact John Croft, AM Hub Manager, on 03 9800 3666, or email jcroft@amtil.com.au. www.amhub.net.au www.cdu.edu.au

Call us now at

1 800 632 953

to discuss how you can transform your metal manufacturing processes emona.com.au/markforged

AMT FEB/MAR 2020

061

062

ADDITIVE MANUFACTURING

Selective laser melting – An attractive solution for aerospace Aerospace parts require materials with certain critical properties like high strength-to-weight ratios, that can function effectively in exceptionally high temperatures. The aerospace industry always demands cutting edge technology, and is now benefitting from advances in additive manufacturing using selective laser melting processes.

Additive manufacturing, commonly known as 3D metal printing, allows for the manufacture of complex shapes from light metals with high mechanical strength. This unique material combination yields parts with a high strength to weight ratio along with good corrosion and fatigue resistance.

One of the most popular powder-based materials is the titanium alloy Ti-6Al4V, which has found its way into both aerospace and medical applications.

Titanium is already widely used in aircraft manufacture to prevent fatigue cracks or in structural parts like the frames of cockpit windows. Applications of titanium alloys are even more widely used in military aircraft, helicopters and spacecraft due to their high performance and unique properties, particularly weight reduction.

Selective laser melting machines are regarded as the most versatile additive manufacturing technology because the system can process a wide spectrum of materials that include aluminium, titanium, iron, nickel, cobalt, copper-based alloys and their composites. Choosing the appropriate material depends on a number of factors that essentially depend on the part requirements and process parameters.

For example, optimised parameters that meet the minimum mechanical property requirements of a part can be achieved by focusing on optimising the machine parameters to build a fully dense part.

However, this has the effect of lengthening the build time. By focusing on optimising the heat cycles, the build time will be quicker, though this will depend not just on the machine parameters but on the material being used.

In the manufacture of titanium alloys in 3D metal printing machines, the formation phase and mechanical properties can be controlled by process parameter optimisation. In general, in the manufacture of complex parts, laser power control is extremely desirable, and it is in this area – of exploring parameter optimisation – that the technology manufacturer SLM Solutions is working with a number of companies in the aerospace sector.

SLM Solutions machines equipped with multi-beam laser systems and bi-directional powder applications offer the advantage of shortening production time – an attractive

AMT FEB/MAR 2020

option recognised by Rolls Royce which recently added an SLM500 quad laser machine to help develop its additive manufacturing capability for aerospace components. In November 2019, BEAMIT, one of the largest additive manufacturing suppliers in Europe, also acquired an SLM500, adding to its existing bank of eight selective laser melting machines to specifically develop high-speed parameters using the aluminium alloys Al2024X and Al6061.

Typology optimisation is defined as a mathematical method that optimises material layout within a given design space, with load specifications, boundary constraints and conditions, with the goal of maximising the performance of the system.

Some selective laser melting machines provide open parameters so that different applications can be adjusted to meet specific requirements.

With laser systems, the higher the laser power is, the faster the melting time is, a function of multi-laser systems, but as the build comprises a layering process, careful management of the laser beam power is needed to avoid porosity or fusion defects in the component.

Lowering the beam energy will take longer to process the component, but may be necessary to generate parts with very small geometric features.

Process optimisation plays a key role in securing the benefits of 3D printed metal components with small, accurate features; internal channels; lattices and similar features that reduce overall weight; honeycomb structures; and complex heat exchange structures.

Early in 2019 a UK-based spaceflight company, Orbex, used an SLM800 largeformat metal additive manufacturing system featuring a 260mm x 500mm powder bed that can build parts 800mm tall. Unique parameters optimised the

particular geometry required, allowing the engine to be built in a single piece using a special nickel alloy creating a structure 30% lighter and 20% more efficient than any other launch vehicle in its category.

Using biomimetic (founded in nature) design principles, CellCore – a design company in Germany – incorporated a lattice structure in its development of a monolithic thrust chamber for the aerospace industry. The lattice structure both improved cooling and increased stability, as well as achieving a reduction in weight. CellCore chose to use IN718, a precipitation hardening nickelchromium alloy with exceptional tensile, fatigue, creep and breaking strength up to 700 degrees Celsius suitable for a rocket propulsion engine.

Recently, Honeywell Aerospace, a user of additive manufacturing technologies with expertise across various platforms and applications, has commenced working with SLM Solutions in qualification of aluminium builds using increased layer thicknesses of 60 to 90 microns. Honeywell will begin with the standard set of aluminium parameters supplied by SLM Solutions, to further develop advanced parameter sets for quad-laser systems, with the aim of applying them in serial-production.

ADDITIVE MANUFACTURING

Additive manufacturing is advancing at a rapid pace, drawn on by the aerospace and automotive sectors. SLM Solutions has not just focused on process parameters to achieve more effective builds, but has focused on the development of selective laser melting technology itself. In 2017 a

partnership between Divergent and SLM Solutions saw the creation of multi-laser machines that offer all the benefits of 3D metal printing with faster and improved manufacturing capability that will be affordable and provide greater efficiency.

At the Formnext 2019 additive manufacturing technology exhitibiton in Germany, Divergent displayed a suspension and chassis structure built using the whole suite of SLM Solutions laser machines.

The next step is to purchase five preproduction machines from SLM Solutions to integrate into the Divergent facility in Los Angeles, California, and then to accelerate development and increase time to market.

As envisaged by Divergent CEO Kevin Czinger, the company plans to acquire 20 of SLM Solutions’s next-generation systems to be able to roll-out product on demand.

Selective laser melting is finding its way into the aerospace industry through innovative and exciting developments, while seemingly charging its way into the automotive industry at the same time. Fortunately, one industry group will leverage from the other, such is the power of additive manufacturing using selective laser melting. www.raymax.com.au

ADD SOMETHING NEW! Prima Industrie believes in additive manufacturing.

Thanks to our Powder Bed Fusion and Laser Metal Deposition solutions, now you can build, repair and prototype - adding value and shaping the vision of your business.

More than 40 years of cutting edge technology in sheet metal machinery along with the laser and electronics industries has led Prima Industrie to Prima Additive - A division which is dedicated to metal additive manufacturing systems that guarantee a close partnership with customers, competitiveness, and efficiency.

So, add something new and choose Prima Additive from IMTS Machinery.

For more information, please contact IMTS Machinery E | sales@imts.com.au W | imts.com.au P | +61 3 9314 9888

AMT FEB/MAR 2020

063

064

ADDITIVE MANUFACTURING

Thermwood introduces new LSAM model Thermwood has released a brand new machine model that offers a greater range of choices for large-scale additive manufacturing applications. Called the LSAM MT, the new machine offers an all-new configuration and significant advantages in various applications.

Thermwood is a US-based manufacturer of CNC machinery that markets its products and services through offices in 11 countries. Its has also become a technology and market leader in largescale additive manufacturing (LSAM) systems for thermoplastic composite moulds, tooling, patterns and parts. Its line of LSAM machines can perform both 3D printing and trimming operations on the same machine. Its systems are marketed to major companies in the aerospace, marine, automotive and foundry industries, as well as military, government and defence contractors.

Unlike standard LSAM systems, which feature dual gantries operating over a large fixed table, the LSAM MT (which stands for “Moving Table”) features a single fixed gantry mounted over a moving table.

This configuration offers several significant advantages, not the least of which is a dramatically lower price.

Despite the lower price, the LSAM MT is still a massive, robust industrial production machine capable of reliable, day-in and dayout production. Unlike standard LSAM systems, the MT can be configured as a “Print Only” machine. The logic for this is simple.

Near-net-shape printed tools dramatically reduce machining time for many companies currently machining tools from solid blocks of material. This frees up significant machining capacity that is already purchased and installed. For these companies, it makes no sense to purchase additional machining capacity with their additive system, since the change to additive frees up more than enough existing capacity to handle everything they can print. With this in mind, Thermwood decided to offer both “Print and Trim” and a “Print Only” versions of the MT. The MT is available in two table sizes – 3m wide x 1.5m deep, and 3m x 3m. The larger machine actually has a table measuring 3m x 3.6m, with a 3m x 3m working area. The extra 60cm is used to mount an optional Vertical Layer Print table. The larger MT machine can be equipped with a new version of Thermwood’s patented Vertical Layer Printing technology. This means that it can make parts up to 3m x 3m and 1.5m high using traditional Horizontal Layer Printing, or 1.5m x 3m and 3m high using Vertical Layer Printing.

Since the print technology and print heads used on the MT are the same as those used on Thermwood’s larger machines it offers the same throughput, print quality and layer-to-layer fusion that has made Thermwood a leader in LSAM. As with the larger systems, the MT can process high-temperature polymers, which are ideal for autoclave-capable tooling or compression moulds for thermoset materials.

With the addition of the MT, selecting the best size and configuration for an LSAM may not be quite as straightforward as it first appears. It depends on two major factors plus some additional considerations.

The major factors are the material being printed and the size of the parts needed. Of these two, the material being printed is the most significant.

For the purposes of machine selection, reinforced thermoplastic composite materials for room-temperature or low-temperature applications such as foundry patterns, boat plugs, boat and yacht moulds, building structures and other similar applications can generally be bonded securely with a variety of industrial adhesives.

For these type of parts, even for really large parts, the smaller less expensive machine may be a better choice. The part can be separated into sections, which can be printed individually and bonded into the final, potentially extremely large structure.

Although it seems counter-intuitive, this approach can be faster than printing the large structure as a single piece on a larger, more expensive machine. To better understand, it is necessary to consider the basics of the print process. Additive manufactured parts are printed in layers. The speed at which a layer can be printed depends primarily on how long it takes for the polymer being printed to cool enough to support the next layer. This layer cooling time depends on the polymer and is not affected by the size of the part. Each layer of a particular polymer takes the same amount of time, regardless of how big it is.

LSAM print heads can print faster – sometimes significantly faster – than is needed for most parts. Often it can print two, three or more parts in the cooling time required for each layer. The large machine

AMT FEB/MAR 2020

ADDITIVE MANUFACTURING

is only printing a single part, one layer at a time, making it two or three times slower. To print the part in one piece, the large machine must operate continuously, around the clock, sometimes for days.

This is not a problem for factories that operate on all three shifts, but it can present staffing problems for single-shift operations. With the MT, several different segments of the same part can often be printed in a single shift. Depending on the item being printed, it is possible to print as much in a single shift as the large machine, printing a single part, can do in 24 hours.

For large parts made from bondable materials, often the smaller, less expensive machine is a better choice.

Materials intended for high-temperature applications – such as PSU, PESU, PEI, or Ultem – generally are resistant enough to solvents that they can’t be effectively bonded. Even if they could, few if any adhesives exist that can withstand the operating temperature or the thermal cycling these materials experience. For these applications, the machine needs to be large enough to print the part in one piece, even though it could be slower. This is where larger machine configurations are needed. The larger machines also offer the ability to print and trim at the same time, which may be beneficial in some circumstances.

Since the print heads are the same on all Thermwood LSAMs, the smaller MT can be used for these high-temperature parts, provided they fit in the available envelope. Just like the standard LSAMs, the MT comes complete, fully engineered, with everything needed for production operation. www.flecknoe.com.au

AMT FEB/MAR 2020

065

066

ADDITIVE MANUFACTURING

Additive manufacturing in acoustic research and new development Advanced 3D printing technology is not limited to rapid prototyping of products and industrial design concepts.

At RMIT University, its value for scientific research and potential development are undeniable.

For a long time, additive manufacturing has been known as a new processing method for rapidly prototyping concept designs in various industrial sectors. Nowadays, advanced 3D printing technology is on the cusp of reaching a critical level in the innovation, research & development of new products. Research activity at RMIT’s School of Engineering shows the feasibility of using 3D printing technology for acoustic research and noise control applications.

A number of micro-perforated panel multilayer acoustic absorbers have been fabricated using 3D printing technology.

These sound absorbers are particularly good at attenuating noise in a specific frequency band.

The research motivation A micro-perforated panel absorber (MPPA) usually consists of a thin panel with many sub-millimetre-sized perforations in the front of a rigidly backed air cavity, forming a mass- and spring-resonant sound absorber.

Such sound absorbers are used in acoustic design to enhance noise attenuation and to tune the sound absorption peak frequency in various industrial applications, such as transport vehicles and buildings.

The geometric design of an MPPA layer to obtain the desired acoustic absorption capabilities is a relatively easy challenge but manufacturing the many sub-millimetresized perforations by using a micro-punch can be challenging. Punching on the surface of a thin panel may lead to veneer tear out and partially plugged, tapered and rough walls, which significantly affect the acoustic performance of the acoustic absorber. Other manufacturing methods, such as laser technology, are costly – particularly when the perforation hole density of an MPPA layer is high. Such concerns have significantly reduced the accuracy and authenticity of the acoustic research on sustainable development. To overcome these manufacturing defects and improve research efficiency, the alternative manufacturing method of using 3D printing technology to fabricate a high-precision acoustic absorber was first introduced and investigated by Noise and Vibration Research Group at RMIT University.

In the previous two years, the research team had successfully used 3D printed MPPA structures to control the peak sound absorption coefficient of an acoustic absorber so that it lies in a specific frequency band by printing the MPPA

AMT FEB/MAR 2020

Micro-perforated panel absorber (MPPA) test samples with different perforation ratios printed at RMIT University’s Advanced Manufacturing Precinct.

structure with different perforation ratios.

In its current research, a multilayer acoustic absorber (a combination of an MPPA layer, a non-woven porous sound absorbing material, and an air gap) was used to improve the broadband and low-frequency sound absorption.

The test specimens have a thickness of t = 1mm, a sample diameter of 29mm and hole diameter of d = 0.6mm. For research purposes, the MPPA structures were designed with different hole spacings of b = 2mm, 3mm, 4mm and 5mm to provide a range of perforation ratios.

The method

The sound absorption coefficients (SAC) of the multilayer acoustic absorbers were measured by using the two-microphone transfer function method (Brüel & Kjær impedance measurement tube Type 4206) in the RMIT Noise, Vibration and Harshness (NVH) laboratory, according to the ASTM E1050-12 standard. The multilayer acoustic absorbers include a 3D printed MPPA layer, a porous sound absorbing material layer, and an air gap.

The MPPA structures are firstly designed with different perforation spacings to provide a range of open area ratios, for generating different acoustic inertia. The geometric designs are made similar to existing MPPA structures used in various industrial sectors. The well-designed MPPA specimens are then digitally sliced and fabricated by using a ProJet 7000 3D printer at RMIT’s Advanced Manufacturing Precinct (AMP) in Melbourne. The ProJet 7000 uses stereolithography (SLA) technology to print accurate and perfectly formed MPPA structures on a layer by layer approach using ultraviolet light.

The printed structures have a fine layer resolution of 0.0254mm, and they have an accuracy of between 0.025mm and 0.05mm per 25.4mm of part dimension.

In order to predict the theoretical acoustic properties of the multilayer acoustic absorbers, the transfer matrix method (TMM) is used. A transfer matrix is developed for each layer. By connecting the individual transfer matrices in order, the surface impedances and the sound absorption coefficients of the multilayer acoustic absorbers are calculated.

ADDITIVE MANUFACTURING A Brüel & Kjær impedance tube test at RMIT University’s Bundoora Campus.

Finally, the theoretical results and the experimental data are compared, to characterise the effects of various parameters such as the open area ratio of the MPPA layer, the depth of the air gap, and the presence/absence of the porous material layer on the sound absorption coefficients. This enabled the best arrangement and combination of the layers to be found, both for improving the low-frequency sound absorption, and for obtaining the sound absorption in a much wider frequency bandwidth.

The results and new development The measurement data was compared with theoretical results for the multilayer acoustic absorbers, and the results of this research demonstrate that the experiment data agrees fairly well with the theoretical model.

This confirms that the MPPA layer can be precisely fabricated as designed using 3D printing technology, and can provide good sound absorption performance when backed with porous sound absorbing materials and air gaps.

The results also showed that increasing the

open area ratio of the MPPA layer yielded a higher acoustic resonance frequency for the peak sound absorption coefficient. The acoustic resonance frequency was found to be dependent on the depth of the air gap behind the MPPA layer. The acoustic resonant frequency of the corresponding peak value of the sound absorption coefficient was reduced, with an increasing air gap behind the MPPA test specimens in the impedance tube. The significant improvement of the sound absorption coefficient at low to mid frequencies can be attributed to the porous material layer and the air gap (a multilayer sound absorber).

Additive manufacturing is different from traditional methods, such as etching, jetting or laser technology, which are difficult and costly to use to produce a high density of sub-millimetre-sized perforations in acoustic absorbers. In this research, the

3D printing technology was successfully used for this acoustic application due to the ease with which the geometry can be customised. For future research purposes, an MPPA layer with arbitrary cross-sectional perforations, and gradient of crosssectional perforations could be realised by using the 3D printing method, which allows the production of an MPPA layer with high shape complexity. These possible new developments of MPPA structures are believed to be able to give wider bandwidth broadband sound absorption.

In recent years, 3D printers have become much cheaper to produce; they are suitable for use with different materials; and the products can be printed with different strengths and hardness. The 3D printed multilayer acoustic absorber can also be used in different industrial applications, for example, in vehicle interior trim design and in acoustic optimisation. In summary, the research will help to better design and control the cabin interior noise level – particularly when focus is required on certain frequency bands.

By Dr Zhengqing Liu, Prof Mohammad Fard, Prof John Laurence Davy and Prof Milan Brandt, of the Noise and Vibration Research Group at RMIT’s School of Engineering. www.rmit.edu.au www.zjut.edu.cn

AMT FEB/MAR 2020

067

068

ADDITIVE MANUFACTURING

US researchers develop record-throughput 3D printer Researchers at Northwestern University in the US have developed a new, futuristic 3D printer that is so big and so fast it can print an object the size of an adult human in just a couple of hours.

Called HARP (high-area rapid printing), the new technology enables a record-breaking throughput that can manufacture products on demand. Over the last 30 years, most efforts in 3D printing have been aimed at pushing the limits of legacy technologies. Often, the pursuit of larger parts has come at the cost of speed, throughput and resolution. With HARP technology, this compromise is unnecessary, enabling it to compete with both the resolution and throughput of traditional manufacturing techniques.

The prototype HARP technology is 4m tall with a 0.23sqm print bed and can print about 45cm in an hour — a record throughput for the 3D printing field. This means it can print single, large parts or many different small parts at once. Professor Chad A Mirkin, who led the product’s development along with researchers David Walker and James Hedrick, predicts that HARP will be available commercially in the next 18 months.

“3D printing is conceptually powerful but has been limited practically,” said Mirkin. “If we could print fast without limitations on materials and size, we could revolutionize manufacturing. HARP is poised to do that.”

Keeping it cool HARP uses a new, patent-pending version of stereolithography, a type of 3D printing that converts liquid plastic into solid objects.

HARP prints vertically and uses projected ultraviolet light to cure the liquid resins into hardened plastic. This process can print pieces that are hard, elastic or even ceramic. These continually printed parts are mechanically robust as opposed to the laminated structures common to other 3D-printing technologies. They can be used as parts for cars, airplanes, dentistry, orthotics, fashion and much more.

A major limiting factor for current 3D printers is heat. Every resinbased 3D printer generates a lot of heat when running at fast speeds — sometimes exceeding 180 degrees Celsius. Not only does this lead to dangerously hot surface temperatures, it also can cause printed parts to crack and deform. The faster it is, the more heat the printer generates. And if it’s big and fast, the heat is incredibly intense.

This problem has convinced most 3D printing companies to remain small.

“When these printers run at high speeds, a great deal of heat is generated from the polymerisation of the resin,” said Walker. “They have no way to dissipate it.”

The Northwestern technology bypasses this problem with a nonstick liquid that behaves like liquid Teflon. HARP projects light through a window to solidify resin on top of a vertically moving plate. The liquid Teflon flows over the window to remove heat and then circulates it through a cooling unit.

“Our technology generates heat just like the others,” Mirkin said.

“But we have an interface that removes the heat.”

“The interface is also nonstick, which keeps the resin from adhering to the printer itself,” added. Hedrick “This increases the printer’s speed by a hundred-fold because the parts do not have to be repeatedly cleaved from the bottom of the print vat.”

Goodbye, warehouses Current manufacturing methods can be cumbersome processes.

They often require filling pre-designed moulds, which are expensive, static and take up valuable storage space. Using moulds, manufacturers print parts in advance — often guessing how many they might need — and store them in giant warehouses.

AMT FEB/MAR 2020

HARP prints vertically, using ultraviolet light to cure liquid resins into hardened plastic.

Although 3D printing is transitioning from prototyping to manufacturing, current 3D printers’ size and speed have limited them to small-batch production. HARP is the first printer that can handle large batches and large parts in addition to small parts.

“When you can print fast and large, it can really change the way we think about manufacturing,” Mirkin said. “With HARP, you can build anything you want without molds and without a warehouse full of parts. You can print anything you can imagine on-demand.”

While other print technologies have slowed down or reduced their resolution to go big, HARP does not make such concessions.

“Obviously there are many types of 3D printers out there — you see printers making buildings, bridges and car bodies, and conversely you see printers that can make small parts at very high resolutions,” Walker said. “We’re excited because this is the largest and highestthroughput printer in its class.”

Printers on the scale of HARP often produce parts that must be sanded or machined down to their final geometry. This adds a large labour cost to the production process. HARP is in a class of 3D printers that uses high-resolution light-patterning to achieve readyto-use parts without extensive post-processing. The result is a commercially viable route to the manufacturing of consumer goods.

Nano goes big A world-renowned expert in nanotechnology, Mirkin invented the world’s smallest printer in 1999. Called dip-pen nanolithography, the technology uses a tiny pen to pattern nanoscale features. He then transitioned this to an array of tiny pens that channel light through each pen to locally generate features from photo-sensitive materials. The special nonstick interface used in HARP originated while working to develop this technology into a nanoscale 3D printer.

“From a volumetric standpoint, we have spanned over 18 orders of magnitude,” Mirkin said. www.northwestern.edu

ADDITIVE MANUFACTURING

New 3D printing technique produces ‘living’ 4D materials UNSW Sydney researchers have successfully merged 3D/4D printing with a chemical process to produce “living” resin, which has huge potential for fields as diverse as recycling and biomedicine.

4D printing is a subset of 3D printing where the printed object can transform its shape in response to certain conditions.Repairing and reusing plastics and delivering cancer drugs more effectively are just two potential applications for the new 3D/4D printing technology, based on a research collaboration between UNSW Sydney and the University of Auckland that successfully merges 3D/4D printing and photo-controlled/living polymerisation – a chemical process to create polymers.

The research could one day put an end to plastics ending up in landfill.

Image by Pasi Mäenpää from Pixabay.

The new controlled polymerisation method, where the researchers used visible light to create an environmentally friendly “living” plastic or polymer, opens a new world of possibilities for the manufacture of advanced solid materials. Polymers can be synthetic, such as plastic, as well as biological, for example, DNA. The research built upon the UNSW Sydney Boyer Lab’s 2014 discovery of PET-RAFT polymerisation (Photoinduced Electron/ energy Transfer-Reversible Addition Fragmentation Chain Transfer polymerisation), a new way to make controlled polymers using visible light, using the Reversible Addition Fragmentation Chain Transfer (RAFT) polymerisation technique discovered by the CSIRO (Graeme Moad, San Thang and Enzo Rizzard). Such polymers can be reactivated for further growth, unlike traditional polymers which are “dead” after being made.

Since this development, the technology has expanded and has proven useful for making well-controlled molecules for many applications, including drug delivery and other biomaterials.

World-first discovery Lead author Cyrille Boyer said his team’s latest breakthrough was a world first in the development of a new 3D printing system using PET-RAFT polymerisation, to allow 3D printed materials to be easily modified after printing.

“Controlled polymerisation has never been used in 3D and 4D printing before, because the rates of typical controlled polymerisation processes are too slow for 3D/4D printing, where the reaction must be fast for practical printing speeds,” Prof Boyer said. “After two years of research and hundreds of experiments, we developed a rapid process compatible with 3D printing.

“In contrast to conventional 3D printing, our new method of using visible light allows us to control the architecture of the polymers and tune the mechanical properties of the materials prepared by our process. This new process also gives us access to 4D printing and allows the material to be transformed or functionalised, which was not previously possible.”

UNSW’s Nathaniel Corrigan said a bonus advantage of their new system was the ability to finely control all molecules in the 3D-printed material.

of applications for everyday items – particularly if a deformed or broken object needed to be repaired or modified.

“The main application is of course recycling, because instead of using a plastic object once, it can be repaired and reused,” he said.“For ordinary recycling you take the materials away and have to reconstruct them, but for the new ‘living’ material it will be able to repair itself.

“For example, if you want to put the UNSW logo on a mug, you can modify the surface of the object and grow the polymers to show UNSW because the object is not dead; it’s a living object and can continue to grow and expand.”

Dr Corrigan said another major benefit of the new process was its compatibility with biomedicine, because extreme conditions were unnecessary.

“Current 3D printing approaches are typically limited by the harsh conditions required, such as strong UV light and toxic chemicals, which limits their use in making biomaterials,” he said. “But with the application of PET-RAFT polymerisation to 3D printing, we can produce long polymer molecules using visible light rather than heat, which is the typical polymerisation method.

“Using heat above 40 degrees kills cells, but for visible light polymerisation we can use room temperature, so the viability of the cells is much higher.”

Prof Boyer said objects made through this new process could more easily be used in advanced bio-applications, such as tissue engineering, for example, where a tissue structure is used to form new, viable tissue for medical purposes.

“4D printing is a subset of 3D printing. But with 4D printing, the 3D-printed object can change its shape and chemical or physical properties and adapt to its environment,” Dr Corrigan said. “In our work, the 3D-printed material could reversibly change its shape when it was exposed to water and then dried. For example, the 3D object starts as a flat plane and when exposed to certain conditions, it will start to fold – that’s a 4D material. So, the fourth dimension is time.”

“Our new method targets small-scale, niche applications in fields like microelectronics and biomedicine – a huge area for us – that require very advanced polymers,” he said.

From reducing waste to biomedical applications

“We want to explore our system to find and address any limitations to allow for better uptake and implementation of this technology,” he said. “There is so much we can do by combining 3D and 4D printing with controlled polymerisation to make advanced and functional materials for many applications to benefit society.”

The researchers are hopeful that their new 3D/4D printing process using PET-RAFT polymerisation will lead to the production of functional materials to solve many of the problems facing society today. Prof Boyer said the new method had a multitude

3D and 4D printing for everyone Prof Boyer said the new technique would allow commercial and non-expert operators to produce materials with seemingly endless properties and applications.

www.auckland.ac.nz

www.unsw.edu.au

AMT FEB/MAR 2020

069

070

ADDITIVE MANUFACTURING

3D Printing Studios builds factory of the future with EOS Joint CEOs and founders of 3D Printing Studios, Howard Wood and Stuart Grover began their business with a mission to help customers “bring their ideas to life” by leveraging the latest technologies in additive manufacturing.

Their 3D printing bureau offers services such as rapid prototyping, functional production items and short-run manufacturing. Due to customer demand they also offer reverse engineering, as well as 3D design, equipment hire and training. The business was established in Sydney in 2013. It was Australia’s first ever 3D printing retail shop and the fifth worldwide. The business expanded to Perth a year later, and then to Melbourne in 2017.

In December, Howard and Stuart realised their vision to open a factory of the future where they specialise in mass personalisation – that is, functional items personalised for customers. Repeat shortrun products can save customers large production set-up costs and cut down on waste with a just-in-time production approach.

Howard and Stuart’s factory of the future vision was realised with a world-class additive manufacturing solution supplied

by John Hart: an EOS P396 industrial 3D printer, capable of producing thousands of

Howard Wood in front of his new EOS P 396 industrial 3D printer.

high-quality plastic parts per week.

“We purchased the EOS because we needed this type of machine to continue our expansion,” says Howard. “We have been involved with additive manufacturing for a number of years and EOS has a reputation of producing reliable high-quality machines. This machine is renowned for reliability and when we did the ROI (return on investment) it made a lot of sense. It also has a large build area, suitable to our plan for high volume production.”

With total build size of 340mm x 340mm x 600mm, the EOS P396 covers the medium build volume range and sets the manufacturing standard for many industries like medical, defence and aerospace.

The EOS P 396 processes an extensive portfolio of thermoplastic materials on an industrial scale, and is acclaimed for reproducible and constant component quality, cost-effective manufacturing and high productivity.

“The success of the Australian manufacturing sector relies on the momentum created by advanced manufacturing technologies such as selective laser sintering (SLS) and direct metal laser sintering (DMLS),” says Glenn Evans, John Hart’s NSW Branch Manager. “Companies like 3D Printing Studios are key to this success as they bring a lot of experience to the table and have supported hundreds of others in their journey to creating competitive advantages with additive manufacturing.” www.johnhart.com.au www.3dprintingstudios.com

How 3D printing will transform design and engineering in the future 3D printing is triggering a change in the way organisations build and design products, offering cost reductions, the ability to improve products by applying design thinking principles such as latticing, part consolidation, and lightweighting, as well as savings in supply chains, product storage, and waste.

3D printing is maturing quickly, and so too is the future of engineering and design.

For example, the automotive industry can now benefit from much shorter lead times when using 3D printing, which allows faster development and testing of components.

As 3D printing technology evolves, and new materials are developed, products that were previously not viable to print because of size, accuracy and material constraints become feasible.

There has been a huge surge across the industry recently towards end-use parts.

3D printing’s ability to manufacture and combine parts has become more effective and is increasingly being integrated into an augmented manufacturing process.

Eric Holtsmark, General Manager – Strategy, Transformation & Technology at Konica Minolta Australia, said: “The future of product development can also be aided by 3D printing. The design of

AMT FEB/MAR 2020

consumer goods such as electronics depends heavily on current market needs.

As these needs change, 3D printing not only offers manufacturers a way to adapt quickly by shortening the design stage, but also the ability to produce cost-effective short production runs to test the market, or offer customised versions of a product.

Rapid prototyping in the pre-manufacturing stage lets businesses manufacture faster and reach markets sooner. Businesses also benefit from improved risk reduction and agility as they can study prototypes to reduce faults and optimise the product before it goes to market.”

To maximise and understand the freedom 3D printing allows, industries should invest time to rethink and rebuild their workflows and processes as they relate to the opportunities emerging. As these industries must keep up with a relentless pace of innovation, it is important for businesses to

prepare their internal systems before they integrate 3D printing to ensure a smooth, successful adoption.

Likewise, education institutions must explore 3D printing technologies in more depth to prepare future designers and engineers for the realities of the future workplace. 3D printing will continue to evolve and cover more ground in manufacturing processes, so it is important that tomorrow’s workers are equipped with the expertise to drive the rapid development of end-use parts in manufacturing.

“The evolution of 3D printing can help to power the world of design, health, engineering and manufacturing, create new jobs and increase innovation on a global scale,” Holtsmark adds. “3D printing will revolutionise key industries and change the future landscape of engineering and design.” www.konicaminolta.com.au

071

ADDITIVE MANUFACTURING

Why you should be asking “Which material?, not “Which 3D printer?”

AUDIENCE

All too often companies looking to invest in 3D printing start looking at the 3D printers, trawling through endless specifications, and being barraged with jargon, trying to draw comparisons with existing subtractive technologies for comparison. But what if this is the wrong approach?

9000+

With material development expanding at a phenomenal rate, what you can produce using additive manufacturing now comes down to the properties and characteristics acquired through the source material, coupled with post-print processes.

“With most of our clients it is not a question of which 3D printer to buy, it is what material is most suitable, together with the size of the object,” says Lee Bilby, Chief Operations Officer of Bilby 3D. “From there the 3D printer correct for them is usually obvious.”

Australian polyurethane engineering experts Richmond Wheels and Castors (RWC) has been utilising milling and casting on their production line for 61 years. According to David Powell, Quality Assurance Manager at RWC: “Prior to adopting 3D printing we went through the process of going to seminars & training and got totally confused.”

RWC engaged in a consultation with Bilby 3D to explore possibilities. Was there a material that could make a mould capable of withstanding the pressure and curing temperature of a polyurethane casting?

Bilby 3D has been in 3D printing for more than a decade, and regards keeping up to date with material developments as of paramount importance. Bilby 3D’s team of engineers and researchers test products outside manufacturers’ intended applications to explore the potential for its clients across the country. It has also partnered with internationally leading 3D printing material scientists to manufacture custom materials for its clients that perform

TARGETTED CONTACTS

in just the way their applications need it to.

Bilby 3D researched the specific environmental conditions that RWC’s end product would be subject to, such as temperature and pressure. It then produced a mould for RWC identical to a 30cm diameter one that was being milled.

It used Proto-Pasta High Temp PLA, postcured through annealing over 11 hrs at a temperature of 70 degrees Celsius. The team at RWC then used the mould to cast a polyurethane wheel – reportedly the first polyurethane cast from a 3D printed mould.

“We have a lot of internal learnings around trying to change our mindset built on 30 years of conventional machining and part manufacture,” added Powell. “There is new thinking required when adopting to this type of manufacturing process.”

Cost considerations are a key benefit of 3D printing when compared to traditional milling. Moulds created using 3D printing, like the one Bilby 3D made for RWC, would normally take similar manufacturing times using milling. However, 3D printed parts can have significant material and labour cost saving; 3D Printers have a smaller footprint, and are quieter and cheaper.

Therefore it’s possible to manufacture more in a smaller space at a lower investment cost compared with milling. Once a 3D print job is set up, it is repeatable, with low labour costs, and the raw materials tend to be much cheaper and are starting to provide real-world solutions in unexpected applications. www.bilby3D.com.au www.richmondau.com

IMPACT 20.02% AVERAGE OPEN RATES

OUTCOME 8.03%

AVERAGE CLICK THRUS

RESULTS STATISTICAL REPORTING SUBMITTED

AMTIL PRODUCT E-BLASTS Call Anne Samuelsson on 0400 115 525 or email asamuelsson@amtil.com.au for all enquiries.

AMTIL1305

www.amtil.com.au

AMT FEB/MAR 2020

072

INDUSTRY 4.0

Triangle gains efficiency, performance in smaller footprint with Balluff To meet the demands of customers wanting smaller, more efficient machines that also meet exacting design requirements, Triangle Package Machinery Company incorporated IO-Link controls architecture and sensors from Balluff. This allowed Triangle to significantly reduce the footprint, reduce cabling, reduce panel size, improve sanitary features, and enable ease of maintenance in its latest modular machine design.

In the packaging industry, floor space costs money; the wider the machine, the fewer lines you can operate. Triangle, a Chicagobased manufacturer of vertical form fill seal machines primarily for the food packaging industry, was presented a unique challenge by its salad industry customers. Triangle’s research with clients revealed they needed a high production rate on each line, but a lower machine speed to allow leafy greens to fall nicely in the bag. To answer that need, Triangle’s research & development team designed its new Compact Sanitary Bagger (CSB), which is narrow enough to install two machines per line in a twin configuration.

Triangle knows the demands of the food packaging industry very well. A sanitary design is a necessity, so the Triangle team knew they’d build a solid stainless steel frame, fully welded, with round bars so there would be no place where product could accumulate. The control box on Triangle’s existing vertical form fill seal (VFFS) bagging machines sits on one side of the frame.

This configuration was useful for cleaning and performing maintenance, but it made the machine about 1.5m wide. Designing a narrower machine would require a different approach.

Three companies were identified for a competitive bidding process with the technology and support to help Triangle realise a new design. The company chose Balluff. Balluff has a large and growing library of IO-Link sensors, and the reputation of its support made this a confident choice.

However, the clincher was Balluff’s IP69K stainless steel IO-Link master device block.

With an I/O block that met regulatory requirements, some components could be moved out of the control box and onto the machine.

“Usually control boxes are bigger than they need to be,” says Michael Wolf, Research & Development Manager at Triangle. “The control box we typically use, it’s not fully packed if you buy a regular machine. But then if you buy a zipper applicator or other features, you add three or four servos into it, and then that control box is full.”

That accounts for the full-size pivoting control box that’s a standard feature on Triangle’s full-size VFFS bagging machines.

“We operate now with the understanding

AMT FEB/MAR 2020

that pretty much every control box is designed uniquely for the customer who purchased that machine,” adds Wolf. “So, if you can imagine the need to have new electrical drawings, new bills of materials every time you have a new configuration, you can get a sense of the complexity of the design and assembly of these machines.”

Moreover there are a lot of configurations available: standard options include cooling, deflators, deflectors, stagers, and interfaces to labellers or daters; plus special options like ultrasonic sealing, three types of sealing jaws, three types of motors, registration, web edge detection, and stack lights. The number of variations can grow into the tens of thousands. These options require wiring, including cables that used to penetrate the control box. Using Balluff’s stainless steel master block and hub, Triangle reduced the number of cables penetrating the control box from 40-50, to about 25. This allowed them to reduce the control box size by 50% and mount it into the inside of the machine.

IO-Link’s expandability means they can add optional features without running additional cabling to the control box, either during initial assembly or as a retrofit. Triangle now has a standard control box, which can be produced in quantity and stored in inventory, there by reducing assembly time.

With a minimised control box, they were able to build the CSB at only 91cm wide and still produce a 33cm-wide bag. The

CSB is about 60% the width of the existing XM model and makes a bag 90% as big.

The design also has improved the CSB’s ergonomics. The default discharge height was increased so the CSB could integrate with sanitary conveyors, which must be higher off the floor.

The CSB is designed to have two machines installed side-by-side. This twin configuration makes the most efficient use of available floor space. It also allows salad industry customers to place a single scale over two machines, permitting them to run each machine at 60-70 bags per minute for a total of up to 140 bags per minute.

Using IO-Link enabled Triangle to design a machine with these features and dimensions but choosing IO-Link wasn’t a foregone conclusion. IO-Link is an open standard, so IO-Link products are developed by many different companies. In that way, it is like USB, but many other open standards have not been fully embraced by the marketplace and lost support. The Triangle team decided that IO-Link was a mature enough standard and that the IOLink market was mature enough to be their choice. And the breadth of Balluff’s IO-Link portfolio helped them draw that conclusion.

Another attractive element of IO-Link is that it allows analogue signals to be added without adding significant cost. Cabling connects to a hub instead of being run to the control box. This allows for added

INDUSTRY 4.0

sealing time, which is a critical parameter, over the whole range without needing to change the hardware configuration when the forming tube is changed.

“The programmer is actually monitoring the amount of time that the sealer is in contact with the film, which is the most critical parameter. Without the sensor, you have to trust that the valve moves. But here we have it verified,” Wolf said. “Without the sensor to get this information, they’d need a servo motor.”

As the machine’s PLC program is enhanced, more predictive maintenance features will become available. That means that if a customer needs help from Triangle, Triangle support staff can connect remotely and see the machine’s status without having to be physically on-site. That can lead to troubleshooting within 30 minutes instead of waiting for someone to fly out or drive to the customer.

options and future enhancements to the controls without having to redesign the control box. In addition, the digitised data sent through IO-Link opens new problemsolving possibilities.

is being changed and the forming tube is swapped out. In addition, this lets them monitor the speed at which it operates and the consistency of the seal time better than they could previously.

An example of IO-Link’s ability to turn configurations into recipes is the dancer arm, which maintains the correct tension on the bagging film as it comes off the roll. Triangle’s previous method involved using an analogue sensor, which required configuration by the service technian during initial installation. The technician had to change the physical position of the sensor to calibrate the home location.

Now with a Balluff IO-Link sensor on the air cylinder, a technician assembling the machine pulls the dancer to one position and clicks “Teach”, and set-up is complete.

Having an IO-Link sensor measuring the full stroke of the cylinder allows them to skip the manual set-up of the sensor.

“If we start getting a leaky cylinder, we’ll be able to detect that using the sensors and notify a customer to replace a cylinder,” said Wolf.

The position where the cylinder is supposed to stop is different for different-sized air cylinders. Triangle added a continuous sensor so customers can monitor the

To Wolf, calling the CSB a smart machine sounds like marketing lingo, and Triangle hasn’t yet realised all the benefits of IOLink. Customers, too, aren’t all equally ready to take advantage of the industrial internet of things. There’s sometimes a perception that more technology will make the machine harder to operate or require more training.

Triangle’s new “Smart Machine Ready” design is already an improvement for Triangle’s team. And when end users are ready to take advantage of all its features, the company will be prepared to help them operate faster and more efficiently, using Balluff’s IO-Link solutions. www.balluff.com www.trianglepackage.com

IO-Link enables diagnostics at the device level – letting users know if a photo sensor is getting dirty, for example. Triangle is additionally using IO-Link data to gather diagnostic data on the machine as a whole.

A position sensor was added on the CSB’s back-seal cylinder, which would have been cost-prohibitive in the past. By using a cylinder with a position sensor, Triangle was able to redesign the back-seal assembly and simplify the set-up when a bag size

AMT FEB/MAR 2020

073

074

INDUSTRY 4.0

Realising the promise of Industry 4.0 in Australian manufacturing Industry 4.0 is transforming how organisations in almost every industrial sector operate. Australian manufacturers must embrace the potential these technologies can offer if they are to remain competitive and continue to grow.

By George Harb.

The Australian manufacturing industry has endured a number of challenges over the past decade. When you consider the Global Financial Crisis (GFC), the growth of overseas manufacturing (particularly in China), and the end of Australia’s automotive assembly operations, there have been a number of events that have posed significant threats to the industry locally.

Despite these challenges, the sector has remained a valuable contributor to the Australian economy. In fact, according to the Australian Bureau of Statistics, the manufacturing industry contributes approximately $100bn to Australia’s annual GDP and employs around 900,000 Australians. Moreover, employment in the sector is expected to continue to increase over the next five years.

Gaining an advantage from Industry 4.0 While the manufacturing sector is expected to continue to grow, it must embrace modern technologies, such as those that encompass Industry 4.0. This new era is best defined by the deployment of digital technologies to transform every aspect of manufacturing and industrial operations. According to the World Economic Forum’s Readiness for the Future of Production Report, Australia is positioned as having “high potential” for Industry 4.0. To achieve this potential, Australian manufacturers must not rest on their laurels; they must continue to invest in digital innovations and integrate new technologies into an increasing range of processes and supply chains. By doing this, the Australian manufacturing industry will experience new opportunities and benefits.

Underpinning Industry 4.0 is the Industrial Internet of Things (IIoT), whereby the vast majority of equipment and machines are connected to the internet via IIoT devices such as sensors actuators, tags, beacons and receivers. This provides manufacturers with a wealth of data and greater visibility into the performance of equipment and processes for better decision-making, helping to identify areas for improvement and innovation.

For example, consider the transportation of perishable goods. By monitoring and analysing the temperature and conditions of goods in transit, organisations can use the data to better provision for their safe and timely delivery in the future.

Manufacturing around the world is currently undrgoing a renaissance as these new connected technologies help to improve the uptime of serviceable equipment through predictive maintenance, improve the track and trace of goods as they move through the supply chain, and ensure factory part bins, for example, are replenished at the optimum time. Manufacturers are leveraging IIoT to create automated “smart factories”, which increase efficiency and reduce costs, while enabling them to better use human resources to monitor and innovate processes. IIoT technologies are allowing manufacturing to run faster and smarter, becoming more self-aware in terms of how production operations are managed and optimised.

By deriving actionable insights from connected devices, manufacturers will become more competitive – armed with information-backed decision-making, tailoring products to consumers’ specific requests through customisation, which will lead to better customer experiences. Many manufacturers worldwide are incorporating IIoT devices in their products to capture and analyse how customers actually use the products, which then inform new product upgrades and releases. In addition, data from IIoT technologies is being used to lay a foundation for delivering new business models and associated services such as remote diagnostics.

Managing increased complexity from Industry 4.0 While the potential for benefits is great, incorporating Industry 4.0 innovations also presents new challenges for Australian manufacturers. Integrating and managing a few IIoT sensors is simple; however manufacturers today can deploy thousands of IIoT devices to conduct different tasks. These all connect to a network via different methods: LTE, LPWAN, Wi-Fi, bluetooth, satellite, and ethernet. As of yet, there are no common standards or connection methods for these devices.

With more specialised IIoT applications appearing and with IIoT devices being initially deployed to solve specific use cases (for example, machine monitoring or fleet management), many manufacturers are finding themselves with multiple IIoT platforms, often from different vendors. On top of this, new technologies like digital twinning and collaborative robots are entering production operations.

George Harb

AMT FEB/MAR 2020

INDUSTRY 4.0 In this complex environment, Australian manufacturers must think carefully about how they integrate and govern different types of devices and technologies, how they manage an ever-increasing volume and velocity of data coming from these devices, and how they analyse and derive insights from the data so that operations can be optimised. Industry 4.0 is also not simply about the IIoT devices: it becomes a complex digital ecosystem of people, systems and things. In this latest industrial revolution, manufacturers are evolving their environments from liner-based systems to complex digital ecosystems where manufacturers, suppliers and partners work together more collaboratively. Manufacturers must think differently about how they share information, including potentially sensitive product and manufacturing details, not only within their own plant walls, but also with external ecosystem members.

Data security and privacy are among the biggest considerations for Industry 4.0 adoption among Australian manufacturers.

The modern manufacturing process has a consistent flow and exchange of sensitive, mission-critical information moving from different devices, platforms and ecosystem participants. It’s imperative this information is captured, transmitted and stored properly and is not compromised. Failure to do so can have a costly and damaging impact not only on vital operating technology and processes, but also on the reputations of ecosystem participants.

Secure IIoT networks will underpin all future Industry 4.0 and digital transformation initiatives.

Preparing for success in Industry 4.0 Realising the promise of Industry 4.0 and the IIoT is not for the faint of heart, but Australian manufacturers can prepare for success by carefully assessing business goals for each deployment of these new technologies. Australian manufacturers must also adopt comprehensive, secure, centralised IIoT platforms which can help them gain maximum value from Industry 4.0 investments. These platforms should: • Provide digital backbones to which all Industry 4.0 technologies can connect.

• Provision, connect and manage all devices and technologies, regardless of connection method.

• Integrate other IIoT platforms specific to use cases.

• Integrate Industry 4.0 technologies with manufacturing and business processes.

• Securely collect, manage, and analyse data.

• Facilitate secure information sharing between manufacturing operations and key ecosystem partners.

• Scale to allow Australian manufacturers to meet changing requirements of the challenging Australian manufacturing market.

The best centralised Industry 4.0 and IIoT platforms will also enable an identity-centric, zero-trust approach to ensuring critical devices and associated data streams are protected from tampering or misuse. These platforms automatically sense and establish secure connections with devices anywhere in the IIoT architecture. They deploy identity and access management capabilities to clearly define the role, purpose and lifecycle of each device, system or person within the connected ecosystem and to allow only appropriate access to data and devices.

ARE YOU OPTIMISING YOUR R&D CLAIM POTENTIAL? William Buck are the accountants and advisers to Australian Manufacturing Technology Institute Limited (AMTIL) and preferred supplier to members. William Buck has a dedicated R&D Incentives team with over 15 years experience consulting in the R&D space. We offer a complimentary consultation to assess your businesses opportunity to make R&D Tax Incentive claims.

In a complimentary consultation we will undergo the following; — Preliminary evaluation of R&D claim eligibility — Review of past R&D claims — Explore opportunities to maximise R&D claims (past and future) — Uncover Accelerating Commercialisation (AC) grant opportunities.

A personal touch backed by relevant experience We work with a wide range of manufacturing clients offering a complete range of R&D, business, tax and advisory services from a network of local offices. This gives our team key insights to the industry and the ability to offer a complete business solution.

To book your William Buck Hour contact Dr Rita Choueiri Dr Rita Choueiri Principal, R&D Incentives Ph: 03 8823 6840 rita.choueiri@williambuck.com

While the Australian manufacturing industry has endured a number of challenges and threats in recent years, it is still uniquely positioned to make a significant impact moving forward. In the age of technology and connectivity, it’s now more important than ever for the industry to embrace Industry 4.0, investing in innovative solutions and integrating them into manufacturing processes.

By doing so, the Australian manufacturing industry will thrive.

George Harb is Regional Vice-President – Business Ecosystems at OpenText APAC. www.opentext.com.au

AMT FEB/MAR 2020

075

076

INDUSTRY 4.0

Industry 4.0: A revolution from edge-to-edge The Fourth Industrial Revolution is about connectivity, data and analytics – taking the infrastructure you already have, and making it work faster and smarter. By Stephen Bovis.

Australian businesses in the manufacturing, transport and logistics industry are seeking new ways to connect processes to more accurately capture analytics and use data insights to improve workflow from the factory floor to the store shelf.

One way to harness the connected network is through the Internet of Things (IoT), and connecting existing physical hardware to an edge computing system to collect and analyse data.

The nuts and bolts of IoT IoT isn’t one plug-and-play solution. It’s an interconnected network of sensors and data collection that helps make the most of company-owned devices.

Installing IoT sensors into your business can drastically change the way your hardware works. For instance, if you have a production centre, its primary purpose would be to create products. But with the right IoT implementation, every machine in the centre can have a secondary purpose – to feed you data, and improve your business.

Businesses across industries such as construction, manufacturing, healthcare, mining and agriculture are already using IoT sensors to measure and analyse their performance data. For the manufacturing industry, these sensors could monitor the performance of a worksite machine and provide data that can be used to make it more efficient. In a 2018 study, PWC and the Australian Computer Society suggested that by implementing IoT sensors, the manufacturing, construction, healthcare, mining and agriculture industries stand to gain an annual saving of $194bn-$308bn.

The manufacturing industry alone sits to gain $50bn-$88bn from implementing IoT. Gartner recently highlighted that businesses are only making use of 6% of their data, meaning 94% is lost or unused. Much of this is happening in edge cases, where the data source is furthest away from the home base. That’s why Hewlett Packard Enterprises globally has been looking at how edge computing can give businesses better access to their remote data sources, without the expense of building remote servers.

The challenge for most businesses comes in the implementation of these data solutions.

Sure, you might run a warehouse and think IoT sensors can help you manage stock levels and highlight periods of congestion, but what’s the best way to install them, and how do you capitalise on that data?

AMT FEB/MAR 2020

Produce, analyse, improve, repeat Once your business is producing terrabytes of data, the next challenge is data distribution and storage. For many businesses, running massive data centres to collate and analyse all that data isn’t practical; that’s where edge computing comes in.

Gartner analysts predict that in six years, 75% of enterprise data will be generated and processed outside of data centres. But it turns out that transferring sensor data to the cloud (and back) is slow, expensive, and can be insecure. At the edge of the network, which can be anywhere, bandwidth is often scarce and intermittent and it’s expensive to transmit large volumes of data through the network to the cloud.

That’s what we mean by ‘the edge’. It’s anywhere the data is being produced, be it a factory floor, an oil rig or a storefront – and an edge IoT system takes the data produced there and provides the tools to analyse it on site.

Early concepts of the new decentralisation paradigm said we need a stopover – called a “cloudlet” – to not only sort and forward, but process data right at the edge. Today, these cloudlets are often represented by mini, micro and edge data centres; small, rugged form factors equipped with cooling and uninterruptable power supplies.

Edge systems must maintain a small physical size, while possessing the power to run full enterprise versions of IoT applications, analytics and data management identical to the software running in a data centre.

But enterprise-level IT at the edge is not

enough. Converging the systems with both the operational technology (OT) and the information technology (IT) is a necessary next step.

Bridging the gap between OT and IT The convergence of OT and IT supports making physical processes as flexible, intelligent and autonomous as if they were virtual processes. Edge systems are the bridgehead of this convergence.

An IT position that enables intelligent operations on OT territory. Sensor data shows businesses where and how to make improvements, so that businesses can be more efficient and effective.

Setting up and running a complete edge system of this type is highly complex because it requires the orchestration of a large number of different components. For example, industrial systems with sensors and control systems; drivers, adapters and middleware for bidirectional communication between OT and IT systems; and standard IT applications at the edge, in the data centre, and in the cloud.

But the reward is in finding more efficient ways of working, and creating a more agile business that is able to adapt to new challenges and improve as needed.

By connecting your physical hardware to sensors and measuring the data produced, every manufacturing business has the opportunity to improve workflow, productivity and eventual products.

Stephen Bovis is the Vice-President and Managing Director for Hewlett Packard Enterprise South Pacific. www.hpe.com

077

INDUSTRY 4.0

High IQ tools optimise metalworking in a digital world The digitisation of manufacturing – a key element of Industry 4.0 – is redefining production methods, and the metalworking industry is taking note, despite its characteristic traditionalism. Metalworkers have started to adapt to this new environment by building or overhauling systems to facilitate more efficient processes.

New demands have affected and influenced almost every element of a technology process: from planning and communication networks, to machinery – and even cutting tools, which are arguably the most conservative element in a manufacturing system. Cutting tool producers need to react appropriately and provide products according to these new requirements.

Digitisation in the cutting tool field is characterised by two emerging trends. The first trend is to enable the cutting tool to communicate with advanced machinery and cyber-physical production systems in order to advise about variables such as tool wear, predictable tool life, total time of the tool involved in cutting, and so on.

The second trend relates to the information about the tool that should be provided by a cutting tool manufacturer. Manufacturers are expected to supply data about their products, and catalogs and guides have long been an integral part of the product itself.

The challenge now is to include digital information as a necessary essential element of a cutting tool, which ensures applying tools in various steps of a production process, starting with virtual manufacturing. A good illustration of this is the ISO 13399 standard, which specifies computer representation and data exchange for information about the cutting tools and their holders – a first step for making the tool digital data platform-independent. Only tools digitally specified in accordance to this standard will be utilised by smart factories, making comprehensive digitised data sources an important direction for cutting tool manufacturers; this integration of data will form an inseparable part of a cutting tool. Cutting tool manufacturers will not only improve their own production by implementing advanced technologies but will represent an essential link in an industrial information chain providing data for smart factories and engineering companies. One cutting tool manufacturer that recognises the central importance of developing and adopting digitised solutions for metalworking operations is Iscar. Its Matrix system, an automated tool dispenser that is an integral shop-floorlevel element of a smart factory, as well as tool assembly options in 3D and 2D formats in E-CAT, Iscar’s electronic catalogue, are typical examples of the way its products are intended to unify the material and virtual worlds of smart manufacturing.

Virtual assembly In addition to the existing milling tool assembly option, E-CAT has enriched its instruments for virtual manufacturing by introducing a new assembly option that relates to drills and taps. This new function allows creating the twin representation of a drilling or tapping tool assembly based on the ISO 13399 standard (see Figure 1). The assemblies are accessible in both 3D and 2D files, which can be downloaded from E-CAT on the Iscar website and incorporated directly into a user’s CAM system. As a result, various simulations of cutting operations, collision checking, finding an optimal tool configuration, and other functions can be performed. The simulations prevent or significantly diminish the possible errors on the shop floor and help to save time and cut costs in process planning.

Smart scan Data on Iscar’s tool dimensions, inserts, appropriate tool holders and recommended cutting data is accessible via the Iscar 4.0Pro mobile application, developed for maximising tooling utilisation.

The Iscar 4.0Pro mobile application includes a smart 2D Matrix barcode scanner that acts as a digital gateway to advanced tooling resources.

ISCAR 4.0Pro is a smart 2D Matrix barcode scanner (see Figure 2) that acts as a digital gateway to advanced tooling resources of the company, so that customers can make better decisions regarding tool selection and their realisation on the shop floor. The application provides quick access to technical data for each Iscar product.

The information corresponds to the ISO 13399 standard and to the tool assembly, cutting conditions, tool material grades, weight, user manuals, and numerous other items. The data is accessible by scanning the 2D Data Matrix barcode, which appears on Iscar tools and product packages.

A world of information Iscar recently launched Iscar World, an expanded application that embraces all Iscar’s online apps, interfaces, and product Iscar recently launched Iscar World, an expanded application catalogues in a single space (see that embraces all Iscar’s online Figure 3). The app gives instant apps, interfaces, and product access to E-CAT, ISCAR 4.0Pro, catalogues in a single space.

E-Commerce (an online tool ordering system), a media channel, Iscar Tool Advisor – an expert system for tool selecting, technical data, machining calculations, frequently asked questions and more, enabling users to review, compare, check, and select the tooling solutions that are right for their needs. The application constantly updates and expands its store of knowledge by collecting new data, opening a virtual doorway to a whole world of updated information.

Smart manufacturing in the Industry 4.0 era features a combination of real and virtual worlds, based on network technologies, for every link of the manufacturing chain including cutting tools. Advanced manufacturing systems require cutting tools to “possess” a rich world of relevant data – a high IQ – as a necessary condition for incorporating the tool into their intelligent machining processes. www.iscar.com.au

AMT FEB/MAR 2020

078

ONE-ON-ONE

Dr Christopher Hegarty has been CEO of the ANCA Group since July 2018. He spoke to William Poole.

AMT: You’ve been CEO at ANCA for about a year and a half now.

How’s it gone so far?

Christopher Hegarty: In general, very positive. It’s a great company, fantastic products. We have more recently faced some tough market conditions. That’s driven by the end of the smartphone boom; trade issues between China and the US aren’t helping, and Europe’s got its own struggles, so people are cautious. But we have some fantastic new products in the pipeline that will really grow our business, so I’m looking forward to the next upturn.

ANCA is a machine tool manufacturer, we make tool and cutter grinders, automation systems and metal fabrication, but our customers have demand for more products than that: other machines, other process steps. There’s a lot we can do to help around integration and automation, delivering an end-to-end tool production system, with no manual operations at all. That’s the vision. That’s what we’re aiming for.

And the beauty of that is it’s a much bigger market than just the machine part; it’s highly attractive for customers because you can produce higher quality at lower cost. And it plays to our strengths.

ANCA has a very strong background in software and control systems.

We’re extremely good at software. We’re very good at automation.

And frankly, most of our competitors aren’t; they bought their control systems in, so software’s not a core skill. For us it really is.

AMT: Tell us about your background before coming into ANCA. CH: I’m an electrical engineer. I studied at University of Queensland and then UC (University of California) Berkeley. I initially went into consulting with McKinsey for five years, then moved into high-tech manufacturing in the semiconductor industry. In semiconductors there’s a continual process of technological change because they’re always pushing for smaller geometries, and that’s constantly driving you forward because the machines have to get better and better. So it’s a challenging environment. That’s where I spent most of my time, mainly in Switzerland, but also Germany.

Then for personal reasons we wanted to move back to Australia. I was at EMO and somebody said “You should talk to ANCA. They’re Australian.” And I had no idea. I laughed and said “Australian?

You’ve got to be kidding. Austrian, right?” But I looked ANCA up and was very interested. I contacted (ANCA co-founder) Pat Boland, and one thing led to another. I never thought I’d be back.

AMT: ANCA is a rare Australian advanced manufacturing business succeeding globally. What can other manufacturers here learn from ANCA? CH: I think, first and foremost, innovation is key. We’re a high-cost country. When I left Australia in the 1980s, we weren’t, we were relatively inexpensive, certainly compared to Europe and the US. The world has changed. Europe and the US are even more expensive, and we’ve joined that club. Asia is cheaper than we are, and they’re pretty good at what they do. So you’ve got to innovate: either manufacture the product cheaply even though we’re an expensive place to do business; or make a product so good people will buy it even though it’s expensive. Either way, you need innovation, in the manufacturing supply chain, or in the product.

AMT FEB/MAR 2020

That’s what makes ANCA what it is. We have a long history of innovation. We’re recognised as an innovation leader. And it’s imperative we keep that. We do everything we can to keep manufacturing costs down – that’s why we have a factory in Thailand as well as here. But if you ask customers “Why buy an ANCA?”, it’s the capabilities we offer. We just do things our competitors can’t.

We had a Japanese customer here, a family-owned business that had only ever bought Japanese machines, but they’ve got new blood in the board, an American guy, who said they should buy outside Japan. They decided to give ANCA machines a try, and the gentleman who came from Japan for the run-off of that machine was absolutely blown away by the capability.

Local knowhow is also important. You need to be aware the world is very diverse, and the Australian way of doing things doesn’t play everywhere. You need to consider who you’re dealing with, their culture, their local practices and customs. I’ve certainly seen Australian companies shoot themselves in the foot by assuming everyone’s like us.

A third thing that’s equally important is that Australians can be very relaxed – this can be a great positive but also something to be aware of. Much of the world doesn’t run that way; it’s much more tightly stitched. If you go in only with that attitude, you could potentially be at a disadvantage. Instead, the expectation is you jump higher. Japanese or Korean customers for example are incredibly demanding; it’s a harder place for Australian companies to enter but as with ANCA it is very possible and worthwhile.

AMT: You’ve worked in manufacturing both here and overseas.

What are Australian manufacturing’s greatest strengths?

CH: We have great attributes for getting things done, solving problems. I’ve seen that recently in this company. One customer was putting incredibly high demands on performance, and the team’s initial reaction was “We’ll never do that - but we’ll give it a go.” But we did, we got there. Over a couple of weeks, with people across the company working very collaboratively, and addressing whatever they could to get the machine running faster, they did it.

That’s very Australian. Swiss or German companies don’t work that way. They’ll get there, but it’ll take a lot longer.

I think it is helpful that we’re very isolated. We’re used to making do. At ANCA, we essentially have no suppliers locally. A couple of machine shops, like Total Precision, but generally we do a lot ourselves. That’s a great way to be innovative, because necessity is the mother of invention. It makes us very practical. We don’t look for perfect solutions, we look for pragmatic solutions that are good enough. Of course, there’s also a downside to this – lower volumes give less potential to optimise. We have a large global supply chain for standard components such as linear rails.

Another one, and it’s strange to cite as a positive, is Australia’s got somewhat relaxed employment laws and practices, certainly compared to Europe where it’s generally much more restrictive, which makes companies very cautious. Here if you’re not sure about somebody, you can hire them and give them a try; if it doesn’t work out, okay, no harm done – they move on. European companies tend

079

I’ve actually had this argument with people we’ve interviewed, who’ve said: “But how long are you guys going to be here? When are the lights going out?” And it’s like “Aarrgh... the lights aren’t going out. We’re growing.” But for someone at the start of their career, it’s a fair question. If you read the press about manufacturing, it’s generally not terribly positive.

The second big challenge is a dwindling supply, particularly in engineering, of people we want to hire. There’s just fewer of them being educated. For ANCA in particular, before the car industry shut down, there was lots of cross pollination. We have people here who had worked in automotive, and there were people who went from ANCA to the automotive industry. That isn’t happening anywhere near as much, and that’s a terrible shame.

In my background, the semiconductor industry follows the Silicon Valley model: you’ve got clusters of companies doing similar things, in a similar space. And there’s a lot of flow of people between them.

That raises the bar for everybody, because knowhow flows around, people see different things, they go to new companies and face new situations, and they say “Oh at such and such, we did this.

Why don’t we try that?” That’s been a very successful model for the semiconductor industry. But we don’t get enough of that, certainly compared to the US and Europe.

The third challenge is expertise. Australia has good universities, but they don’t co-operate anywhere near as closely as in Europe, or California. In the companies I worked at in Europe, we had good close co-operations with universities: academics and professors on call, long research relationships, PhD students helping us design our stuff and we’d pay for part of their education. In Australia we do some of that, but nowhere near enough. And relationships with universities here are much more bureaucratic, much more difficult.

not to do that. If they have question marks about someone, they just won’t hire them. Again, it’s a strange one, but it makes us more flexible and it gives employees with “unusual” backgrounds a better chance too.

AMT: And what do you think are the challenges facing the industry here?

CH: One of the worst is the general perception manufacturing is finished in Australia. I’ve heard it so many times. But if you look at US manufacturing for example, in employment terms it’s shrunk over the last few decades, but in dollar output value, it’s grown enormously.

That’s a combination of better processes; automation, meaning less labour; and higher-value products. So manufacturing is anything but dead. It’s not employing as many people, but it’s employing more highly skilled people, and therefore more highly paid people.

We do work very successfully with the Advanced Manufacturing Growth Centre (AMGC) and have a number of active projects with them which have been working very well. However, my experience has been that when you look at our collaboration with universities more generally there is lots of opportunity that we are not yet realising. For example, in Germany, I was very impressed with the Fraunhofer Institutes. They’re fantastic, with deep knowhow, deep expertise. The CSIRO does what they can, but there’s not the depth of expertise compared to Fraunhofer.

AMT: What do you think Government could do to support the industry?

CH: First it would help if they’d even mention manufacturing. I’ve never seen anything in the press where manufacturing was the focus. There’s plenty about coal-mining, farming and tourism. If you look at the Swiss or German press, manufacturing’s a big sector, treated with importance. If our Government could do something to raise our profile, that would be so helpful.

Continued next page

AMT FEB/MAR 2020

080

ONE-ON-ONE Contined from previous page

One specific policy area – which I have to say I think has zero chance under the current Government – is that our business is very cyclical.

We have ups and downs. Machine tool industries generally are like that. Two years ago we had a boom, now we’re in a downturn, in two years it’s probably going to be booming again. Our European competitors face the same problem. In Switzerland, they have government programs named Kurzarbeit, which means ‘short work’. A company like us that’s in a downturn and needs to reduce costs can approach the Government and apply for Kurzarbeit. If they approve it, the company only has to pay 80% of the employee’s salary, the Government pays 20%, and the employee works 80%, a four-day week, but normally gets their full salary. Germany has a very similar programme. The benefit is we can hang onto people in the downturn who we otherwise couldn’t afford. And when things improve again, we get back to full capacity and go from there.

It’s a wonderful way to soften the blow of these swings, because sadly, what happens here, where there’s no such support, is we end up letting people go that we don’t want to let go, and it’s very hard to get them back. So to me, that’s proven extremely effective.

And even though people say “The Government’s paying and that comes out of taxes”, the company performs better on the upswing, and then it pays more tax. You’ve just got to think more long-term.

I know competitors of ours in Europe are doing this right now, and it makes me jealous. Another thing, and the Swiss government is very effective at this, is working with companies, opening doors abroad, getting us into industry groups, getting openings, leads, introductions through ambassadors or trade representatives. We don’t get anywhere near enough of that from Government. We get some, but we could do with a whole lot more.

AMT: What are the key trends you see having an impact on ANCA and the industry?

CH: Well, markets always shift, but the situation’s become more dynamic. A big one is the automotive market’s move from internal combustion to either fully electric vehicles or hybrid electric vehicles.

What you believe here depends on where you’re sitting: if you work for Tesla, you think fully electric cars will take over the world; if you work for Japanese manufacturers, you think hybrids will take over. That’s important for us because about 20% of our customers make automotive products: engine blocks, gearboxes and so on.

Fully electric cars have fewer machine components than internal combustion engines, so if the world goes fully electric there’ll be a drop in demand for cutting tools. If, however, the world goes hybrid, with both gasoline and electric engines in the car, total demand will in fact increase. But no-one really knows which way that will play out. That’s a trend we’re keeping a very close eye on.

Another thing is the smartphone boom is behind us. That drove enormous volumes and a lot of innovation. An incredible amount of machining went into the iPhone case, using cutting tools made on our machines. Demand hasn’t dropped so much per se, but the installed base is now so high that they’ve got enough to cover the demand. And people also hang onto their phones longer than they used to. The good news is there are significant increases in volume coming along, especially from areas like aerospace. Boeing or Airbus have full order books for 5-10 years, with many aircrafts being produced. There are up and coming competitors in China; in Brazil, Embraer that is well established now. That’s driving a lot of demand, and the market’s changing because engines in particular – something we’re big in – have to be much more reliable, which puts tighter tolerances on machining, better control, better tracking and so on. Another trend is additive manufacturing. A lot of people see it as a threat, because rather than machining something it can be additively manufactured. But no additive manufacturing process can produce a surface finish like machining. And it’s also an opportunity.

AMT FEB/MAR 2020

One project we’ve got is to look at using additive manufacturing as an alternative to grinding. If you make a tool such as an endmill, you can only make shapes you can grind with the grinding wheel, but with additive you have many more degrees of freedom. You can make different shapes, you don’t have the limitations of the grinding wheel. And it plays into our capabilities in software. So I see that as a big opportunity for ANCA, not just a threat.

Another area is smart factories and Industry 4.0. There was a fantastic article in a Swiss newspaper recently about Fraisa, who is a good customer of ours. They were concerned they could no longer manufacture profitably in Switzerland, that they’d have to move production somewhere in Eastern Europe. They approached ANCA and said “We’re looking for a fully automated solution to do this lights-out.” We delivered a solution that runs all weekend with no-one there, and they’re very happy with it. Fraisa’s CEO was out here and he said “With this solution, we can continue to manufacture in Switzerland.” And the skill level of the workforce has changed dramatically. Fraisa went from relatively unskilled 20 years ago to a highly skilled workforce these days. There are basically no unskilled people left. And they didn’t do it by firing them; they trained them.

That Fraisa automation example is a good one, but it’s an isolated system, a little automated cell. We’re looking at going beyond that, to cover everything. Fraisa’s a big company; they can afford to invest in that kind of thing. We want to come up with solutions smaller companies can afford. In the US, for example, we’ve got a lot of customers – ‘Mom-&-Pop’ operations – with four or five employees.

There’s tremendous potential for them to increase profitability if their machines could run at weekends without anyone there, while guaranteeing a good product. That’s an important part of the smart factory solution, to guarantee what’s coming out is right.

AMT: What are your ambitions for ANCA going forward?

CH: In July we launched ANCA Vision 2025, including what we call Complete Tool Production, expanding our footprint for an end-toend production system. It’s basically providing customers a turnkey solution where we deliver everything: all the automation, all the integration, all the consumables. That’s very exciting because that market is much bigger than the tool and cutter grinder market on its own. Customers typically have 10 to 15 steps a product might go through from start to finish; we currently provide one of those steps.

A high value-add step, but only one. There’s a lot more that gets done, and that’s something that we’re going to address.

Then we’ve got ANCA Motion. We recently had some good interactions with a global automation systems provider in Asia, who we visited and presented to, and they were absolutely blown away by the capabilities ANCA Motion has - absolutely world-class. Noone can match some of the things we do, especially things like linear motors, or in the CNC. There’s a big untapped market for ANCA Motion, a lot of potential for it to become much bigger than it currently is, and we’re pushing that very aggressively.

AMT: And what’s the most rewarding aspect of the job?

CH: Well I’m still an engineer at heart. I love taking an idea, turning it into a product, and making a lot of money out of it. You know: first it’s an idea, then we make a prototype, we get it working properly, then it sells incredibly well and people love it. That’s a great feeling.

Another thing I really like is listening carefully to customers about what they’re looking to get solved. What bugs them about what they currently do? What problems would they like solved? There’s nothing better than leveraging our technology to solve their problems in a way they totally didn’t expect – coming out of left field and blindsiding them, so they say “Oh that’s brilliant. I never would have thought of it, but it’s just what I want.” www.anca.com

MATERIAL REMOVAL

Cutting edge automatic tool changing maximises spindle on time Tibo Tiefbohrtechnik is a global operation, with sales, manufacturing and service across several continents, specialising in the design, manufacture, installation, application and after-sales support of modular deep hole drilling machines.

Founded in 1994 and with its headquarters in the town of Pfullingen in BadenWürttemberg, to the south of Stuttgart, Germany, Tibo today is one of the leading suppliers of single-spindle and multi-spindle gun-drilling and BTA deep hole drilling machines for a broad range of applications.

Embedded into a medium-sized group consisting of 14 companies and more than 1,000 employees, its customers benefit from quick turnaround in all aspects of their deep hole drilling requirements, with many applications tailored to customers’ individual requirements.

As a German machine tool builder, Tibo manufactures exclusively in its own plant in Pfullingen. And a predominantly local supply chain means it can proudly claim that its machines are made in Germany.

Whether it’s gun drilling or the BTA method, or whether it’s a single or multi-spindle system, Tibo deep hole drilling machines boast impressive precision, speed, quality and durability, as well as a unique design consisting of modular sub-assemblies that are well proven in harsh and demanding applications.

The Tibo modular system allows almost limitless configuration possibilities, from the universal standard machine through to highly-specific special machines.

This enables the company to offer every customer an optimum machine design to suit their own individual drilling task. Since sub-assemblies are normally available from stock, its lead times are considerably shorter than those of its competitors or industry standards: the average time from placement of an order to delivery is just four to six months, or a suitable machine can be found from the ones that the company has in stock.

One of Tibo’s customers in the hydraulic cylinder sector approached the company for a new machine for a new range of components. The range consisted of parts with three different diameters to be machined. The application was: counter boring, skiving and roller burnishing for each diameter and the customer wanted to increase efficiency, with an emphasis on maximising spindle on time. Another critical requirement was to improve the work environment for the employees along with reduced manual handling, maximised workflow and minimum setup.

To meet the above challenges, Tibo decided to fully automate the complete

process, not only part loading and unloading, which was already done many times before, but also the automated tool exchange. The modular B250-3000 was therefore selected as the base machine.

Tibo designed the workpiece loading and unloading based on its modular systems. Due to the wide variety and range of components produced by the customer, it adapted its standard modular components and designed new application-specific modules to meet the customers’ needs.

Exchanging the tools, however, was a more complex challenge. To automate tooling changeover, and in close co-operation with the customer, Tibo designed and installed a gantry system that attaches to the oil pressure head, vibration damper, drill tube, counter boring head, skiving head and roller burnishing head, and exchanged the complete tooling string as an assembly.

The gantry system takes the tools off the machine and places them in a storage rack.

For this application there was room for three tools, but it can be easily adapted to hold more tools. Tibo designed an automated clamping system for the drill tube, the oil pressure head and the vibration damper.

The system ensures safe, repeatable lifting and exact positioning of all tools.

The final challenge was to ensure that all elements of the system were controlled from the machine’s control system. This was achieved by utilising the latest Siemens PLC technology, remote I/O and Profi-bus to connect and process communication between the part loader, tool loading and machine tool. The machine control and operator interface was based on the userfriendly, Tibo touch screen control, which is easy to use and has been specifically developed to monitor all boring parameters, allow adaptive control “on the fly”, and ensure ease of use for the operator, while providing quality and process data for the manufacturing team.

After installation by Tibo at the customer’s plant, the customer was highly satisfied with the results, which even exceeded the expected output on units. www.tibo.com www.teco.net.au

AMT FEB/MAR 2020

081

082

MATERIAL REMOVAL

The benefits of automating material removal processes As manufacturers struggle to overcome an apparent skills shortage, material removal is a rapidly growing application area for robotics.

Once constrained to a few specialist tasks due to limitations in force sensing and machine vision, today’s manufacturing environment sees a broad range of applications, from trimming flashing from plastic and aluminium mouldings, removing moulding flash and edging material from carbon fibre products, polishing moulds and dies, and deburring edges following machining.

While previously these applications relied solely on compliant tools, more recent developments such as force sensing control and vision have created the ability to handle variability in the position and size of the material that has to be removed.

Force sensing provides greater control over cutting loads and the direction of the applied force, leading to more consistent and cleaner edges. In more recent times, the robot is used to articulate the part itself over the tool, versus the traditional method of a robot mounted tool. Whichever approach is used, the accuracy and path repeatability of the robot provides less variability across the substrate, irrespective of the die or machine they were manufactured in, overcoming one of the major hurdles for manufacturers – rejected parts due to inaccuracy and a lack of consistency. By applying the appropriate amount of pressure between the part and the material removal equipment, precise results can be achieved in every cycle.

The most obvious advantage of robotic material removal solutions is the superior repeatability when compared to traditional means. However there are several other key advantages and flow-on effects that need to be considered when evaluating the benefits of a system: 1. The increased accuracy and consistency in an automated material removal system result in a significant reduction in reject parts. The flow-on effect is a reduction in quality-related concerns, such as rework, scrap, or warranty concerns. Typically, when a customer finds a part that doesn’t meet the tolerance, they will return the entire batch, so it is critical that these are reduced or eliminated at the point source of origin. The adoption of robotic vision provides real-time error proofing to ensure proper process and product quality.

This robot is fitted with a force torque sensor.

It is mounted between the frame of the end of arm tooling and the spindle so that the robot can “feel” the loads during trimming and deburring. The spindle has a tool change function, which allows it to change between a range of tools using BT30 tool changers.

AMT FEB/MAR 2020

2. Another major advantage is the improvements in throughput, or speed.

A correctly programmed vision and force sensing material removal system can reduce the production time significantly. A recent case study by Automated Solutions Australia (ASA) found that throughput was able to be increased by 50% over traditional manual operation.

3. The expense related with tooling consumables means that the tools wear at a much lower and more predicable rate, so the preventative maintenance costs associated in maintaining these items is further reduced.

4. Removing people from the process facilitates a reduction in exposure to harmful fumes, dust, and repetitive tasks that can often lead to repetitive strain injuries such as carpal tunnel syndrome and vibration white finger.

At the same time, reducing human exposure also reduces the annual expense of personal protective

equipment (PPE) in the form of protective eyewear and earmuffs.

5. A further flow-on effect of the higher consistency part-to-part is a reduced requirement for manual inspection labour.

The recent technological advancements in robotics have created a much more diverse application range for material removal.

While the applications for automated material removal have grown, the benefits of implementing a system are sound and proven: precise results resulting in less scrap and a reduction of waste at the point source of origin; improved throughput; a reduction in consumables; reduced exposure for personnel to potentially hazardous working environments; and a reduction in the labour requirements for manual inspection.

These considerations need to be carefully balanced against a business case for automating your material removal process to determine the total annualised rate of return on the equipment. Given economies of scale, the question must be asked – will you innovate, or evaporate? www.automatedsolutions.com.au

MATERIAL REMOVAL

Investing in machinery: The key to Plastool’s success Specialising in precision engineering and tool making, Mordialloc-based Plastool recently ramped up its capabilities with a Makino V80S vertical machining centre from Headland.

MAXIMISE

YOUR PRODUCTIVITY

Plastool was established by Bert Down in the 1950s, originally operating out of Box Hill, Victoria. The company has undergone significant growth over the years, and now employs a staff of 14 at a purposebuilt 1,600sqm facility in Mordialloc, in Melbourne’s south-eastern suburbs. The business remains very much a family operation, with Bert’s sons Gary and Andrew now serving as Chief Executive Officer and Manufacturing Director respectively.

WITH HIGH PERFORMANCE SOLUTIONS

Plastool provides high-precision 3D CNC machining, engineering and toolmaking solutions. This includes new tooling, repairs, and modifications to all types of moulds. The company’s primary focus is on the food packaging, aerospace, defence, automotive, housewares, medical, electronics, building and construction industries. It has now expanded into thinwall plastic and composite tooling.

According to Kieron Donoghue, Project Manager at Plastool, the secret to Plastool’s success has always been good leadership.

“Gary and Andrew Down always research the future trends of the market and pursue them,” he explains. “They are willing to reinvest any profits back into the company.

This includes investing in new machinery and equipment, as well as keeping employees’ skills and training up to date.

Our strengths are being able to do things with more accuracy than our competitors.

We take on more difficult challenges and trickier jobs than other companies.”

With a talented, dedicated team, Plastool’s success is underpinned by the high quality of the work it delivers. The team at Plastool produces impressive results, with integrity, attention to detail and client service.

Their technical expertise and project management systems are second to none.

Every job is on time and accurate.

Donoghue discusses why Plastool recently purchased the Makino V80S vertical machining centre from Headland: “The Makino V80S has a larger machining envelope than any of our current machines.

It has higher tolerance capabilities, with five axes. This enables us to fit more parts on the table and change our programming styles. Makino has a great reputation. And it was the size we needed. New machinery means expansion and putting more work through the factory. This allows us to be more productive.”

Kieron Donoghue, Project Manager at Plastool, with the Makino V80S vertical machining centre.

Investing in technology such as the Makino V80S help Plastool optimise its operations and maintain a competitive edge, Donoghue add: “The machines save us time, increase efficiencies, and increase our market size.

We have machines that few companies have. They’re high end, five-axis and not easy to come by. We can take on work from anyone; we enable anyone to have access to this equipment.”

The team at Plastool were very pleased with Headland’s customer service.

“Headland is always very attentive,” says Donoghue. “They are very helpful and always solve problems for us.”

Large-scale manufacturing such as the automotive industry may have declined in Australia, but Donoghue regards this as a positive – not a negative – for businesses like Plastool.

“In Australia, we’re becoming more of a niche market,” he says. “As long as you can find something that you’re good at, and find a customer who needs what you can offer, the opportunities are there. Keep developing your skills and keep travelling down that road.” www.headland.com.au www.plastool.com.au

Contact us for more information digital@sutton.com.au

www.suttontools.com

AMT FEB/MAR 2020

083

084

MATERIAL REMOVAL

Precision packed into a small footprint Spanish manufacturing business Vilardell-Purtí recently expanded its fleet of Tornos equipment with a MultiSwiss 6x16 machine as it strengthens its capabilities in the field of high-precision turning.

Headquartered near Barcelona, in the Catalonia region, Vilardell specialises in the production of precision parts with a high added value. The company comprises two divisions: the Medical Division and the Industrial Division. Jordi Roy Torras, Manager of the Industrial Division, says Vilardell has specialised in the production of highly complex parts for some time.

“This is our core competence. Something we have developed year after year and part by part,” he explains. “We employ 165 staff and they are very important to us. Almost every day, we are faced with new challenges.

Even with the best machines, we wouldn’t be able to tackle these challenges, if we didn’t have such a strong team!

“Our customers know that they can count on us and on our expertise when it comes to meeting any machining challenge. We have to keep our minds open and focus on innovation as one of our key values.

Each and every one of us has to remain innovative, irrespective of his or her position or function within the company - that’s essential for our business.”

To meet this demand, the company has invested in technology from Tornos. The long-standing collaboration with Tornos now boasts an impressive inventory of equipment that includes a small number of single-spindle CAM machines (T-4, R-10 and MS7) and a large number of multispindle machines (AS 14, SAS 16 and SAS 16 DC). In terms of CNC machines, the company’s fleet includes the Deco 10, Deco 13, Deco 20, Sigma 20 and the EvoDeco 16 models.

“We are determined to provide our customers with comprehensive service and are collaborating closely with them,” says Roy Torras. “We try to understand their needs and provide advice to jointly optimise the machining processes. Over time, we have gathered a profound expertise in our key markets, and we can efficiently advise our customers in various fields, be it in the automotive, aerospace or in any other industrial sector requiring precision-turned parts. “The focus is on high added-value products and this requires us to integrate new technologies, such as the latest machines from Tornos. We also pay special attention to quality and we hold ISO: 9001 and IATF: 16949 certifications.”

Recently, Vilardell added to its workshop with the purchase of a MultiSwiss 6x16 machine. Roy Torras explains what made the company opt for this machine.

AMT FEB/MAR 2020

“The choice was driven by rational motivation. In terms of technical specifications, the machine is simply the best in the market,” he says. “However, we had to also consider the restricted space in our plant. The MultiSwiss boasts the most compact footprint and is definitely the most efficient machine in the market. At first sight, this small footprint may seem to be trivial.

However, it makes the difference.

“The machine is really doing well and the fact that it is equipped with a container comprising all peripherals is a key advantage for us. The machine works perfectly and the peripherals are very well integrated. We are extremely satisfied with the machine performance. The hydrostatic features work wonders and we are able to achieve an excellent surface finish whereas the tool wear is well below the wear of conventional machines.”

In addition, Roy Torras adds that the new machine boasts an array of excellent ergonomic features: “The operator can really enter the machining area without difficulty. The tools can easily be installed in the machine without the need for the operator to lean into the machining area, and the machine set-up can be realised in next to no time. The MultiSwiss doesn’t only offer excellent performance but also complete ease of operation. Thanks to its high level of productivity, the machine enables us to multiply our performance per square metre while guaranteeing an outstanding part quality both in terms of precision and surface finish.

“It should also be noted that the collaboration with Tornos is excellent and that their service stands out for its high responsiveness. This really is a combination that pays off for us.” www.swisstec.com.au www.vilardellpurti.com

086

CUTTING TOOLS

Reducing tool costs per part – Application solutions for automotive The cost per part (cpp) is the gauge by which process efficiency is measured in the automotive industry. The machining tool represents a not inconsequential cost factor in this regard.

This is particularly true of solid carbide tools (round tools), which are primarily used for holemaking, milling and threading. Estimates calculated by tool specialists Walter indicates that these tools already make up around half of the machining applications in the automotive industry today. Depending on the characteristics of the component, drilling and threading work with round tools influences approximately 15% to 50% of the total costs per part. Being able to reduce costs once again here remains a key factor for success.

All aspects of machining The transition from combustion engines to electric motors or other alternative drives, which is gaining momentum as a result of tighter environmental regulations, touches every area of the automotive industry – right up to every last detail in the production processes. Walter has been on hand to actively accompany the sector through these changes from the very start: the company presents car manufacturers and suppliers around the world with a comprehensive portfolio of tools and services, which is constantly expanding through the addition of innovative new solutions. This means the automotive experts at Walter are always up to speed with the ever-growing number of new materials. What’s more, existing tool solutions for established processes are also optimised, usually to meet customer-specific requirements, or alternative solutions are devised on the basis of new technologies.

Lightweight materials now represent a significant portion of automotive production. For instance, the proportion of engine blocks made from aluminium today is already around 70% – in an area of industry that until only recently still favoured traditional materials such as grey cast iron and steel. Aluminium alloys have already become the default materials for transmission cases or oil pump housings, both for chassis elements and in structural components. And with the growing trend for electric drives, we will see more and more of these alloys in use.

Seeing the bigger picture to reduce costs Complicated machining tasks (including in tasks involving these new materials) or sophisticated part geometries with a lot of cavities increase the complexity of the machining process and, in turn, put extreme pressure on costs. This is where machining experts such as the team at Walter come in.

“As a manufacturer of premium products with 100 years of experience, we already offer highly effective and optimum solutions for a diverse range of applications from our standard range, which comprises more than 25,000 products in the solid carbide segment alone,” explains Gerardo Campitiello, Component Manager – Transportation at Walter. “Walter’s expertise, or ‘Engineering Kompetenz’, however, extends far beyond the individual machining tool. We focus on the overall machining strategy and the customer’s machining process.

“If our experts are involved in the development of production and tool management processes from an early stage, customers will often experience efficiency gains that are felt via more than just the machining tool. Requirements such as making unmanned production processes safe, ensuring reproducible process reliability and quality across a company’s production sites, or making tools available at all times, can only be met by taking a holistic approach.

Whether selecting the right tools from the Walter standard range or developing a special tool to meet process-specific specifications, it takes careful consideration of the full picture.”

An instantly productive special tool In the automotive industry, processes that may seem timeconsuming on paper are actually completed in very tight time frames in practice. It is with this in mind that Walter establishes its own processes and structures: for instance, tools from the standard range are with the customer within 24 hours of ordering.

The Walter Technology Center presents opportunities for visualisations and simulations, and allows developers to test new solutions on the machine.

AMT FEB/MAR 2020

CUTTING TOOLS

Greater pull-out strength under dynamic forces: The Walter thread former

A typical task for most series manufacturers: drilling identical or deep holes into a workpiece made from aluminium alloy, such as a cylinder head.

The Walter Xpress special tool service ordinarily delivers tools, which are developed and manufactured to customer specifications, within two to four weeks. This is based on an automated 3D process, which can be adapted to suit the project in question. A dedicated inhouse department (Business Applications Development) constantly monitors market trends to improve existing application solutions and develop brand new approaches. This team of engineers takes on the role of Component Managers, responsible for individual components such as engine blocks, housings, e-axle drives, turbine casings or crankshafts. They are among the first to know about market trends and technological advances, which is reflected in their product development work.

The new Walter solutions can be tested in true-to-life situations at the Technology Center in Tübingen, Germany. The test run on the machine incorporates the very latest visualisation and simulation technologies.

This means Walter customers in all areas of the automotive industry benefit from the in-depth technical expertise of an innovative service provider who is active the world over and is also involved in the relevant fundamental research. The company makes major investments in its own research & development projects, and in the development of its own production capabilities in areas that competitors often contract out to third parties. For instance, Walter is one of the few providers on the market to have its own coating system.

Productivity boosted 30% in aluminium: The Walter DC166 A typical task for most series manufacturers is drilling lots of identical or deep holes into a workpiece made from aluminium alloy, such as a cylinder head. With its specialist solid carbide drill, the DC166, Walter presents a tool that increases productivity by up to 30% compared to previous conventional drill bits. The DC166’s special cutting edge geometry – with point tapering, ultra-sharp cutting edges and polished flutes – means the drill can produce a significantly faster feed rate. When drilling 16 holes, each measuring 60mm deep, into a cylinder head made from AlSi10MgCu, for example, customers are able to halve their machining time. One drill machines 2,000 workpieces, which is double that of the previous standard process. This special tool with through coolant is specially designed for minimum quantity lubrication (MQL) or cooling with emulsion.

When forming threads in ISO P materials, the process reliability primarily depends on how susceptible the thread former is to breaking. With its TC430, Walter provides a model that stands out for its durability. The extremely long tool life of the TC430 thread former, which is suitable for blindhole and through-hole threads, is the result of a new substrate, the geometry with more polygons, and an innovative new kind of pre-treatment and post-treatment. The result is that, despite having more polygons, the TC430 Supreme reduces the torque by around 30%. This means that the thread former is also well suited for use in machines with a low power consumption.

Walter is planning to launch another carbide thread former for ISO P materials in early 2020: the new tool has already proven its exceptional properties in ongoing field tests. Designed for blank holes and through holes of up to a maximum of 3.5xDN, it demonstrates twice the tool life of comparable formers. It was possible to reduce the power consumption on the spindle by more than 30%. www.walter-tools.com

Walter acquires US-based Melin Tool Company Walter has reached an agreement to acquire the privately owned US-based company Melin Tool Company, a manufacturer of solid carbide and HSS end mills, drills and countersinks.

Melin is a growing company, supported by innovations in the solid carbide endmill product family making the acquisition a strategic fit to enlarge Walter’s milling business in the US. The US is a key market for Walter and the acquisition strengthens the company’s round tool offering, especially for the aerospace industry and the US channel partner market.

The acquisition gives Walter customers access to advanced cutting tool solutions and responsive support. A stronger footprint presence of Walter in the USA allows to grow the inch assortments in line with local market requirements and to support the market with customised tooling solutions even better.

“The acquisition is aligned with our focus on expanding our milling business in round tools and reconditioning capabilities close to customers in the American market,” says Richard Harris, President of Walter. “I am very pleased that we have reached an agreement to acquire Melin Tool Company as it increases our market presence and has a strong innovation focus and high service level that is aligned with Walter’s approach to doing business.”

Michael Wochna will remain in Melin as president.

Melin’s offer is focused in solid carbide end mills, drills and countersinks to the aerospace and medical sectors. Its production facility is in Cleveland, Ohio, with an additional warehouse in California. The company has approximately 100 employees. www.melintool.com

AMT FEB/MAR 2020

087

88

CUTTING TOOLS

Sutton Tools: Key trends in automotive and aerospace At the recent EMO 2019 manufacturing technology exhibition in Hannover, Germany, Jeff Boyd, Key Markets Manager at Sutton Tools, sat down with Stephen Las Marias to talk about trends and opportunities in the cutting tools market, and some of the product innovations at the company.

Established in 1917, Sutton Tools is a family-owned company manufacturing cutting tools for the metal cutting industry.

The company supplies tools to end-user markets including automotive, medical, mining, power generation, aerospace, defence and the oil & gas industries.

Founded by William Henry Sutton, the company is currently managed by the fourth generation of the Sutton family.

Stephen Las Marias: Tell us about yourself and your role in the company.

Jeff Boyd: I have a background in product engineering and technical R&D. That kind of matured into a more of a technical role in the field. In 2011, I headed up to Singapore, where I ran the company’s operation and distribution centre. I was there for nearly five years, running the Asian markets. Currently my role is to support our teams globally, and bring the necessary market information back to our head office to support our production facility.

We offer a wide range of solutions for the metal cutting industry. We have a division in Europe, based in the Netherlands, which supplies the European region; and then from our Melbourne headquarters, we are very focused on the Asian market, where we supply various engineered cutting tools, to increase the end-user’s productivity. We have salespeople located in all the major markets in Europe and Asia. And for a company our size, that’s probably where we mainly focus on. In these markets, we have a particular focus on aerospace machining of difficult high-strength materials and automotive tapping.

SLM: What challenges are you seeing in the industry?

JB: Every market has a different challenge.

If I bring it down to one thing, it is finding the right people in those markets. People are engaged in the market, and have very good relationships, because we know we have a very good, very stable product at a competitive price and the right quality.

But at the end of the day, you really need the right people that you can trust to be able to really find the right solution to offer the customer, to bring the benefit to the customer; to bring these products to them.

SLM: What opportunities are you seeing in South-East Asia?

JB: I would say South-East Asia has a very strong aerospace/aviation market, and from our experiences and successes in the machining of titaniums and inconels

AMT FEB/MAR 2020

Sutton Tools’ stand at the EMO 2019 manufacturing technology exhibition, held in Hannover, Germany, last September.

– particularly in the French aerospace markets over the past few years – that has allowed us to leverage this knowledge and open up a number of new opportunities for Sutton Tools in South-East Asia. That said, automotive tapping applications in Thailand and Indonesia are also of particular interest when it comes to thread forming of forged steel components.

SLM: You mentioned you were in Philippines recently. What are the opportunities you are seeing in that market?

JB: I was in the Philippines for the PDMEX 2019 event, to support our distributor there. We have a couple of aerospace customers and a few automotive customers in the Philippines. It is kind of similar, the aerospace companies based there are very much machining exotic materials including titanium, and we have a very good relationship with them for many years. There are also quite a few automotive customers, again for tapping. And they are our two strengths, really. We are not going to take on everything, they are our main areas for our products. We like to do things really well, and we put a lot of our resources into supporting the brand.

Jeff Boyd, Key Markets Manager of Sutton Tools.

CUTTING TOOLS Sutton Tools manufactures cutting tools for end-user markets including automotive, medical, mining, power generation, aerospace, defence and the oil & gas industries.

the market there for the subcontractors to Airbus, which is really seeing a lot of growth in the market, particularly this year. That’s a very important area for this exhibition for us.

But we are also showcasing some new products ready for 2020. We’ve recently purchased some new equipment to produce extra-long series carbides drills.

We’re releasing a range of 15xD, 20xD and 30xD carbide drills in 2020, which we are showcasing here, as well as a lot of our taps for automotive tapping applications.

SLM: What can you say about e-mobility?

JB: We have a number of customers, particularly in China, for electric vehicles (EVs), and, you know, a lot of materials there are silicon-based aluminium. We have very good solutions for producing threads when it comes to forming taps for those materials. As the internal combustion engine is seeing a demise, we are focusing on EVs, and diversifying our offer; focusing from an engineering point of view on those materials necessary to produce the electric vehicles.

SLM: What products have you been highlighting at EMO 2019?

JB: We are highlighting industry-based solutions here, so we have a program for super alloy materials for the aerospace industry. In terms of machining, we have a very good carbide grade and geometry ideal for high metal removal rates with dynamic-type machining strategies. We have done a lot of independent testing with our tools, and we have about three sales guys in the south of France supporting

SLM: The cutting tools market is very competitive. What makes your products unique in the market?

JB: Sutton Tools is flexible in the way we go about our business. We really like to work with the customers, and the end-users. We are very focused on talking to the end-user, understanding what their challenges are, and we try to be flexible enough to offer a solution in that way.

Reprinted courtesy Asia Pacific Metalworking Equipment News. www.equipment-news.com www.suttontools.com

AMT FEB/MAR 2020

089

090

CUTTING TOOLS

Developing unique products to meet rail demands When renovating railway lines there are generally two preferred options: grinding or dynamic milling. Compared to grinding, the high-speed reprofiling of a line represents significant time and financial savings.

Specially designed trains, operating at a constant speed of 700 metres per hour, machine the existing track profile. By removing millimetres of metal from the damaged surface, the track is restored to its original condition. With each application, the first cutter roughens the surface, the second one finishes it, and the two units act on both rails simultaneously. The operation provides a high-quality surface finish, while metal chips produced during the milling stage are transferred to a nearby container, ensuring no debris is left on the track.

This ‘on the-move’ application requires specialised equipment to achieve optimum results, such as ‘train machine tools’ designed to carry dynamic rail milling cutters and inserts. An increasing number of these are being produced by leading global manufacturers as demand from railway organisations and government bodies for track maintenance increases.

Global cutting tool manufacturer Dormer Pramet works in partnership with several high-speed milling machine manufacturers to delivery key projects around the world. One of these projects included the milling of three different rail profiles for a customer in the Netherlands.

Dormer Pramet’s 600mm diameter dynamic rail milling cutter was able to machine the combined profile (60E1, 54E1, 46E3 1:40) and another profile 54E5 1:40, without having to change the inserts. Using the same cutting tools across several profiles is hugely beneficial as it saves both time and costs, reducing the number of tool changeovers. “As with all railway projects, each application is different from the next, so we regularly tailor our products to meet the need of the customer,” said Tomas Hantek, Application Manager - Railway - at Dormer Pramet. “It is very important we work closely with the machine tool manufacturer and rail organisation to identify where adaptions need to be made to achieve the desired results.” The development of new rail technology is constantly taking place and modifications are needed on both sides to optimise the match between the machine and cutting tool. Dormer Pramet has adapted its popular dynamic milling cutter in various sizes, from 300mm to 900mm, with plans to develop a 1,400mm diameter version in the future.

“We recently delivered a 300mm diameter dynamic rail milling cutter to a customer for testing,” adds Hantek. “This has been custom made to specifically fit their new machine. In the first trial, they discovered that the cutter profile was as they required. However, they realised their new machine was not strong or rigid enough to cope with the demands of the application. We are now working with them to make some changes and help move the project forward.”

At present, Dormer Pramet has more than 50 dynamic rail milling cutters out in the market, including in the Netherlands, Germany and Poland. This is an indication of the international nature of the railway segment, with tool suppliers, machine tool builders and customers from different parts of the world, working together on applications which often take place in different countries.

This not only requires precise logistical management, but an understanding of different standards and accreditations between countries. Many projects involve large international organisations, as well as support from government agencies and administrations, along with affiliated transport associations.

Wheel returning Another example where Dormer Pramet provides support to the railway segment is in wheel returning. This too can see standard tools being modified to become custom-made specials, unique to the requirement of the application. Its assortment of rectangular LNMT and round ROEX inserts, for example, have proven a big hit with customers in North America. A customer in Philadelphia was having issues with its previous LNMT inserts as

The same wheel profiling application now with chip control, using Dormer Pramet’s modified LNMT insert.

AMT FEB/MAR 2020

A wheel profiling application with no chip control.

CUTTING TOOLS

Dynamic rail milling application in operation using the Dormer Pramet cutter and inserts.

they were not able to break chips during a wheel turning operation.

The resultant long, continuous swarf congested the area around the workpiece. The process to clear the chips is not only time-consuming but can also be hazardous.

Dormer Pramet put forward its standard LNMT inserts, but during tests, found these too did not break the chips as required. Following further feedback and discussions with the customer, the company was able to make two key changes to its insert. First it added a corner radius chip breaker to relieve some of the pressure on the tool. It then tailored the geometry and design of the insert to prevent nesting at high depths of cut.

The end user wanted to make one pass, so the LNMT insert needed to be able to achieve a staggering 18mm depth of cut at the first attempt. Following the changes, the insert was put in for further testing. Not only did this new design fix the chip control problem, but it consistently outperformed all other inserts tested. The customer now orders from Dormer Pramet. In addition, the company has started to use their RCMX, RCMT and TNMG inserts on a variety of operations, such as the turning down of axles. This has allowed them to reduce cycle time by an average of 30%, saving more than US$30,000 in the first year, with greater operational efficiency and improved performance.

Railway wheel turning is an area Dormer Pramet is looking to expand its assortment further. Where the LNMT can support large depths of cut, the company is now working on a new insert for delivering small depths of cut, around 1mm.

A popular trend with customers when machining railway wheels is to perform the operation with a low depth of cut. This is still completed in one pass, but the reconditioning will be required more often between uses. This new product will support those applications. It is currently in the testing phase, with the aim to launch the insert this year. www.dormerpramet.com

AMT FEB/MAR 2020

091

92

QUALITY & INSPECTION

Mitutoyo sparks quality revolution for busbar manufacturer Universal Electric Corporation has built a globally recognised brand that relies on measurement equipment from Mitutoyo to guarantee product quality.

In 1936, Pittsburgh’s Great Flood crippled Western Pennsylvania leaving thousands without electricity. In an effort to help restore the city’s electricity, Donald Ross started the Allegheny Electric Company. In its drive to bring safety to the manufacturing industry, it noted that the wiring method in existing overhead cranes was very dangerous. After decades of innovation, the company invented the Track Busway.

As the company grew and further broadened its product lines beyond trolley conductor systems, it changed its name to Universal Electric Corporation (UEC). This marked the creation of two separate divisions when UEC introduced STARLINE Plug-In Raceway.

First introduced in 1987, STARLINE Track Busway is now the industry-leading electrical power distribution system for missioncritical data centre facilities in markets such as industrial, retail and higher education markets. The company has built a globally recognised brand that relies on measurement equipment from Mitutoyo to guarantee product quality.

The UK division of UEC moved into a new 5,500sqm factory in Reading in 2018 to support the European customer base. Being both UL- and ETL-listed, and CE-marked for use anywhere in the world, the quality of the company’s Busway product lines is a critical factor for the business.

As the Quality Director at the UK facility in Reading, Clive Larke says: “I joined STARLINE about three years ago to help set up the global quality programme, and a key part of that was a global metrology programme. It became apparent that we needed to upgrade our metrology ability, particularly on the back of our aggressive growth both in Europe and Asia. We needed to assist our supply chain to set up our products, manufacturing and support with them.”

The Crysta Apex 574 CMM in operation.

Referring to the company’s relationship with Mitutoyo, Larke says: “I have worked in quality assurance for around 25 years and in that time I have worked with a number of different providers. The one thing that sets Mitutoyo apart from its competitors is its global reach and the after-sales support. It really is unparalleled.”

Tasked with implementing a standardised measurement facility on three different continents with the facility for seamless global integration and conformity, Larke approached Mitutoyo.

With regard to the metrology department, Larke continues: “As part of the global strategy, we wanted to produce a mirror image on both this side of the Atlantic, the US and in our other hub in Asia.

We control all three labs from this hub here in Reading. STARLINE is premium brand and our customers expect a premium product, and this is our way of developing a unique way in the market to support our customers.”

As Mitutoyo’s Southern Area Technical Sales Engineer Trevor Stubbs recalls: “I had previously supplied Clive with Mitutoyo products when he was at a different company, so when he joined STARLINE, he got in touch to see how we could best undertake his metrology project. Initially, Clive brought a number of parts to our Andover headquarters where we conducted extensive testing, trials and conformance reporting.”

From this assessment, Mitutoyo recommended a number of suitable products. This included the Crysta Apex 574 three-axis coordinate measuring machine (CMM), the Quick Vision Active QVL404 two-axis CNC measuring system, the Quick Image QI A2010 image recognition and measuring system, and the LH600E height gauge. It also suggested a selection of hand tools, a granite table and a number of other ancillary products.

“Much to our surprise, Clive didn’t only order the equipment for the Reading facility; he also placed an order for the Singapore and US sites,” said Stubbs. “By mirroring the Mitutoyo equipment specified for the Reading site, the company can ensure complete uniformity across all its manufacturing sites.

An example of a STARLINE system.

AMT FEB/MAR 2020

“The Crysta Apex CMM is used for measuring critical dimensions as well as the dimensions on mating parts that require an optimal fit. STARLINE manufactures thousands of components and assemblies, so the Crysta Apex will also be used to measure the dimensions of a section of extruded aluminium prior it being entered into production and assembly. Additionally, the QVL-404 is applied to measure extrusions with exceptional speed and efficiency.”

QUALITY & INSPECTION This uncompromising level of speed and precision is provided by an automatic edge detection function and an automatic image focus facility, which both combine to allow automatic measuring with nothing more than ‘rough’ positioning on the surface of the machine. This allows STARLINE to automate a lot of its metrology department. For example, the CMM and the QV can be set up to automatically run while one of the staff in the quality department can undertake other tasks, such as measuring extrusions on the height gauge.

Steve Roddy, who oversees the metrology departments in the UK and at the overseas sites, says: “We have a Crysta Apex 574 threeaxis CMM and a Quick Vision Active two-axis machine. We also have a Quick Image (QI) that is all used for measuring the products that come into our business. We measure each individual subcomponent that comes into the business. This is to ensure that we have repeatability, and it is a guarantee to our customers; it’s also to ensure we meet all the drawing tolerances specified.”

“The relationship we have with Mitutoyo is really good, whether it’s here, in the US or in Singapore. I can go to Singapore and contact the Mitutoyo guys in the UK and within an hour I’ll get a response, whether it’s an email or a phone call – and this is the same in the UK. The training has been absolutely fantastic and all the machines have designated training programmes. And there are also advanced courses available to go on.”

Looking to the future growth potential of the business and its relationship with Mitutoyo, Roddy continues: “If there is any further growth within the business, we will definitely be working with Mitutoyo to support this growth.” www.starlinepower.com www.mtiqualos.com.au

The Mitutoyo Quick Vision measuring system.

Dimac’s tool presetter range adds respected Zoller brand Tool presetters improve quality and boost productivity by precisely measuring any tool offline with micron accuracy, allowing CNC machines to keep cutting, optimising machine uptime and maximising tool life.

Tool presetters provide three key features in one machine: measuring, presetting, and inspecting tools. They save set-up time, improve accuracy, produce better-quality parts, and minimise scrap.

including a direct link via ethernet to various CNC machines. This facilitates the direct transfer of a measured tool’s library of results, thus eliminating the potential of damaging data entry errors.

A state-of-the-art image processing system measures tools’ cutting edges in seconds, saving and documenting the results, meaning time-wasting fine adjustments are a thing of the past. Adjustable boring bars can be easily set with micron precision in under a minute, which in turn eradicates frustrating “trial and error” cutting. Tool run-out can also be checked and cutting inserts inspected using the on-board inspection camera.

EZset are manufactured in Germany and assembled with high-quality brand name components, such as Bosch pneumatic components, THK guides and Heidenhain glass scales, to ensure a long, maintenance-free lifetime. Equipped with image-processing based on the newest technology available, a precise tool mounting spindle and numerous measurement functions, EZset sets a benchmark in cost-effective tool presetting.

“Presetting and measuring allows for shorter fitting times and greater productivity; while your machine works you can get the next tool ready,” says Paul Fowler, Managing Director of Dimac Tools. “Thanks to correctly preset tools, the very first part will be of the highest quality. You can also be confident the tool will perform perfectly until the end of the tool life, thereby minimising the chance of rejects.

Zoller is a German brand founded by Alfred Zoller; the company today is still run by the Zoller family, now in its third generation. Since 1968 more than 28,000 presetting and measuring machines as well as tool measuring machines have been sold, with worldwide unrivaled software solutions.

“We’ve been distributing our EZset tool presetters for a number of years and these have enabled many CNC operators to improve their productivity and quality. To ensure we cater to all market segments, we’ve now added the respected German Zoller range to complement our existing EZset models. No matter what your requirements or budget, we are confident we will now have a presetter to suit your needs perfectly.”

In addition to an extensive range of models, both EZset and Zoller offer extensive hardware and software options to suit individual operator’s production needs. Both brands have optional features

All Zoller presetters feature the highest-quality components, including a high-precision freely accessible tool holder spindle, state-of-theart optics, leading-image processing technology and comfortable, easy-to-use ergonomic control units.

“Precisely measured cutting tools deliver at least a 15% increase in productivity in your manufacturing processes,”Fowler added.

“The initial investment in a tool presetting device is quickly returned through the increased productivity, higher quality and less waste.

They are easy to operate and will save a company time and money.” www.dimac.com.au

AMT FEB/MAR 2020

93

094

FORMING & FABRICATION

Service and support: Applied/Yawei partnership boosts growth at KNS Metals By enhancing its capabilities with the acquisition of state-of-the-art equipment manufacturing equipment from Yawei, KNS Metals continues to build its status as one of Victoria’s fastest growing sheet metal companies.

Proudly family-owned and operated, KNS was founded by Kamal Singh. Kamal had been working in the sheet metal industry for more than 30 years when in 2014 he spotted an opportunity in the marketplace.

With his extensive experience, he believed that it was the right time to go it alone. He took that knowledge with him when he founded the company with his wife and two sons.

The business has grown rapidly over the past several years. Today KNS now operates with around 10-15 staff at its facility in Dandenong South, south east of Melbourne. Amal, Kamal’s elder son, is now the company’s General Manager.

KNS Metals specialises in custom programming and design fabrication for both commercial and residential customers. Commercial is the backbone of the company, providing around 95% of its business, while residential makes up the remainder. The company also offers a range of other services, including CNC turret punching, laser cutting, pressbrake bending and welding. KNS operates Australia-wide but most of the clients that it deals with directly are based in Victoria.

Most of the company’s work comes through word-of-mouth. As such they have never had much need to advertise, though they are now expanding into social media.

Kamal and Amal believe that their business has been successful due to their knowledge of the industry and outstanding customer service. While working in the business, Amal has also been completing his electrical engineering degree. The knowledge he has gained from this has been beneficial in enhancing the company’s overall expertise.

“Our past experience as well as our critical and logical thinking helped a lot; and with this knowledge we can give customers great lead times and great quality products,” Kamal says.

Kamal had become aware of Applied Machinery after he purchased an Amada AE-2510 turret punch from them. When KNS required another new machine, Applied was the first place he went to.

“We had dealt with Applied previously so it was only natural for us to do business with them again,” he explains. “We were looking for the right machine and after discussion with Applied found that the Yawei pressbrake they offered was just what we were after.”

AMT FEB/MAR 2020

Kamal Singh (left) and Amal Singh from KNS Metals.

Applied helped the team at KNS set up the machine when it was delivered, and this help was vital. It also impressed the company.

“When we moved to our new factory, Applied came in after-hours and helped us set up over just one weekend,” says Amal.

“We packed up on Friday and we were back working on Monday – that’s how much of a help they were,” Kamal adds.

The subsequent service and back-up that KNS received from Applied has been the reason why they’ve stuck with them.

Amal remarks: “We have a great working relationship with Applied and we are certain that will continue into the future.”

The pressbrake has made a significant impact upon the company.

“We are very pleased with how the machine’s gone so far,” says Kamal. “We

will likely get a second one as we anticipate further growth in part thanks to the effect the pressbrake has had.”

KNS was previously outsourcing a number of jobs due to limitations on its laser-cutting resources. However, once they began subcontracting a couple of years ago, they soon realised they required their own inhouse laser-cutter that would be able to perform high-quality precision cuts.

KNS went to Applied again and after reviewing Yawei’s extensive range of fibre lasers purchased an HLF-15303kW model.

Amal and Kamal were particularly impressed with the machine’s quality components, such as the Siemens Controller. Importantly, this purchase allowed many of those previously outsourced jobs to come back in-house and massively expanded their cutting capabilities.

FORMING & FABRICATION

The Yawei fibre laser offers a number of clear advantages, and the benefits the machine brings have already had a direct impact on the service provided by KNS. “We have found that the fibre laser is consistent and the speed and accuracy of cutting is brilliant,” says Amal. “We’ve had the machine for three or four months now and our staff are very happy with its ease of use and the way in which it operates.”

“Our lead times have greatly improved as a result of having the machine,” Kamal adds.

“We feel that we have taken back control of certain elements of our business.”

The company also enjoys the added reassurance that Applied is always on hand to assist them.

“Occasionally, when we require additional assistance and technical guidance with the fibre laser, Applied has been available to help us right away,” Amal notes. “We are grateful for that support.”

Much like the pressbrake, the success of the fibre laser has also meant that a second machine is likely to come at some point in the future. “Laser cutting has become a big part of our business in recent times so

the machine was a vital purchase,” says Kamal. “We are already booked out for the next six months because of the work we are now able to perform with the Yawei.”

Amal and Kamal would like to keep on growing and expanding their customer base, and KNS’ dedication to customer service and high-quality products will ensure they will continue to be a leading Australian sheet metal company long into the future. The success they have achieved

in such a short time has meant they will probably have to upscale yet again.

“We are very happy with our growth over the past few years and in the short term we will probably purchase another Yawei guillotine and turret punch press,” Kamal concludes.

“We will probably move to larger premises because we realise our current factory is not as big as what we wanted!” www.appliedmachinery.com.au www.knsmetals.com.au

AMT FEB/MAR 2020

095

096

COMPANY FOCUS

Ignite Digi – Combining artistry with engineering There’s surely no better way to know your market than by using your own products. Ignite Digi, a small but highpunching outfit designing and manufacturing camera accessories from its base in Hobart, Tasmania, was its own first customer. But it’s been busy adding a host of impressive names to its client base ever since. By Dee Rudebeck.

Ignite Digi’s co-founders Tom Waugh (left) and Chris Fox.

Ignite Digi was co-founded by cinematographer Tom Waugh and Chris Fox, an aeronautical engineer with 10 years experience in the Royal Australian Air Force (RAAF). The company started out as a drone and camera operating team, hiring out their services to film and television productions. However, they found their creativity and vision were being limited by the capabilities of accessories available at the time – so they invented their own.

Self-taught, Chris began producing carbonfibre camera attachments with a 600mm x 900mm CNC router, before progressing to aluminium. Before long, other people in the industry began noticing their time-saving components via social media and began asking the pair to manufacture parts for them, so they began milling custom orders in Chris’s garage.

Today, while Ignite Digi remains involved in the film and television industry, its core business has turned from primarily filming, to designing, manufacturing and selling accessories to other industry professionals.

Ignite Digi make their accessories for highend cinema cameras and the two leading gimbal brands. A gimbal is a motorised stabiliser for moving cameras, either handheld or mounted on drones, vehicles or cables. Gimbals have only been used in the film industry for the past five or six years.

“Gimbals disrupted the market by enabling

AMT FEB/MAR 2020

people to get shots that previously would only have been possible with exceptionally expensive remote heads,” says Chris.

“People are able to get stabilised footage from tracking vehicles that historically required half a million or million-dollar investment. Now they can get virtually the same shot for around $15,000.”

Tom explains it from a cinematographer’s viewpoint: “Because drone work is all about minimising weight, some of our products have unlocked camera and lens combinations that previously had not been possible.”

Ignite Digi’s smallest part begins in price at $115, while the fully linked-in system is around $8,000, including all battery plates and cables.The ecosystem is a range of well thought-out, quick-release parts. According to Tom, now the company’s sales manager, it’s an “ecosystem of parts that can be used individually but work better as a whole”.

“In car terms, we are the after-market accessories and performance parts to make the gimbal platform at its most usable,” adds Chris. “Our whole system developed for operators to quickly transition the camera and gimbal package between the different modes [handheld, tripod, drone, remote-controlled buggy] in under a minute. We were the first to systematically solve every element in the process and the system keeps evolving.”

Ignite Digi were early players in their field.

The pair met when Chris was working in materials handling in the mines in Port Hedland, Western Australia, where he had recognised the potential of drones.

“I realised there was an opportunity to take people out of harm’s way by using drones for a lot of activities,” he says. “So I started getting the required licences though the Civil Aviation Authority and tried to establish a business plan.”

Chris was also a keen photographer and a colleague approached him to make a film about a project. However, Chris needed an editor; he was introduced to Tom, who was already working in the film industry. When the pair joined forces in 2014 as the drone and camera team, Tom was only 24 and Chris, at 36, had 20-odd years’ experience under his belt. As a former freelancer, Tom laughs: “So when we both threw ourselves into it full-time, I went into my highestpaying job, while Chris started his lowest.”

They were soon being sent all over the country to shoot films, commercials and TV dramas. One of the first was The Kettering Incident in 2014, the biggest production that year using drones.

Tom explains how they worked: “Chris flew the drone and I was controlling the camera on the bottom separately, in discussion with the film director and director of photography.”

TASMANIA Ignite Digi specialises in the design and manufacture of camera accessories for film and television industry professions.

“This is what makes us unique,” chimes Chris. “Between us, we are able to come up with solutions that just a group of filmmakers or just a group of engineers wouldn’t come up with, because on a daily basis we are having conversations that cross the boundary between the two. Some people think there is a limitation to how you can film something because the equipment doesn’t exist, but I look at it and think ‘That’s just a case of making that bit of equipment’.”

Upscaling operations Chris and Tom are now running a busy production line. The company had a stirling 2019 that involved moving out of Chris’s 80sqm garage into a 400sqm workshop, as well as taking on new employees – by March this year, they will have four more fulltimers, up from the two co-founders at the beginning of last year. And the bigger space has meant new milling machine purchases.

“We started developing our parts on a basic three-axis vertical mill [Optimill F80 CNC] in 2016,” says Chris. “And as we grew and sales increased, we identified the need to become more efficient in our manufacturing processes. In 2017 we invested in a four-axis vertical mill [LK machinery TC-710 CNC] to speed up our development time and production abilities.

In January 2019 we purchased an Okuma Genos 540M and it arrived when we moved into the warehouse. That’s really allowed us to upscale our production in the last 12 months.” All this has helped Ignite Digi win Manufacturer of the Year at the 2019 Tasmanian Export Awards, while Tom took the inaugural Young Exporter award. And now they are about to expand again.

“We have a new Okuma MB-4000H coming in early 2020, which is similar to the Okuma we have but on steroids,” says Chris.

“Massive steroids,” adds Tom. The team at Ignite Digi do all their own 3D solid modelling, CAD work and CAM

programming, and the new automated horizontal mill will enable them to operate lights-out production, 24 hours a day, seven days a week… “If we can sell enough parts,” laughs Tom. Chris adds: “The MB-4000H has a 10-pallet pool on it. We should be able to spend a couple of hours loading the machine and then have it run for 24 to 36 hours without much trouble. It depends on the size of the part as to how many it will make – but basically a lot. We’re expecting that machine to more than double our capacity.”

“The Okuma will allow us to manufacture each incremental component for the accessory together in a single run – and this is game-changing because some of our accessories have six or seven different parts we need to manufacture for a single assembly. Previously, we’ve had to batch manufacture those parts individually and in large quantities, which is extremely timeconsuming.” The machine is a $750,000 investment, with all the set-up costs. Other specs include a 15,000rpm spindle and 146 tool magazine.

“The Okuma MB-4000H is a giant leap for us on a productivity and investment level,” says Tom. “It’s more valuable than all the other machines put together – and a bit.”

The rise in production comes after the team’s efforts to grow their market and brand awareness have paid off. The pair put the turning point down to attending their first ever trade show – the Cinegear Expo in Los Angeles in 2018 – where they won a technical award, jointly taking the Best Camera Accessory. Tom says: “We were competing against all the big, multi-million dollar outfits.”

The personal relationships developed at the Cinegear show also proved crucial because 50% of their customers are based in the US. “We were literally meeting our customers for the first time in person. Business from Australia is only 2%, and in terms of

Tasmania we are our only customers, so we don’t get much face-to-face.”

They have also entered the European market, and recently attended the IBC Expo in the Netherlands. “Our social media journey has been a big part of our success, but the trade show probably legitimised us,” says Tom. “Customers saw us as real people, not just a faceless company on the internet. And they saw that we manufacture our own product line.”

It’s a line the pair are continually refining through their own experience, which has not been without its challenges.

“We’ve sunk a few drones over the years, with expensive cameras on them,” says Chris. “Both were recovered thankfully, but that’s not an easy day at the office.”

Did they still work?

“No,” he laughs. “But it makes the insurance claim easier.” It’s this process of trial and error in the field that gives Ignite Digi their edge.

“At the same time that we’re working on concept, we are also working on how we will make the part,” says Chris. “Having that super-tight link between the design aspect and the machining aspect is the key advantage for us.

“We’re investing in advanced workholding to enable flexible manufacturing within the MB-4000H. We will have our entire range of products being made on the machine in the course of a 24-hour period if we want to.”

This will allow them to be more responsive to orders and potentially be able to hold lower inventory levels, which would make a huge difference given the exceptional logistical challenges they face being based in Tasmania. There is no technical support available locally for their work. Even basics, such as raw materials and tooling supplies, are non-existent.

Continued next page

AMT FEB/MAR 2020

097

98

TASMANIA

COMPANY FOCUS Contiuned from previous page

“We have a three-week lead time for materials, then we have to get our parts anodised in Victoria at the end, and that’s a two-week turn-around,” says Chris. “So we have five weeks more to worry about in our logistics pipeline than companies in Melbourne or Sydney or LA.” But it was also this isolation that fostered their ingenuity. Chris explains: “If you consider shooting a film in LA, one rental house there would have more cameras than all of Australia, so when they need an extra camera to go on the gimbal and one to be used handheld, they’d just go and hire another. But in Tasmania there was one camera and we had it, so we had to be creative about how to best use it. That was the catalyst to create our ecosystem to speed up the onset workflow.”

The Ignite Digi team.

Big-name customers Despite the geographic disadvantage, Ignite Digi still has the media teams at Apple, Sony, Uber and Telsa contacting them for kit.

“When I got the email from Apple, I thought it was a scam at first,” says Tom. “I emailed the guy and asked technical questions to see if he was legitimate. We checked his address at Infinite Loop in California and he replied with the correct technical answers.

He’d found us because someone he’d worked with had our components. Having people from the biggest companies in the world buying our parts blew our minds.”

And while the pair are still working on big Australian productions such as The Gloaming (currently screening on Stan), their parts have been used on Marvel films, Disney’s new Mulan, and various Netflix series internationally.

“Through our manufacturing, we’re remotely working on some of the biggest film sets in the world by virtue of our design and thought process,” says Tom. Current projects include developing accessories for a radio-controlled car that can attach a gimbal for creative tracking shots. The other focus is implementing automation systems to accompany the Okuma MB-4000H’s arrival, to ensure Ignite Digi can reliably make its high-quality components from day one.

“We’ve invested in CAMplete TruePath verification software as part of the preparation,” says Chris. “We have a fully realistic 3D model of the MB-4000H, and with the software, we virtually run the machine with our designs and 100% verify that the operation will be successful prior to manufacturing. In terms of collision avoidance and improving our process, we’re able to model the exact behaviour of the machine.”

AMT FEB/MAR 2020

Ignite Digi recently moved to a 400sqm workshop in Hobart.

Tom says this is already informing purchase decisions about what workholding and tools they need: “Basically, Chris has started using the machine with our designs before the Okuma arrives.” The business will no doubt evolve again now.

“When drones were new, we helped pushed the limits of storytelling,” says Tom. “Sometimes we worked with a director who had never used a drone and it was satisfying to discover new ways to tell the story or capture a shot. But now with the sales and support, I really enjoy helping people to solve problems and push their limits of storytelling.”

Their ambitions for the future include expanding into more advanced manufacturing technology. Chris wants to add a five-axis machine to their arsenal… “and maybe go on holiday one day”.

For Tom, it’s also about fostering a community of support for professionals using gimbals. He says that, because they are relatively new tools, some directors refuse to work with gimbals after one bad experience on set: “We want to break down those barriers so people know it’s not like it was five years ago.”

Tom recognises that, like all businesses, things can go wrong, and Ignite Digi immediately sends the customer a replacement part before waiting for theirs to be returned, as most manufacturers do, because “if you’re in the middle of a film shoot, that’s not going to work”.

“It’s a risk we take and an expense we wear, but it’s part of our servicing and pricing,” he explains. “That’s how we would want a company to support us, so that’s what we do.”

That ethos of supporting their customers seems to be reflected in Ignite Digi’s relationship with suppliers such as Okuma.

When Chris was sourcing milling machines, he approached a lot of the big players, but he says it was Okuma who took the time to really engage, even though Ignite Digi was just two guys in a garage at the time.

“That resulted in us buying the first Okuma, which has been outstanding, and now lining up a very big investment with the new one.

It was hard to go past them.”

It sounds like something Ignite Digi’s customers might say about Tom and Chris and their team. www.ignitedigi.com.au

Hotspots is proudly owned and managed

by AMTIL

Getting the right job, making the right piece •

You need a specific component made, but don’t have the capabilities in house.

•

Your company has landed a major project, but your workshop or your workforce just aren’t big enough to handle the volume required.

•

Your business is diversifying into an area where the expertise available within the company is not sufficient.

HotSpots is a service designed to connect AMTIL members with opportunities to help their businesses grow. That piece of work that you need done might be just the sort of opportunity they’re looking for. And by featuring that opportunity as a HotSpot, you gain access to a wealth of Australian manufacturing capability and expertise.

Our regular AMTIL HotSpots email goes out to over 1,000 people every month, making HotSpots an incredibly powerful way to reach large numbers of key decision-makers from across the manufacturing sector.

Provided your opportunity meets our criteria for listing, inclusion in AMTIL HotSpots is free. If you have something you feel will meet our criteria, please forward it to AMTIL for assessment by emailing info@amtil.com.au with the subject line HOTSPOT. www.amtil.com.au/Membership/Hotspots

1285AMTIL2016/5

100

TASMANIA

STATE SPOTLIGHT

Maltec Engineering – Chasing other fish in the sea The city of Burnie in northern Tasmania has taken a few blows in recent years. Local manufacturing has shed many jobs due to offshore moves and a downturn in forestry and mining. Meanwhile, aquaculture has expanded rapidly in Tasmania since the 1990s and is now one of the State’s major industries. One Burnie-based business is thriving on the transition to manufacturing for aquaculture.

Locally owned and operated, Maltec Engineering is a family business providing cutting-edge engineering solutions for clients across multiple industries including mining, construction, forestry, agriculture and aquaculture, in both Australian and international markets since 2001. The company’s modern workshop offers a full range of services, including CNC and manual machining, fabrication, profile cutting, robot welding, sandblasting and painting, utilising Lean advanced manufacturing principles.

Maltec’s General Manager, Lindsay Malley, identified improved growth opportunities in manufacturing for the aquaculture sector three years ago through his involvement in a local industry networking group, where he was invited to submit a tender to a Tasmanian-based aquaculture company looking to manufacture its own components due to problems they suffered with the quality of imported parts.

The parts required by the customer are for use in extremely corrosive environments and require machining to high tolerances.

Drive shafts, mounts and enclosures made from a mix of plastics, stainless steels and aluminium form the main components of the final assembly.

“Once we knew what parts were required by our prospective customer, we were able to increase our competitive advantage by relying on John Hart to help us create a world-class solution with the most efficient machines for the task,” Malley explains.

“Once the installation and training had been completed by John Hart, we were able to jump straight into the production and dispatch parts.”

Maltec invested in two new Mazak machines. The Mazak Variaxis i-500 is a five-axis machining centre designed for multi-surface machining, delivering reduced in-process time, high accuracy and unrivalled machine ergonomics. It features a maximum spindle speed of 18,000rpm and a table diameter of 500mm. The high-speed spindle and an optional pallet changer deliver faster material removal and reduce part changeover times.

Although Maltec already has two Mazak Variaxis 730 BT50 machines on the workshop floor, it was decided that a smaller BT40 machine would be far more efficient in machining the smaller components in large quantities required for each delivery.

AMT FEB/MAR 2020

Maltec General Manager Lindsay Malley (right) and CNC Machinist Stephen McLaren (left) in front of one of two recent additions to the company’s Mazak fleet, the Quick Turn 200MY.

The Mazak Quick Turn 200MY CNC turning centre with multi-tasking capability brings together advanced technology, productivity and value to deliver exceptional performance. As an MY configuration, the machine features milling capability and Y-axis functionality along with a standard through-hole chuck package, and integral turning spindle motor to process a wide range of parts in a single set-up. The Y-axis functionality has reduced the number of machining operations needed to make a single part, and increased machine utilisation.

Both new machines have provided an increase in efficient manufacturing and have accelerated rates of production for complex parts in a single set-up, allowing Maltec to meet ever-expanding demand to fulfil growing orders to strict delivery schedules. The company runs two shifts to keep up with customer demand for parts.

“Utilising the full potential of both these machines has helped us to realise our production goals whilst maintaining adequate staffing levels to cover both shifts,” Malley adds. “By investing in quality machinery, we have ensured that we will have maximum machine production availability both now and into the future.”

Today the shop boasts nine Mazaks, including the VTC 200B that the business started with in 2001.

“Two of the main reasons we started with Mazak back in 2001 was the ease-of-use and the reliability of these machines. This is still the case today,” Malley explains. “The controllers are quick to learn and easy to use, which has always made training new users an easy task. It also allows us to move our operators around to other Mazak machines as required, as they are quickly able to understand and operate the other types of machines at other stations.”

In addition, Malley cites another important benefit: “Moving programs from the older machines to the newer machines is easily achieved. This allows us to make full use of the improved features on the newer machines and reduces the need to completely reprogram these jobs without wasting valuable time and resources.”

When asked about the relationship with John Hart, Malley responds: “Operating from Tasmania can sometimes be frustrating with the Bass Strait an obstacle for outgoing goods and also for receiving timely service. This has never been an issue in our 18-year relationship with the John Hart team. Be it via phone or in person, they have always provided prompt and knowledgeable service from our first machine purchase and installation, right up to our last.” www.johnhart.com.au www.malteceng.com.au

TASMANIA

STATE SPOTLIGHT

Tasmanian trial paves way for wider application of Segnut technology Australian fastening systems innovator Segnut has been buoyed by results achieved during a recent trial of its world-first, patented threaded nut system. Positive testing of the product at Rio Tinto’s Bell Bay Aluminium refinery in northern Tasmania will see wider application of the Segnut technology at the site.

The Segnut significantly cuts the time taken to remove seized and damaged nuts reducing maintenance downtime and boosting productivity. It also eliminates the need for hazardous removal methods such as oxy cutting (i.e. gas axing), hydraulic nut splitting and angle grinding, making nut removal significantly safer.

The Segnut has a patented inner section consisting of three segments held captive by an outer retaining sleeve. When the outer sleeve is turned a few degrees in the tightening direction, the Segnut releases from the bolt and falls away. This means a damaged nut can be removed without it having to travel back up the bolt thread.

At Bell Bay Aluminium, Segnuts were used to secure wear plates on the paste mixers as part of the carbon anode manufacturing process. They were operated at temperatures in excess of 250 degrees Celsius.

The securing bolts must be removed from the inside of the machine, making periodic removal of the plates difficult and timeconsuming. It also required maintenance personnel to work in confined spaces and make use of high-risk oxy-acetylene cutting.

Segnut provided a solution that removed the need for dangerous high-energy removal methods and significantly shortened the change-out downtime.

“Being a smelting environment with multiple risks surrounding fumes and hot works in the same place, elimination of these practices in the refinery is a high safety priority for the Bell Bay team,” said Segnut Managing

Director, David Izzard. “Introducing Segnut has been a major step towards achieving that goal. Segnut will now be added to the site’s inventory management system and will be a regular supply item for day-to-day operations”.

Product Development, Tom Baskovich, said the trials have helped Segnut to understand the challenges presented by harsh mining environments and enabled it to further engineer the product to solve specific problems.

The Bell Bay Aluminium trial was among several conducted in recent months. An in-service trial at Infrabuild’s steel recycling facility in Laverton, Victoria, measured the Segnut’s performance as a fastener in extreme conditions. The nuts were used to secure the water-filled insulating jacket on a furnace running at 1,300 degrees Celsius, with the nuts themselves exposed to temperatures as high as 450 degrees Celsius. After eight weeks, tests showed that the nuts’ oxide coating remained intact and that the structural integrity of the nut had not been compromised. Segnut Director

Founded in 2015, Segnut Pty Ltd is an Australian-owned company with a core purpose to bring to market innovative products that provide safer, more efficient industrial solutions. The Segnut product is a world-first, proprietary threaded nut product with a patented inner section consisting of three segments held captive by an outer retaining sleeve. When the outer sleeve is turned a few degrees in the tightening direction, the Segnut releases from the bolt and falls away. Segnut is based in Perth, Western Australia. www.segnut.com

Funding to help Tasmanian start-ups get export-ready The Federal Government has announced the provision of $463,100 for the delivery of the Seedlab Tasmania project, an incubator focused on helping Tasmanian start-ups to become export-ready.

Minister for Industry, Science and Technology Karen Andrews said the Incubator Support initiative helps develop entrepreneurial talent and introduces regional businesses in the food, drink and agri-food/tourism sectors to national and international markets.

“The Morrison Government is supporting the growth of globally-focused Aussie start-ups to secure long-term economic prosperity,” Minister Andrews said.

“Through the Incubator Support initiative,

we equip start-up businesses with the capabilities to tackle international markets and flourish. This will ultimately mean a more competitive Australia and more jobs, including in regional communities.”

Federal Member for Bass - Bridget Archer - said the project funding will assist local start-ups to develop the capabilities required to achieve commercial success in international markets and realise their economic potential faster. “I’m thrilled that a significant portion of the Seedlab

Tasmania project will take place in northern Tasmania,” Archer said. “Seedlab Tasmania is all about cultivating a network of experts, resources and market insights to accelerate these ventures towards exports, and high-wage jobs in regional Tasmania.

This funding will help develop Australia’s innovation ecosystem.” www.business.gov.au/incubatorrecipients www.business.gov.au/assistance/ incubator-support

AMT FEB/MAR 2020

101

102

ADVANCED MATERIALS & COMPOSITES

IMCRC in $2.57m collaborative research project to commercialise zeolite process The Innovative Manufacturing CRC (IMCRC) has partnered with Neometals and Queensland University of Technology (QUT) to accelerate the development of zeolite production in Australia.

Perth-based project development company Neometals has developed a patent-pending process that converts aluminosilicate residue – a waste material produced when extracting lithium from ore concentrates – into an advanced material know as synthetic zeolites. Zeolites are microporous, aluminosilicate minerals commonly used as molecular sieves, sorbents and catalysts in applications such as gas separation, water purification and green chemistry.

Chris Reed, Managing Director of Neometals, explained that his company’s research has shown a gap in the market and high potential to add upstream value to the lithium production chain.

“Australian mining companies involved in the lithium production chain have the opportunity to convert aluminosilicate residue to zeolites to offset production costs, add value to a waste material which is abundant in the mining sector, and at the same time mitigate issues with environmental responsibility,” said Reed.

In partnership with QUT, Neometals plans to advance the proofof-concept zeolite synthesis method, which has been successfully demonstrated at bench scale. Over the next two years, QUT will be establishing and road testing a digitalised pilot plant at their Banyo Pilot Plant facility. By championing “smart” manufacturing processes and incorporating advanced inline monitoring technologies, the pilot plant will be able to track the entire aluminosilicate minerals processing route – from its initial extraction to transforming it into high-performing synthetic zeolite.

Professor Graeme J Millar, who will lead the QUT research team, highlighted that the proofof-concept had shown how a mining waste product otherwise destined for landfill can costeffectively be repurposed.

“With the use of data analytics and machine learning, we can gather information that will allow us to set up operational control parameters to ensure that customer product requirements are met,” said Millar. “At the same time, the data will drive the optimisation of the plant performance, which will help Neometals to explore innovative business models to compete on a global scale.”

The $2.57m research project includes $450,000 of matched funding from IMCRC and Neometals to introduce digitalisation into mineral processing plants. The project is due to start in February.

David Chuter, IMCRC CEO and Managing Director, pointed out that Neometals is in a unique position to add up-stream value to Australia’s lithium mining sector.

“By taking a proactive and innovative approach to dealing with waste from their lithium refinery, Neometals has developed and proven a new process to produce high value synthetic Zeolite which will allow the organisation to extend their reach and secure new market opportunities,” said Chuter. “The project, by integrating new digital manufacturing processes and capabilities, will enable Neometals to test all production parameters and upscale manufacturing to an economic industrial scale.” www.imcrc.org www.qut.edu.au www.neometals.com.au

Naval Group Pacific, UNSW Sydney demonstrate potential new composite applications Naval Group Pacific, in partnership with the ARC Training Centre for Automated Manufacture of Advanced Composites (AMAC) at UNSW Sydney, has successfully demonstrated how a carbon composite embedded with fibre optics could be used for structural applications in marine vessels.

The proof-of-concept test was designed to determine how a composite embedded with fibre optics could be used in the masts of marine vessels that may house vital equipment such as radars and periscopes. The use of composites can decrease the weight of the mast, which in turn can reduce the vessel’s overall weight due to a lighter counterbalance being required. By applying fibre optics that allow for structural health monitoring (SHM), it is possible to save vital maintenance time and resources over the lifetime of any vessel to which it is applied.

Over the course of five days, AMAC and Naval Group successfully demonstrated how the composite embedded with fibre optic sensors can be used to assess the performance under mechanical loads. Airspeed, an Australian designer and manufacturer of composite materials for aerospace, maritime and energy-related projects also participated in the test.

AMAC has been actively developing the application of fibre optic sensors as SHM solutions for composite structures with proven results. Naval Group and the AMAC at UNSW will continue exploring the collaboration possibilities to support Naval Group’s expanding field of composites-related R&D.

AMT FEB/MAR 2020

AMAC Centre Director Professor Gangadhara Prusty said: “The positive and rapid delivery of the composite test is an evidence of the innovation capabilities of our two organisations. Professor Prusty said that AMAC’s vision is to benefit our strategic industry partners by delivering world-class composite R&D capabilities, typically achieving significant improvement in R&D cost and time overheads. François Romanet, CEO of Naval Group Pacific, added: “Composites are a key capability for modern shipbuilding and it has been mutually beneficial to work with UNSW. We are already looking into furthering our cooperation and including industrial partners in our research.” www.naval-group.com www.unsw.edu.au

From left: Dr Matthew David and Professor Ganga Prusty of AMAC; Iain Walker, UNSW; Dr Margaret Law and Dr Emilien Billaudeau, Naval Group; and Serge Kamkin, AirSpeed.

ADVANCED MATERIALS & COMPOSITES

Swinburne Factory of the Future – New robot to detect carbon fibre defects A world-first, fully digitalised inspection system to detect defects in carbon fibre composite production has been installed in Swinburne’s Factory of the Future.

The system will be integrated into Swinburne’s Industry 4.0 Testlab for 3D printing of carbon fibre composites in 2020, and has the capacity to reduce costs and manufacturing time. The collaborative robotic system, known as DrapeWatch, has been installed as part of a partnership between Swinburne; the University of Stuttgart in Germany and its industry-oncampus research facility ARENA2036; and German composite technology company CIKONI. Carbon fibres are tiny threads of carbon that, when bound together with a polymer, are used to create strong, lightweight materials in aircraft, satellite, civil engineering, and automotive components.

The fibres are rigid and chemically resistant with a high strength and heat tolerance, which makes them ideal for the development of high performance parts.

To demonstrate how DrapeWatch can identify gaps, misalignments and other irregularities, Swinburne researchers are using a representative ‘double-dome’ geometry. This complex shape, made of two conjoined domes, is commonly used in engineering for moulding tests, because the curvature can produce defects to test the system’s precision. The robot is used to control a vision-sensing system that allows the outermost layer to be inspected, as well as an additional probe to study internal defects and send back data.

The clever innovation from CIKONI is in the artificial intelligence algorithms that analyse this data.

Carbon fibre composite manufacturing can be slow and expensive.

Early detection of defects using DrapeWatch will reduce unnecessary costs and waste. The collaborative robot is designed

to work in partnership with human beings, eliminating the need for fencing or safety features as it stops when it senses close human movement.

The Factory of the Future, which is a hub to connect manufacturing businesses to staff, students and the community, is connected with Swinburne’s Manufacturing Futures Research Institute. According to the Institute’s director Professor Bronwyn Fox, the facility provides Australian manufacturers access to cutting-edge technology that contributes to the Fourth Industrial Revolution, or Industry 4.0.

“Manufacturing process inspection is a pillar of Industry 4.0, because it gives you the ability to measure, monitor and inspect the process, collect that data and then use it to enhance process improvement and flexible manufacturing processes,” said Fox. “This technology is strategically aligned with Swinburne’s university-wide Industry 4.0 strategy and we’re very excited to be working with such an innovative company like CIKONI and their unique technology, and to be demonstrating that to industry here in Australia.”

CIKONI Founder Dr Jan-Philipp Fuhr said the project creates ongoing benefits for industry research: “CIKONI, as the developer of DrapeWatch, is honoured to work with Swinburne University of Technology, and especially with their Factory of the Future, on this innovative inspection system. We are looking forward to continuing our close collaboration with Swinburne on DrapeWatch and other innovative composite technology to enable improvements of automated composites production and inspection.” www.swinburne.edu.au

Deakin – Verification win for LeMond carbon fibre tech A revolutionary carbon fibre manufacturing process developed by US company LeMond Carbon has been verified by Bureau Veritas (BV) in a technical audit conducted at Deakin University’s Carbon Nexus facility in Geelong.

LeMond claims its processes offer lower costs and significantly increased output versus traditional carbon fibre technology, and the total oxidation time and material properties verified by BV support this. For the audit, BV measured total oxidation times of sub-15 and sub-20 minutes over two separate production campaigns of 24K standard modulus (SM) carbon fibre, achieving fibre tow properties in excess of 270 GPa tensile modulus and 3,500 MPa tensile strength.

The BV audit was conducted on Carbon Nexus’ 100 metric ton pilot line, which is currently producing samples for trials with LeMond’s target customers in several SM industrial markets. In addition to accurately measuring oxidation times and assuring process traceability, BV oversaw the fibre sampling, packaging and shipping of audit samples for extensive testing at the BV laboratories in Pessac, France. Composite tow tests of the LeMond fibre were completed according to ASTM D 4018-17 standards.

LeMond and Deakin are teamed to commercialise this innovative technology, which enables reductions of 75% and 70% in capex

and energy consumption per kilo of output respectively. The rapid oxidation process enables LeMond to produce carbon fibre with the lowest embodied energy of any standard PAN-based carbon fibre available today.

“This is a significant milestone for our company. Having our technology independently verified by BV validates the revolutionary nature of our technology,” said Greg LeMond, Founder of LeMond Carbon. “My team and I are excited to bring our high-performance low-cost carbon fibre to the global market, and look forward to expanding into new markets where the current high cost of carbon fibre has been a significant barrier to adoption.”

“Deakin has always been excited about the potential of our patented new technology and it is encouraging to receive independent validation that our technology is effective at scale,” said Derek Buckmaster, Director of Carbon Nexus. “We look forward to continuing to support LeMond as it commercialises a lower-cost and lower-emission carbon fibre.” www.lemondcarbon.com www.deakin.edu.au

AMT FEB/MAR 2020

103

104

SOFTWARE

Rubrik cloud expansion drives Fenner Dunlop productivity gains Melbourne-based manufacturer Fenner Dunlop Australia gained 91 days of added productivity by moving to Rubrik’s Cloud Data Management platform, a move that has also led to significant cost savings.

Headquartered in Melbourne, Fenner Dunlop manufactures and supplies a complete conveyor system from head-to-tail: belt, electrics and terminal equipment. With more than 30 sites in Australia, the company delivers engineered conveyor solutions to evolve the way mining companies approach their conveyor belt life cycles, saving costs, and increasing productivity.

“As a company, everything we do is supported by information systems,” said Sammy Jammal, National IT Manager at Fenner Dunlop Australia. “Manufacturing, technical support, installation, maintenance, diagnostics services, you name it.

“If the system is down for even 10 minutes, the whole operation would come to a halt. This not only has financial implications but is detrimental to our brand reputation and diminishes our customers’ confidence. As an IT team, we want to leverage technology that can help optimise our processes, allowing us to focus on enabling our users and thereby benefiting our customers.”

Jammal oversees an IT team of six, which supports more than 900 employees nationwide, including the core applications – spanning finance, payroll, time and attendance, paperless office and workflow automation systems – which employees need to perform their roles.

Prior to Rubrik, Fenner Dunlop struggled with its tape-based legacy backup and disaster recovery solution’s slow performance and time-consuming upgrades. “Our previous solution was extremely unreliable,” said Jammal. “We didn’t know if backups would take four hours, 20 hours, or if they would work at all. Because of this, we were spending 15 hours per week just managing the system. It was important to us to find a solution that would reduce the man hours maintaining backups and allow us to move off tape.”

Since deploying Rubrik, Fenner Dunlop has eliminated the manual management of backups completely. The team now spends less than five minutes per day checking email alerts. Previously, the company was forced to devote an entire weekend to complete full backups to tape, a task that now requires a few minutes.

With 20 to 60 users in each of its Australian locations, the majority of Fenner Dunlop’s workforce works remotely. Many of those who work at customer sites never even visit an office, rendering mobility and accessibility a critical factor to its operations “We want to empower our users to self-serve wherever they are, without limitations of having to be connected to the main server,” said Jammal. “That’s why moving to the cloud is a priority, so our users can do their job from anywhere, anytime, on any device.

“Rubrik was our steppingstone into the cloud; it allowed us to leverage Microsoft Azure for long-term retention. We are now much more confident knowing that it only takes a few clicks to restore and support our users without geographic restrictions.”

Jammal cites a variety of benefits that Fenner Dunlop has accrued from the new system: • 90% management time savings: “With our previous system, we devoted 15 hours per week to just managing backups,” he says. “Now we literally only spend five minutes a day checking email alerts. As a result of adopting Rubrik, we have recovered more than 91 days of additional productivity.”

• 90% faster backup performance: “Incremental-forever backups deliver much faster backups. Previously, we were doing full weekly backups to tape, which would take the entire weekend. Now, backups are completed in minutes.”

AMT FEB/MAR 2020

• Significant cost savings: “By switching to Rubrik, we have reduced costs by eliminating tape, support licenses, and archiving to public cloud.”

• Near-zero recovery time objectives (RTOs): “With Rubrik, recovering files is instantaneous, thanks to its Google-like real-time search capability that makes locating files easy and accurate.”

• Easy cloud archival to Microsoft Azure: “Moving to the cloud was not possible with our previous solution. Rubrik’s native integration with Azure allows us to maximise our storage efficiency as we scale our cloud footprint. We were also able to migrate off tape, eliminating unnecessary overhead and leading to immediate hard savings.”

• CloudOn for disaster recovery: “Disaster recovery is top of mind for us. With Rubrik’s CloudOn, we can quickly spin up cloud instances in Azure, allowing us to easily move workloads between on-prem and cloud to enable a stronger disaster recovery to the cloud. The peace of mind we now have with Rubrik is invaluable.” www.rubrik.com www.fennerdunlop.com.au

SOFTWARE

Nearly 90% of Australian companies set sights on Artificial Intelligence Almost nine out of 10 Australian businesses are planning to make investments in artificial intelligence (AI), according to the findings of a global research study by enterprise applications company IFS into the attitudes and strategies towards AI among business leaders.

About 90% of respondents (both in Australia and globally) reported at least some plans to implement AI in various parts of their business. Inventory planning and logistics was the most commonly reported area of investment in Australia, with 54% planning AI projects (39% globally), while customer relationship management (CRM) was second at 46% (39% globally). Globally, industrial automation was the most common area of AI investment at 45% (compared with 28% in Australia).

world examples where technology is augmenting existing decisionmaking processes by providing users with more timely, accurate and pertinent information.

When asked how they plan to use AI, 57% of those surveyed in Australia (61% globally) said they expected that it would help them make existing workers more productive. Fewer than half, 39% in Australia (48% globally), said that they would use AI to add value to products and services they sell to customers.

About 29% in Australia (18% globally) said that they would proactively use it to replace existing workers.

One early adopter of industrial automation solutions which makes use of robotics to transform its business strategy is leading North American packaging manufacturer Cheer Pack, which deployed a fleet of AIpowered autonomous vehicles to robotise material movements in its US factory and has already seen strong returns on the investment. Cheer Pack Director of IT, Alex Ivkovic noted: “We expect the costs savings to be over US$1.5m per year. In addition, each and every employee will be retasked to a higher-skilled position, helping us with our labour shortage.”

While a majority of respondents anticipated productivity increases from AI, only 21% in Australia (29% globally) anticipated AI would lead to a reduction in headcount in their industry. To manage this, 57% of Australian respondents (56% globally) stated that society could best prepare by changing educational programs to prepare workers to make direct use of AI tools to increase their own productivity. Another 29% (23% globally) said they expect the market to create new jobs for people displaced by AI, while 11% (15% globally) suggested a shortened 30-hour work week.

The study polled 600 business leaders in countries including Australia, Canada, Denmark, France, Finland, Germany, Sweden, the UK and the US, and a broad spectrum of industries involved with their companies’ enterprise technology including enterprise resource planning (ERP), enterprise asset management (EAM), and field service management (FSM).

“AI is no longer an emerging technology. It is being implemented to support business automation in the here and now, as this study clearly proves,” said Bob De Caux of IFS. “We are seeing many real-

“In today’s disruptive economy, the convergence of technologies such as AI, robotic process automation (RPA) and the Internet of Things (IoT) is bolstering a new form of business automation that will provide companies that are brave enough with the tools and services they need to be more competitive and outflank larger competitors.”

De Caux concluded: “The findings of the study and the real-world scenarios being realised with our customers point to the conclusion that the time is right for companies to reap both business and financial benefits from technology automation. Falling for the hype of AI is easy, but success requires disruption to existing business models.

“The technologies themselves are not a panacea, nor are they a universal solution to any problem. However, with the right data model and viable use cases, AI can support improved productivity and deliver significant benefits to both operations and the wider business. AI will be used by the vast majority of organisations in some form in the near future, extracting real value from intelligent processes, for the long term.” www.ifs.com.

Market your business 24/7

1471AMTIL2020

from only $250 per week.

AMTIL DIGITAL MEDIA KIT 2020 NOW AVAILABLE Call Anne Samuelsson at AMTIL on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

AMT FEB/MAR 2020

105

106

SOFTWARE

RoboHelix revolutionises auger flight manufacturing with SolidWorks RoboHelix, a Sydney-based start-up manufacturer, has begun utilising SolidWorks applications from Dassault Systèmes to design robotic systems that automate the helical flight formation process used for products like augers and other drilling equipment in key industrial sectors, notably agriculture, mining and construction.

Auger centrifuges are versatile and effective material handling tools, critical to the conveyance of materials in material handling, geotechnical and mining projects.

Smooth material displacement operations for such projects depend on the precision of the auger fins or blades, commonly referred to as “flights”, formed out of stainless steel or abrasion-resisting steel.

Traditional forming of auger flights utilise hydraulic machines that wield bulky industrial dies, die plates and platens to form the pitch and size of flight diameters.

These die plates and platens are often bulky to handle and time-consuming to tool, adjust and set up, not to mention costprohibitive to replace if they are damaged.

The hydraulics are manually operated with the operator’s hands just millimetres away from reciprocating jaws exerting forces up to 50 tonnes; operator injuries are a high risk, resulting in calls for higher safety standards in helical flight production.

RoboHelix machines incorporate robotics that completely automate flight production.

Utilising HelixNinja, a cloud-based SaaS, the RoboHelix machine applies mathematical algorithms to calculate, analyse, and mimic the natural helical forming path.

At the same time, these algorithms can automatically compensate for material elasticity of augers during the flight forming process, thereby doing away with manual human measurements or calculations that would have otherwise required repeated manual checks and validations.

In addition, the entire flight forming process is enclosed within the RoboHelix machine, which makes it far safer for operators and eliminates the incidence of injuries. With these innovations, RoboHelix machines have proven to increase flight formation setup rates by up to 45 times and decrease power consumption of flight production by up to 300 times.

Over the past five years, the Australian manufacturing industry has been at an inflection point amid rising competition from lower-cost countries in South-East Asia. Advanced automation solutions for manufacturers, such as those provided

by RoboHelix machines, offer Australia the opportunity to regenerate its manufacturing industry and contribute to global supply chains. “We developed the RoboHelix prototype based on the deficiencies we

AMT FEB/MAR 2020

saw in traditional flight forming methods and to introduce a robotic system to automate flight movements,” said Hayel Smair, CEO and Founder of RoboHelix.

“Flight formation is a very precise science.

Dassault Systèmes’ SolidWorks design and simulation applications were integral for us to develop an eight-axis robotic system capable of handling the tolerances necessary for the precise nature of flight production.”

SolidWorks applications empowered RoboHelix in the following ways: • SolidWorks’s design configuration feature breaks down the machine design into its manufacturing stages, which correspond to production drawings.

• SolidWorks’s FEA (finite element analysis) capabilities enable optimisation of components to develop an eight-axis robotic system, which maintains high tolerances, necessary to produce precise flight geometries, during loads of up to 50 tons.

• SolidWorks simulation allowed RoboHelix to eliminate numerous test models and realise better predictive structural behaviours.

• SolidWorks’s ability to change dimensions, tolerances and processes of the machine parts and models onthe-go, whether in part or assembly mode, is a key success factor for RoboHelix machines.

According to IDC, the global robotics market was worth $151bn in 2018, and is expected to double to $210bn by 2022.

By building its revolutionary flight forming eight-axis robotic systems with SolidWorks applications, RoboHelix has become a global exporter to major auger and material handling equipment manufacturers based in Europe and the USA within just two years of its inception. RoboHelix will continue working with the new features of the SolidWorks 2020 portfolio of applications as the company expands and looks to introduce more innovative robotic technologies into its range of flight manufacturing solutions.

“Dassault Systèmes’ SolidWorks provides the design and simulation capabilities for robotics engineers to bring their innovative concepts to production, allowing them to come up with functional prototypes quickly and launch their final products to market smarter and faster,” said Sox Konno, Managing Director, Asia Pacific South, Dassault Systèmes. “We are proud to be the technology partner of RoboHelix, one of Australia’s most exciting ‘Garage to Global’ start-ups, in introducing innovative robotic technology that is revolutionising traditional manufacturing methods in a big way.” www.3ds.com www.robohelix.com

SOFTWARE

Australia’s digital competitiveness is slipping.

Here’s how we can catch up Australia’s ability to compete with other nations in a technology-enabled world is declining, according to a report recently released by the Committee for Economic Development of Australia (CEDA). David Tuffley looks at ways we can make up lost ground.

In 2019 Australia dropped to 14th on the global league table of digital competitiveness, down from 13th last year and ninth in 2015. The results, from the World Digital Competitiveness rankings compiled by the Swiss-based International Institute for Management Development, show that Australia is becoming complacent in areas such as science education, information and communication infrastructure, and digital literacy.

What is digital competitiveness?

Digital competitiveness is a standardised measure of a country’s ability to develop cutting-edge digital technologies as well as its willingness to invest in research and development (R&D) and promote digital literacy training to create new knowledge, all of which are key drivers for economic development.

Proactive countries put money and effort into this process, regarding it as nationbuilding that hedges against future uncertainty. These countries score highly in the rankings. Countries further down the list tend to be reactive, sitting back and letting others go first.

The overall digital competitiveness score has three components: knowledge, technology, and future readiness.

Australia’s scores across these categories show we need to try much harder in future readiness. Our scores are also falling in the sub-categories of adaptive attitudes, business agility, and IT integration. In a field of 63 countries, Australia comes 44th on current digital and technological skills and employers’ willingness to train their staff in these areas.

Which countries are doing it right?

The top ten countries in 2019 were the US, Singapore, Sweden, Denmark, Switzerland, Netherlands, Finland, Hong Kong, Norway, and South Korea. Looking at the strategic approach of the top five, all emphasise knowledge generation, but beyond that there are different approaches to digital competitiveness. The US and Sweden put equal emphasis on knowledge generation, creating a conducive environment for technology development, and fostering a willingness to innovate.

Singapore, Denmark and Switzerland each place heavier emphasis on one or two of the factors.

At 53rd place, Australia ranks abysmally in the proportion of our university graduates in science and mathematics – the people who do research & development now and will continue to do it in the future.

Our universities are among the best in the world, so that is not the problem. If jobs for these graduates existed, universities would be meeting the demand.

Australia’s information and communication technologies, including internet infrastructure, also score very poorly at 54th.

This will not surprise the many Australian businesses and individuals who put up with slow, patchy internet connections. With more computing services and data moving into the cloud, fast internet is essential.

The news is not all bad though. Australia rates highly as a desirable destination for international students. It also scores well on digital access to government services, and ease of starting a business.

Why is Australia slipping?

Australia has grown complacent in certain areas, and we have been unwilling to invest sufficiently in building our digital capability in the areas mentioned. “Sufficient” is the key word. The fact that we are falling behind other countries means we cannot say we are investing enough.

The CEDA report indicates that one key reason for the investment shortfall is the disparity between the public’s and employers’ perspectives on how much it is needed. Industry sees a greater need than the general public does, but government policy tends to align with public sentiment for electoral reasons. Funding is limited and there are many voices competing for a share of government spending. It is the squeaky wheel that gets the oil.

Building digital capability Nation-building projects at scale need a co-ordinated approach across public and private sectors. Building the physical infrastructure to meet future needs is no different in principle to building the nation’s digital capabilities, which includes creating the communication technology, the means to develop new knowledge and ways of applying it to good effect. This is no less important than roads, power stations and hospitals for the nation’s future.

Australia needs to have a long conversation in national, state and local forums about the importance of investing in our digital future.

We need to talk about all the ways R&D can benefit the Australian community, and why businesses need to embrace cutting-edge technology.

If we don’t get consensus on staying competitive we will fall further and further behind as more proactive countries accelerate their efforts. In time the economy will suffer, unemployment will rise and quality of life decline. It is no legacy to leave our children.

We are indeed a lucky country with our resources, but that will take us only so far in the 21st century. For the sake of future generations we have to make a new kind of luck and level up our digital game.

Dr David Tuffley is a Senior Lecturer in Applied Ethics & CyberSecurity and a member of the Institute for Integrated & Intelligent Systems research group at Griffith University in Australia. This article was originally published by The Conversation. www.theconversation.com www.griffith.edu.au

AMT FEB/MAR 2020

107

108

FORUM LAW

Industrial Manslaughter introduced in Victoria, mental illness included The Victorian Government has passed through Parliament a new workplace industrial manslaughter law that includes penalties of $16m and up to 20 years jail for employers responsible for negligently causing death and which includes mental illness resulting in death. Jared Butt explains.

Interestingly, the new offence captures negligent workplace conduct that contributes significantly to a person sustaining an injury or contracting an illness (including a mental illness) that later causes the person’s death. It also captures conduct that occurs outside Victoria but results in a workplace fatality in Victoria.

The Andrews Labor Government said the laws deliver on an election promise, and will fall under the Occupational Health and Safety Act 2004 (OHS Act).

Standing outside Parliament, Attorney-General Jill Hennessy told reporters that the burden of proof for employers to be charged under the new laws would be high, but that employee mental health and wellbeing was covered. “The standard is very high because the penalty is very high. A person who has been brutalised when it comes to their mental health and wellbeing… The laws will apply to this. We want officers to take their OHS responsibilities seriously.”

In a statement, Victorian Chamber of Commerce and Industry (VCCI) Chief Executive Mark Stone said that with such significant penalties on the table, it was vital that the Government got this law right. “We have worked closely with the Government to inform the development of this bill. However, we are not confident that the full range of potential consequences of this legislation has been fully considered.”

“Jointly, employer groups have proposed a number of sound and workable improvements to the drafting of the legislation that would have enhanced its safety objectives. We consider that without some changes the legislation may result in unintended consequence and have detrimental effects on safety, investment and jobs.”

Mr Stone went further and said the law should be expanded to include anyone whose negligence results in death, not just organisations and senior officers. “Once introduced, a workplace manslaughter offence should apply to anyone who has engaged in criminally negligent conduct resulting in death, not just organisations and senior officers. Including employees can only improve safety outcomes.”

The VCCI is also expressing concerns that the laws would disproportionately impact small business. It says the operators of smaller enterprises are more likely to have a ‘hands on’ role in the business, and that overseas experience has shown that they will likely bear the brunt of these laws.

“We need laws that are equitable and that do not just target small business. We also need more education and support for business to help them focus on prevention and provide the safest possible workplaces, and for WorkSafe to ensure its officials are prepared to manage the complexities of a manslaughter case (currently, manslaughter investigations are conducted by highly trained Victoria Police Officers).”

Earlier this year, a number of employer groups expressed concerns over the proposed laws, claiming they would give rise to unintended consequences which impair, rather than enhance, health and safety outcomes. Master Builders Victoria said the laws would likely create litigious environments within organisations and regulators which would prevent learnings from incidents being properly uncovered and adopted.

AMT FEB/MAR 2020

A person who has been brutalised when it comes to their mental health and wellbeing… The laws will apply to this.

State Shadow Finance Minister Gordon Rich-Phillips unsuccessfully pushed for amendments that would consider what an officer accused of negligent conduct knew about the matter concerned, and the extent of their ability to make or participate in decisions.

The new offence makes Victoria the third Australian jurisdiction to enshrine industrial manslaughter into law along with the Australian Capital Territory (under the Crimes Act) and Queensland.

Earlier this year, the review of the national model WHS laws recommended introducing the offence, and Western Australia announced it would mirror the offence in its own WHS Bill.

Similarly, New South Wales and the Northern Territory have both introduced Bills to Parliament that define the offence of industrial manslaughter.

Clyde & Co Australia managing partner Alena Titterton said developments in the industrial manslaughter space at a state level were posing a threat to the harmonisation of health and safety laws nationally. “Notwithstanding commitments to harmonised WHS laws, early signs point to marked jurisdictional differences as the industrial manslaughter offences are introduced around the country. It appears they may apply different legal tests (negligence vs recklessness), apply to different categories of individuals (‘senior officer’ vs ‘officer’) and different penalties ($10m vs $16m) depending on the state or territory in which the fatality takes place.

While we can debate the merits of industrial manslaughter offences, it seems that the tide is in their favour and organisations need to be ready for them.”

Titterton outlines five steps organisations can take to avoid industrial manslaughter offences: 1. Challenge assumptions and promote leadership at all levels 2. Senior leadership must seek out information for verification and assurance 3. Collaborate across industry on leadership and culture 4. Get ahead of the curve on performance indicators 5. Revisit remuneration and incentives myosh is flexible, cloud-based safety software that features interactive dashboards, cutting edge mobile apps and over 50 configurable modules that integrate and adapt to your unique organisational requirements.

The software adapts to language and safety compliance requirements across all industries including energy, mining, logistics, transport, manufacturing, education, and local, state and federal government agencies. myosh will assist you to better understand and manage workplace safety by integrating hazards and incident reporting with investigations, actions and reporting. Staff participation is leveraged by providing easy access to safety information, encouraging workers to contribute to the safety program.

Ph: 1300 469 674

www.myosh.com

FORUM

HEADING

OHS

Silicosis: Why a ban on engineered stone benchtops is needed to save lives As reported in the August/September edition of AMT, Australia has seen a rise in new cases of the lung disease – silicosis. Here, Brendan Torazzi presents the latest findings, concluding that a ban on engineered (artificial) stone benchtops may help save Australian lives.

Cutting artificial stone for kitchen benchtops and other products may increase the risk of fatal lung disease. Hospitals around Australia have seen a rise in new cases of silicosis, a disease often linked to exposure to hazardous dust when manufacturing stone benchtops. As with the ban on asbestos-containing materials in the 20th century, implementing a ban on engineered stone benchtops may help save Australian lives.

What is silicosis?

Silica (also known as quartz) is a mineral found in natural materials, including sand, rock, and ore. When these materials are cut, ground, or blasted, the dust contains varying amounts of silica. It only takes a small amount of the particles to create a potential health hazard and an increased risk of silicosis - a deadly lung disease caused by silica dust damaging the lining of the lungs causing scarring. Severe scarring makes it difficult to breathe and may result in more severe symptoms, such as chest pain and coughing.

Workers may develop silicosis within a few weeks or several decades after the exposure. There are three types of silicosis: Acute; Chronic and Accelerated.

Acute silicosis leads to weight loss and fatigue within several weeks or years of exposure. Chronic silicosis occurs 10 to 30 years later and is more likely to cause extensive scarring and damage to the lungs. Accelerated silicosis develops within a decade of exposure to high levels of silica dust. No matter the type of silicosis, the scarring can become debilitating and potentially fatal.

The dangers of inhaling silica dust are widely known and industries began implementing control measures to reduce the risk of exposure in the 1930s. Almost 100 years later, Australia and other countries have strict regulations for activities that generate silica dust - powerful extraction fans, water spray systems, and respirators helped severely reduce the prevalence of silicosis. Unfortunately, the deadly disease is starting to reappear with greater frequency.

Artificial stone contains more silica Many of the recent cases of silicosis seem to come from industries involved in cutting artificial stone. Compared to natural stone, the artificial stone may contain over twice the amount of silica. Cutting and grinding artificial stone to create benchtops increases the risk of exposure to silica dust. Reports indicate 260 new cases of silicosis across Australia in the past couple of years, with 166 cases in Queensland. The surge was first identified 12 months ago in Queensland. An alarming number of workers were diagnosed after exposure to dust when working with engineered stone kitchen benchtops. Engineered stone is a mixture of resin and 94% to 95% quartz. It is a more cost-effective material compared to natural stone with comparable results, making it a popular choice in kitchens throughout Australia.

Current control measures for reducing exposure As mentioned, the cutting or grinding of stone or concrete involves a variety of regulations, including WHS Act regulations and industry standards. Workers often wear respiratory gear and vacuums and wet cutting help remove dust from the environment. However, these solutions do not always reduce the levels of silica dust to

nonhazardous levels. The effectiveness of the required control measures is also limited due to regulatory compliance. Not all companies strictly follow regulations for protecting workers from exposure. When workers identify potential hazards, they do not always feel comfortable reporting the issue.

During an audit of two Gold Coast businesses, specialists found high levels of dust, despite the company using most of the recommended safety techniques. One of the businesses also failed to use an adequate vacuum for removing dust.

Without stricter enforcement of health and safety regulations, Australia may continue to see a rise in silicosis diagnoses. The surge of new cases has led many people to call for a complete ban on engineered stone benchtops. The current safety recommendations skip the first hierarchy of control. The most effective control measure is the removal of the hazard. By replacing the artificial stone with another material, companies can reduce exposure to silica dust.

Is a ban on artificial stone possible?

Several organisations are working to promote a ban on artificial stone. However, a complete ban is not easy to implement. It requires government regulation and industry-wide adoption.

Artificial stone is widely used to cost-effectively produce kitchen benchtops. Banning the material would have a major impact on the market. However, this would not be the first time that the Australian government has banned a widely used hazardous material.

Companies adapted to the asbestos ban and found suitable alternatives. The same process can happen with artificial stone.

Instead of using engineered stone containing high levels of silica, companies can use natural stone or stone made from recycled glass. Increasing public awareness of the dangers of silica exposure may also help reduce demand for engineered stone benchtops.

In the end, silicosis remains a current threat to thousands of workers throughout Australia. A total ban may not occur, but consumers and businesses can help reduce exposure by selecting other materials for their kitchen counters.

Brendan Torazzi is the CEO of AlertForce - a registered training organisation specialising in short Health and Safety courses to meet compliance. Brendan also runs the Australian Health and Safety Business Podcast and is the owner of OHS.com.au, an online marketplace for safety courses.

Ph: 1800 900 222 www.alertorce.com.au www.OHS.com.au

AMT FEB/MAR 2020

109

110

FORUM ENERGY

Energy efficiency makes good business sense Today there are many reasons why businesses are placing a focus on becoming more energy efficient – using less energy can be good for the environment as well as for a business’ bottom line.

Regardless of your goals, reviewing the efficiency of energy consumption is becoming increasingly commonplace as it makes better business sense.

It’s therefore unsurprising that more industry and government initiatives have become accessible to support business efficiency practices. Some key resources include: 1. Energy.gov.au/business is a national joint initiative of the Australian, state and territory governments administered by the Department of the Environment and Energy. The website supports the implementation of energy efficiency practices and shares best-practice information on energy efficiency, case studies and resource materials.

2. AIG’s (Australian Industry Group) website is full of resources that feature information on energy efficiency, optimisation and management as well as an environment and energy toolkit and energy efficiency checklist.

3. NSW’s Energy Saver program helps businesses identify energy saving opportunities, access funding and assists with project management and training.

4. The Victorian Energy Upgrades Program is designed to make energy efficiency improvements more affordable, contribute to greenhouse gas reduction and encourages investment in energy efficiency goods and services.

5. The Government of SA’s energy efficiency information, advice and programs.

On our part, AGL remains committed to helping businesses become more efficient, through practical guidance around different technologies:

Power Factor Correction: Why pay for energy that can’t be used?

For instance, many customers aren’t aware that – as well as the power that is used in equipment (real power) – a site may draw power that is not directly used (reactive power). The combination of the two is known as apparent power. Power Factor is the relationship between real and apparent power (kVA). If your site has a poor power factor, you could be paying for energy that cannot be used.

The AGL Electroserv team of experts specialises in helping our clients reduce kVA. By designing, manufacturing, installing and servicing Power Factor Correction equipment nationally, we may be able to extend the life of your equipment, ensure compliance with regulatory codes, or help ensure that more power is available for site expansion without the need for new switchboards and cabling.

AMT FEB/MAR 2020

Operational Energy Management: Converting building data into actionable items From human behaviour to software faults and less than efficient hardware, there are many factors that contribute to potential energy wastage in commercial buildings – unless they are regularly monitored and expertly analysed.

That’s where OEM – a set of technologies and processes that identify anomalies as they occur, analyses the cause and reports back to the building manager to have them rectified – comes in.

OEM works by converting a building’s data into actionable items.

AGL has a dedicated team of OEM experts who aim to address this energy wastage and ensure every building we monitor is fully optimised.

How AGL can help?

If you’re interested learning about more ways to reduce your business’s energy consumption, get in touch with an AGL consultant on 1300 986 971 or email energysolutions@agl.com.au or visit agl.com.au/pfc

FORUM

HEADING

FINANCE

Will the proposed changes to the R&D Tax Incentive drive Australian manufacturing offshore?

On 5 December 2019, the Treasury Laws Amendment (R&D Tax Incentive) Bill 2019 was introduced to Parliament.

This Bill proposes numerous changes to the R&D Tax Incentive program, based on a previous 2018 Bill that was temporarily shelved when the Coalition Government took over in August 2018. Rita Choueiri and Berrin Daricili explain.

The revised Bill which will be considered by Parliament early this year (and if enacted expected to apply to all claims from 1 July 2019), could be a significant barrier for the growth of many companies such as the manufacturing sector that rely on government support like the R&D Tax Incentive for much-needed cash-injections.

Disappointingly, the proposed R&D Tax Incentive changes could decrease the benefits available to manufacturing companies performing legitimate R&D activities in Australia. The most impacted would be companies with an aggregated turnover (i.e. which includes the turnover of all grouped entities) above $20m that will be subjected to a new more complicated R&D intensity test.

This test, if it results in a low ‘R&D intensity’ score (‘R&D intensity’ measured by eligible R&D deductions divided by total company expenses) could mean the company may receive a lower R&D benefit than in previous years. Despite numerous expert reports calling for manufacturing innovation in Australia to be nurtured, these changes to the R&D Tax Incentive may impact the manufacturing industry more so than other industries, as high operating costs associated with manufacturing is likely to drive manufacturing companies’ ‘R&D intensity’ down which may increase the likelihood of companies off-shoring their innovative manufacturing activities to lower cost jurisdictions or to ones where their R&D activities are better supported (e.g. countries offering a higher R&D tax benefit rate or other relevant incentives).

An example of the new R&D Intensity calculation would be; a manufacturing company is eligible for the non-refundable tax offset, has R&D expenditure of $1m, $10m total company expenditure and a corporate tax rate of 30%. Under the current R&D Tax Incentive rules this company would be receiving the 38.5% R&D tax offset rate and would receive an offset of $385,000 against its tax payable. However, if this Bill is successful, the company’s offset would be reduced to $373,000.

The table below illustrates how the tax offset rates would apply in this scenario.

R&D expenditure Total company expenditure R&D intensity (R&D expenditure/Total expenditure)

$1M $10M 10%

4% intensity threshold ($10m x 4%)

$400,000

9% intensity threshold ($10m x 9%)

$900,000

Corporate tax rate x R&D expenditure (30% x $1m)

$300,000

4.5% premium tax offset ($400,000 x 4.5%)

$18,000

8.5% premium tax offset ($900,000-$400,000) x 8.5%)

$42,500

12.5% premium tax offset ($1,000,000-$900,000) x 12.5%)

$12,500

Total R&D tax offset ($300,000+$18,000+$42,500+$12,500)

$373,000

Companies with an aggregated turnover below $20m will also be impacted as the refundable tax offset rate will be reduced from the flat rate of 43.5% to 13.5% above the applicable company

tax rate and the refund will be capped at $4m. This means that the refundable R&D rate for 2019-20 will be 41% (down from the current 43.5% rate) and will be further reduced by 2.5-5% over the next three years in line with reductions in the corporate tax rate.

Manufacturing companies currently receiving refundable offsets of greater than $4m (commonly those in the start-up phase) will see their refunds capped at $4m, with remaining offset amounts being treated as a non-refundable offset and applied to the claimant’s income tax payable. Any further offset amounts will be carried forward for use in future income years. However, note that this cap on the refund will not apply to R&D expenses incurred on clinical trials (which is relevant to manufacturing companies that develop medical devices or therapeutics that progress to clinical trials).

The proposed Bill also adds more layers of complexity to other already complex areas of the R&D Tax Incentive, namely the clawback, feedstock and balancing adjustment provisions.

Regarding both feedstock and clawback, the previous provisions will be replaced with a ‘uniform clawback rule’ that will include an amount (subject to calculation) in the assessable income of the R&D entity. Balancing adjustments will provide tax deductions rather than notional R&D deductions, resulting in tax losses rather than tax offsets. Overall, these changes bring additional complexity to the R&D tax law and may further decrease the overall benefit of manufacturing companies claiming R&D. Other proposed changes to the R&D Incentive include: • Increasing maximum annual R&D expenditure from $100m to $150m. Expenditure over $150m will not be subject to any R&D offset rate and will be taxed at the applicable company tax rate.

• Amending the anti-avoidance provisions of the Income Tax Assessment Act 1936 to include the refundable and the non-refundable R&D tax offsets, allowing the Commissioner to apply anti-avoidance laws with respect to the R&D Tax Incentive to prevent claimants from engineering artificial arrangements to access the program.

• The Commissioner of Taxation will publish information about companies accessing the R&D Tax Incentive, including the company name and R&D expenditure amount. Publication of this information will be delayed by two income years to safeguard sensitive activities.

Whilst the team at William Buck understand that the proposed changes are not law yet, we suggest that you consider your company’s eligibility for the new R&D Tax Incentive regime and the overall benefits of claiming. Please contact William Buck’s R&D team for a free consultation or further information about the R&D Tax Incentive and what the proposed changes mean for your company.

Rita Choueiri Partner – Research & Development P: 03 8823 6840 E: Rita.Choueiri@williambuckvic.com.au Berrin Daricili Manager - Research & Development P: 03 8823 6846 E: Berrin.Daricili@williambuckvic.com.au

AMT FEB/MAR 2020

111

112

AMTIL INSIDE

It’s important to get the balance right It’s the start of a new year – a new decade actually – and front and centre of my mind is work/life balance.

When I look back 20 years to when AMTIL began, I can remember nine to five was the norm. Most businesses were the same. The focus was on putting in a good day’s work. How times have changed!

Last year I lost two good mates. Hammo was only 62 when prostate cancer finally got the better of him and Jinxy was 51… a massive heart attack. Way too young and both had a big impact on the way I look at things, particularly given my own battle with bowel cancer two years ago. We all have stories like this to tell, so I’m certainly not alone in this regard.

What these incidents have reminded me is the need to focus as much time on life outside of work as it is on work itself. I’m not saying be slack. I’m saying be flexible enough with your work hours so you have that balance right.

The shift I have seen is from “putting in a good day’s work” to “getting the job done right”. Flexible work hours, working from home, time in lieu, nine-day fortnights, job sharing are all common practice nowadays, and I’m a believer.

At AMTIL we do not have a single staff member who is in the office from nine to five. Every person has their own hours, which have been negotiated to their own personal preference. This can be a daunting proposition for some companies because it takes a lot of effort to make it work.

You need clear individual goals, good resources, strategic planning and a lot of trust. The way I look at it these are four key elements of making a business successful in the first place, so why shy away from the concept?

We all have to work hard and put in the extra effort when needed, but if you feel that your work/life balance (which is different for everybody so it’s hard to define) is not quite where you want it to be, then I encourage you to do something about it.

Shane Infanti, CEO AMTIL

AMT FEB/MAR 2020

AMTIL HEADING INSIDE

Brigitte Stavar named new President of AMTIL Brigitte Stavar has been named as the new President of the Australian Manufacturing Technology Institute Ltd (AMTIL). leadership over AMTIL’s full range of operational initiatives in support of Australia’s advanced manufacturing industry. Her appointment comes shortly after the recent confirmation of Peter Sutton, Managing Director of Sutton Tools, as the newest member of the AMTIL Board, replacing Philip Xuereb, also of Sutton Tools, who is also standing down.

Brigitte brings an impressive track record of manufacturing industry experience, having spent more than 16 years as General Manager at Sheetmetal Machinery Australia, a leading supplier of innovative high-precision sheetmetal machinery, based in Ferntree Gully, Victoria. She has been a member of the AMTIL Board for six years, and succeeds Paul Fowler, Managing Director of Dimac Tooling, who is stepping down having served as President since 2013.

“I look forward to continuing the great work AMTIL is involved with, representing our members’ interests and supporting the current initiatives such as the AM Hub, Export Hub and the Entrepreneurs’ Programme,” said Brigitte. “The Australian manufacturing industry is undergoing change and to remain competitive we need to become innovative, adaptive and flexible; embrace the latest technologies; and improve efficiencies, training and education to be the best we can be in the global economy. The AMTIL Board will focus on developing and supporting strong

“I’m very pleased to be able to welcome Brigitte as our new President,” said AMTIL CEO Shane Infanti. “She is a highly respected figure within the industry, with a wealth of experience and insight that will be of enormous benefit to AMTIL and to our members.

networks in helping businesses grow within the manufacturing sector.”

Together with the AMTIL Board, Brigitte will be responsible for providing strategic

“In addition I must thank Paul for the enormous contribution he has made over the last six years. AMTIL has made huge advances under his leadership. And I would like to also thank Philip, and welcome Peter onto the Board. I feel confident that with Brigitte and the Board we have in place, we are in safe hands for the coming new decade.” www.amtil.com.au

1382AMTIL

AMTIL is delighted to welcome Sterna GL to its Corporate Partnership Program.

AMTIL’s corporate partners offer a selection of products and services that will benefit our members in their business.

For any enquiries about our Corporate Partnerships, and how they can benefit you, contact Anne Samuelsson on 03 9800 3666 or email asamuelsson@amtil.com.au

Our Partners. Our Members.

Your Benefits.

www.amtil.com.au

AMT FEB/MAR 2020

113

114

AMTIL INSIDE

New members AMTIL would like to welcome the following companies who have signed up as new members of our association.

BV PRODUCTS PTY LTD 16 Access Way Carrum Downs VIC 3201 www.bvproducts.com.au

CNC MANUFACTURING PTY LTD 84 Nelson Road Lilydale VIC 3140 www.cncmanufacturing.com.au

SAGE Level 11, 821 Pacific Highway Chatswood NSW 2067 www.sage.com/en-au

Real Business.

Real People.

Real Benefits.

Call AMTIL’s Membership Manager David Mohorovicic on 03 9800 3666 to learn how your business can be part of the leading Advanced Manufacturing association in Australia.

TCL HOFMANN 150 Woodlands Drive Braeside VIC 3195 www.tclhofmann.com.au

www.amtil.com.au

AMTIL members celebrate the Festive Season AMTIL ran a number of Christmas celebrations for its members across Australia during November and December.

Events took place in Adelaide, Perth, Melbourne, Sydney and Brisane. The biggest event was at the Fenix Panorama in Melbourne on 12 December, where more than 150 guests tucked into a three-course meal, drinks and entertainment. Each of the events drew an impressive turnout and the AMTIL members who attended gave very

Adelaide

Brisbane

AMT FEB/MAR 2020

positive feedback. Meanwhile, the AMTIL team were busy jetting around Australia to represent the association at each event.

AMTIL CEO Shane Infanti, said the events were a great opportunity to catch up with the association’s members and thank them for their support during 2019. “This has been a big year for AMTIL, with our most

Perth

Melbourne

successful Austech exhibition to date, initiatives like the Additive Manufacturing Hub really beginning to take shape, and so much more,” said Shane. “So it’s been really nice to see out 2019 with a few of our members across the country, and to hear about their hopes and plans for the 2020s.”

AMTIL INSIDE

SternaGL joins AMTIL Corporate Partner line-up AMTIL has announced the appointment of SternaGL to its Corporate Partner program.

As an internationally recognised and respected freight specialist, SternaGL offers a truly seamless service, utilising resources positioned all over the globe to move freight efficiently from its origin to its destination. SternaGL offers a wide range of cost-efficient and flexible cargo options, including freight-forwarding, customs clearance and transport.

Combining more than 50 years of logistics experience with exceptional human talent and systems, SternaGL provides customers with tailored solutions for any import or export shipments moving via sea, air, rail, road or multi-modal. From parcels to over-dimensional cargo, and everything in between – SternaGL’s dedicated team utilise their extensive skill and expertise to manage the journey of shipments from origin to destination, intact and on time.

SternaGL services a wide range of industries including manufacturing, with extensive experience handling delicate

Samuelsson, AMTIL’s Head of Partnerships & Sales. “This is a partnership that will bring significant new benefits for AMTIL’s members, and we are very much looking forward to working with the SternaGL team.”

process-line machinery and raw materials.

Its consultative approach ensures attention to detail, which invariably leads to strong results and a positive customer experience.

SternaGL operates under four core principles that permeate the organisation into every transaction – Integrity, Care, Accuracy, and Innovation. Under these principles SternaGL presents a refreshing brand of honest advice that helps their its make sound and informed decisions about their supply chains.

“We’re very excited to be able to welcome SternaGL as the latest member of our Corporate Partnership program,” said Anne

AMTIL’S Corporate Partners offer a selection of products and services within specific fields of expertise, for the benefit of AMTIL members. The current line-up of AMTIL Corporate Partners is as follows: • AGL – Energy • Interlease – Business Finance • Rigby Cooke Lawyers – Legal • SternaGL – Freight • William Buck – Accounting/Financial Advice For further information contact Anne Samuelsson, AMTIL’s Head of Partnerships & Sales, on 03 9800366 or email asamuelsson@amtil.com.au. www.amtil.com.au/initiatives/corporatepartnerships www.sternagl.com

Upcoming AMTIL events AMTIL has a packed calendar of professional, educational and social events lined up for the coming months.

The following is just a selection – so start marking up your diaries now.

WA NETWORKING DRINKS

Tues 18 Feb ; 6.00pm-8.30pm Perth, WA SA NETWORKING DRINKS

Wed 19 Feb ; 6.00pm-8.30pm Adelaide, SA VIC NETWORKING DRINKS

Thurs 20 Feb ; 6.00pm-8.30pm Melbourne, VIC NSW NETWORKING DRINKS

Wed 26 Feb ; 6.00pm-8.30pm Sydney, NSW QLD NETWORKING DRINKS

Thurs 27 Feb ; 6.00pm Brisbane, QLD ADDITIVE – THE CHANGING FACE OF MANUFACTURING (Full-day forum with Deakin University) Mon 16 Mar ; 8.00am Geelong, VIC VIC CEOs MEETING 1

Tues 17 Mar ; Dinner Melbourne, VIC NSW CEOs MEETING

Thurs 19 Mar ; Dinner Sydney, NSW VIC CEOs MEETING 2

Thurs 26 Mar ; Dinner Melbourne, VIC

EXPORT HUB BREAKFAST

VIC CEOs MEETING

(in conjunction with MegaTrans 2020) Thurs 2 April ; Breakfast Melbourne, VIC

Wed 29 July ; Dinner Melbourne, VIC

ADDITIVE – THE CHANGING FACE OF MANUFACTURING (Full-day forum with UTS) Tues 12 May ; All-day event, times tbc Sydney, NSW

Tues 27 Oct ; Breakfast, timings tbc Melbourne, VIC

NSW NETWORKING DRINKS

Wed 13 May ; 6.00pm-8.30pm Sydney, NSW WOMEN IN MANUFACTURING NETWORKING BREAKFAST May ; Date & time tbc Sydney, NSW WA NETWORKING FUNCTION

Wed 10 June ; 6.00pm-8.30pm Perth, WA SA NETWORKING FUNCTION

Thurs 11 June ; 6.00pm-8.30pm Adelaide, SA

AMTIL ANNUAL GENERAL MEETING

AMTIL SA CHRISTMAS FUNCTION

Wed 18 Nov ; Dinner Adelaide, SA AMTIL WA CHRISTMAS FUNCTION

Thurs 19 Nov ; Dinner Perth, WA AMTIL NSW CHRISTMAS FUNCTION

Tues 24 Nov ; Dinner Sydney, NSW AMTIL QLD CHRISTMAS FUNCTION

Thurs 26 Nov ; Dinner Brisbane, QLD AMTIL VIC CHRISTMAS DINNER

Thurs 3 Dec ; Dinner Melbourne, VIC

VIC NETWORKING FUNCTION

Tues 30 June ; 6.00pm-8.30pm Melbourne, VIC

All dates, times and venue details may be liable to change, so please check the Events page on the AMTIL website (below) for more up-to-date information and to make bookings. For information on AMTIL events, please call 03 9800 3666, or email Events Manager Kim Banks on kbanks@amtil.com.au. www.amtil.com.au/events

NSW CEOs MEETING

Thurs 16 July ; Dinner Sydney, NSW

Maximise Your Membership Event

AMTIL Power Brokers Event

AMT FEB/MAR 2020

115

116

INDUSTRY CALENDAR

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event More events can be found on AMTIL’s website

INTERNATIONAL EXPO MANUFACTURA Mexico, Monterrey, 11-13 February 2020

ADDITIVE MANUFACTURING FORUM Germany, Berlin 11-12 March.2020

EXPOMAQ Mexico, Leon 21-24 April 2020

www.expomanufactura.com.mx/

www.additivemanufacturingforum.de

www.expomaq.org.mx

THAILAND INDUSTRIAL FAIR Bangkok, Thailand 12-15 February 2020

KONEPAJA Finland, Tampere 17-19 March 2020

www.thailandindustrialfair.com/about-fair

www.konepajamessut.fi/en

SIAMS Switzerland, Moutier 21-24 April 2020 Microtechnology exhibition

CHINA AUTO AFTERMARKET EXHIBITION China, Beijing 18-21 February 2020

TECHNI-SHOW Netherlands, Utrecht 17-20 March 2020

www.ciaacexpo.com

CIAACE China, Beijing 18-21 February 2020 Auto After-Market expo www.ciaacexpo.com

MACHAUTOEXPO India, Ludhiana 21-24 February 2020 www.machautoexpo.in

CME-CHINA MACHINE TOOL EXHIBITION China, Shanghai 25-28 February 2020 www.cme021.com/en

ASIAMOLD China, Guangzhou 26-28 February 2020 www.asiamold-china.cn.messefrankfurt.com

DESIGN ENGINEERING & MANUFACTURING SOLUTIONS EXPO Japan, Chiba 26 - 28 February 2020 www.japan-mfg.jp/en-gb/about/dms.html

METAL & STEEL/FABEX Egypt, Cairo 27-29 February 2020 www.metalsteelegy.com

ADDITIVE MANUFACTURING EXP Switzerland, Lucerne 3 - 4 March 2020 www.visit.am-expo.ch/de

ADVANCED FACTORIES Spain, Barcelona 3-5 March 2020 www.advancedfactories.com/en

IMTE - CHINA INTL MACHINE TOOL EXHIBITION China, Tianjin 6-9 March 2020 www.cantonfair.net/event/1577

METAV Germany, Dusseldorf 10-13 March 2020 www.metav.com/en/METAV_2020

SIMODEC France, La Roche-sur-Foron 10-13 March 2020 www.en.salon-simodec.com

AMT FEB/MAR 2020

www.technishow.nl

GRINDTEC Germany, Augsburg 18-21 March 2020 www.grindtec.de/en

MECSPE Italy, Parma 26-28 March 2020 www.mecspe.com/en

SIMM China, Shenzhen 30 March-02 April 2020 www.simmtime.com

SIMTOS South Korea, Goyang 31 March – 4 April 2020 www.simtos.org/eng

STOM-BLECH & CUTTING Poland, Kielce 31 March – 2 April 2020 www.targikielce.pl/pl/stom-blech.htm

INDUSTRIE PARIS France, Paris 31 March-3 April 2020 www.industrie-expo.com/en

AI EXPO Tokyo, Japan 1-3 April 2020 Artificial Intelligence exhibition www.ai-expo.jp/en-gb.html

MACHTECH & INNOTECH Bulgaria, Sofia 6-9 April 2020 www.machtech.bg

CCMT-CHINA CNC MACHINE TOOL FAIR Shanghai, China 7-11 April 2020 www.ccmtshow.com/enindex.jsp

INTERMOLD//DIE & MOLD OSAKA Japan, Osaka 15-18 April 2020 www.intermold.jp/english

MACH UK, Birmingham 20-24 April 2020 www.machexhibition.com

HANNOVER MESSE Germany, Hannover 20-24 April 2020 www.hannovermesse.de/en

www.siams.ch

FEIMEC Brazil, Sao Paulo 5-9 May 2020 www.feimec.com.br/en

MACHINE TOOLS AFRICA South Africa, Johannesburg 12-15 May 2020 www.machinetoolsafrica.co.za

INTERTOOL Austria, Vienna 12-15 May 2020 www.intertool.at

INTERMACH & MTA Thailand, Bangkok 13-16 May 2020 www.intermachshow.com

CIMES China, Beijing 18-22 May 2020 www.cimes.net.cn/en

METALLOOBRABOTKA Russia Moscow 25-29 May 2020 www.metobr-expo.ru/en

SOUTH CHINA INTERNATIONAL INDUSTRY FAIR China, Shenzhen 2-5 June 2020 www.sciif.com/en

INNOPROM METALWORKING Russia, Ekaterinburg 6-9 July 2020 www.metalworking-expo.com/en

INTERMOLD/DIE & MOLD NAGOYA Japan, Nagoya 17-18 July 2020 www.intermold.jp/english

IMTS USA, Chicago 14-19 September 2020 www.imts.com

INNOTRANS 2020 Germany, Berlin 22-25 September 2020 Leading intl. trade fair for transport technology. www.innotrans.com

EUROBLECH 2020 Germany, Hanover 27-30 October 2020 www.euroblech.com

INDUSTRY CALENDAR HEADING LOCAL AUSTRALASIAN OIL & GAS EXPO PERTH CONVENTION & EXHIBITION CENTRE 11-13 MARCH 2020 Includes specialised industry zones showcasing the latest in instrumentation control and automation, asset integrity, subsea, health, safety & environment and drilling & completion. www.aogexpo.com.au

SYDNEY BUILD ICC SYDNEY 19-20 MARCH 2020 Australia’s Leading Construction, Architecture and Infrastructure Expo. Co-hosted with Sydney Transport and CIVENEX Infrastructure Exhibition. Learn about the major construction projects across Sydney and how to get involved

Advertiser Index

ADVANCED MANUFACTURING EXPO SYDNEY SHOWGROUND 13-15 MAY 2020 Exhibition and conference focused on the latest high-tech manufacturing products and advanced processes. Brings together expert speakers sharing insights and case studies on how to transform your business operations. Whether you want to adopt advanced business models or upgrade production techniques. www.advancedmanufacturingexpo.com.au

Adfoam 89 AirLiquide 49 Applied Machinery

37

Bilby 3D

65

Bystronic 120 Complete Machine Tools

23

DDM Laser

11

Emona Instruments

61

Hare & Forbes

AUSMEDTECH MELBOURNE CONVENTION & EXHIBITION CENTRE 20-21 MAY 2020 Australia’s premier medical technology conference. Includes the latest Medtech technologies and possibilities for the industry.

Hi-Tech Metrology

www.ausmedtech.com.au

Machinery Forum

MEGATRANS MELBOURNE CONVENTION & EXHIBITION CENTRE 1-3 APRIL 2020 Conference and exhibition for the freight and logistics industry. Co-located with Australian Bulk Handling Expo 2020. Three dedicated trade areas: Logistics & Warehousing; Sea & Rail; Road Transport

AUSTRALIAN ENERGY STORAGE ADELAIDE CONVENTION CENTRE 20-21 MAY 2020 Unites all energy storage technologies for utility, commercial, and residential applications.

Includes the latest advances in energy storage for investment in new energy and energy-efficient technologies.

MTI Qualos

www.megatrans.com.au

www.australianenergystorage.com.au

DESIGNBUILD MELBOURNE CONVENTION & EXHIBITION CENTRE 21-23 APRIL 2020 Includes seminars from industry experts on the trends and strategies shaping the architecture, building, construction and design sector. Includes quality building products and sustainable solutions from leading local Australian suppliers and manufacturers. Latest solutions in construction technology and smart buildings from enterprise companies and start-ups in the new Digital Building Zone.

VICTORIAN TRANSPORT INFRASTRUCTURE CONFERENCE 2020 MELBOURNE CONVENTION & EXHIBITION CENTRE 16-17 JUNE 2020 Victoria’s largest transport infrastructure conference, attracting 200+ attendees annually.

Features presentations that discuss the prioritisation, planning and delivery of critical transport infrastructure across the state.

Topics covered - Transport, Ports, Roads, Railways & Airports.

www.sydneybuildexpo.com

www.designbuildexpo.com.au

4-5 91

IMTS

19, 63

Industrial Laser

17

Interlease 57 Iscar 2-3 119 front cover, 13, 41

Okuma 9 Punchtech Australia

6-7

RAM3D 67 Reed Exhibitions

27

Rigby Cooke

39

Sandvik 25 Sutton Tools

83

SternaGL

95

Teco Tooling

85

Thyssenkrupp 15 William Buck

75

Emona

Insert

Interlease

Insert

MTI Qualos

Insert

Sheetmetal Tooling

Insert

www.expotradeglobal.com/events/ victransport

AUSTRALIAN MANUFACTURING TECHNOLOGY YOUR INDUSTRY. YOUR MAGAZINE

APR/MAY20 FEB MAR 2020

BOOK YOUR ADVERTISING NOW! AUSTRALIA’S NO. 1 ADVANCED MANUFACTURING MAGAZINE Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asamuelsson@amtil.com.au

RENEWABLE ENERGY & CLEAN TECH BUSINESS MANAGEMENT STATE SPOTLIGHT: SOUTH AUSTRALIA COMPRESSORS & AIR TECHNOLOGY

APPROX NEW FRONT IERS: SPACE RACE 2.0 TAKES OFF

31,500 AEROSPACE & DEF

ENCE

READERS Industry 4.0 State Spotlight: Tasmania

ROBOTICS & AUTOMATION MOTORS & DRIVES MATERIAL HANDLING CUTTING TOOLS FORMING & FABRICATION MATERIAL REMOVAL

AMT FEB/MAR 2020

117

118

HISTORY

Big wheels & little wheels – the story of UK-born Australian Sir Laurence John Hartnett (1898 – 1986) Australia’s “Father of the Holden” and much more

PART 35

“LET’S MAKE IT OURSELVES!”

The year is 1940, World War 2 is raging and Dunkirk has fallen, which meant that the UK was unable to provide Australia with the military equipment it required. In our last instalment, a mystery courier transports vital gun-plans from Canada to Australia via neutral America, entrusting the plans to a Sydney-bound ship passenger who manages to deliver them to Australia.

T

he passenger duly delivered the drawings, and the story of the two-pounder anti-tank gun was started all over again. Working from those plans and with the production co-ordinated

by GM-H, Sydney and Ruwolt, Melbourne (one of the largest engineering companies in Australia). The bits were farmed out to contracting factories, and the completed components set to arrive at a certain time to “marry up” with the rest of the gun as it went on to the assembly line. This time the factories took only nine months to produce the first twenty-fivepounders. If anyone ever compared other countries’ production speeds from scratch with a job of that magnitude, the Australian achievement just wouldn’t be believed. But we did it. “Is it any wonder,” I used to ask myself, “why I’m so proud of these Australiansand so proud to be called an Australian?”

Just when the two-pounder and many other products started to roll and we were all feeling very pleased with the result, old “Tock” Williams came into my office with a long face. It was so unusual for Tock to be looking downhearted that I knew something really serious had happened.

“They’re very nice little two-pounders, Larry, hut we’ve got no bloody gunsights for them,” he announced. “What!” I almost bellowed. “But they’re coming from England. That’s all been fixed so you told me.”

The gunsights for the two-pounder were telescopic sights, delicate pieces of precision optical equipment. Without its telescopic sight the two-pounder was almost useless. “Tock” then gave me his bad news.

“The English have just told us they’re sorry, but they can’t let us have any. None to spare, or some other reason. But they’re not coming.”

“All right, ‘Tock’, we’ll make them ourselves,” I said.

Then it was his turn to bellow. “Make them ourselves? Do you know what you’re saying? Don’t you know what’s in a gunsight? It’s the most complicated part of the whole gun. They’ve got a special section over in England which does nothing else. Gunsights take years to develop. We haven’t even got any optical glass.”

“Well, let me think this one out. I’m sure there’s an answer to it,” I said. I was still as cocky as ever. If Australia could make the gun itself, it could find some way of making the sight, too. I was sure of it. I began to feel a bit less confident when I realized an optical instrument industry just didn’t exist in Australia. Apart from spectacles made from imported glass, hardly a single optical instrument had ever been made in Australia. The manufacture of optical glass was a highly specialized science, and the techniques involved were little known.

Firms overseas guarded their secrets and their craft jealously. We could get no help from America, either. The Americans were suffering from a “glass famine” and they were still neutral. Pearl Harbour was still more than a year away.

Unless we could pull this one out of the hat, the two-pounder project would be a waste of time, and the twenty-five-pounders would be just as useless. In cases like this, where the problem appears insoluble, the only course to follow is consult the experts. But who, if any, were experts? Physicists or chemists, presumably. I told Keith Brodribb, the

The 25 Pounder was a medium velocity field artillery weapon developed in the UK and produced in Australia from scratch in only nine months via plans delivered from Canada. The two main contractors were Charles Ruwolt P/L of Richmond, Melb, and GM Holden’s Ltd (NSW). The first order was placed on 5 August 1940. Photo courtesy: Museums Victoria/ Ruwolt

Assistant Director-General, of my need. His reaction was immediate.

“You want physicists? - we’ve got half a dozen of them dying to do something to help, but no one’s been able to use them. They sent a letter to (PM) Mr. Menzies offering their assistance, and got a nice letter of thanks, but nothing else. I’ll have them see you straight away”.

On 26 June 1940, I called the physicists together. That meeting led directly to the formation of the Optical Munitions Panel, which later became the Scientific Instruments and Optical Panel.

Well, we’d got the boffins together; now what? From them we got a very good appraisal of the problems: Glass for optical instruments must be absolutely flawless, it must be perfectly transparent and capable of being ground. The glass was made by melting a special type of sand and other chemical ingredients in a refractory, or pot.

This refractory was lined with, or made of, peculiar types of clay-and the success or failure of the “melt” depended to a large degree on the impurities which might leak from the clay. In starting from scratch, the problem would be to find the materials to go into the pot and find the clay to line the pot. No small order, this.

England could not help us. We asked for the loan of an expert, but this was refused. The conditions they imposed for future participation in any industry formed-in return for showing one or two of our men their techniques-were so tough that we decided to ignore them and make the glass ourselves somehow.

This is an extract from ‘Big Wheels & Little Wheels’, by Sir Laurence Hartnett as told to John Veitch, 1964. © Deirdre Barnett.

AMT FEB/MAR 2020

To be continued…

MACHINERY FORUM (NSW) Pty Ltd 33 Brodie Street, Rydalmere NSW 2116 Ref. Mr. Heino Windhorst T. +61 (02) 96389600 E. heino@mafosyd.com.au

The next best compact panel bender

PREMIUM BENDING QUALITY

ZERO SET-UP TIME

FULLY AUTOMATIC PRODUCTION CYCLE, MANUAL L/UL

ONE UNIVERSAL BENDING TOOL

EASY USER INTERFACE

THICKNESS RANGE: FROM 0.4 TO 2.5 MM

MAX BENDING HEIGHT: 165 MM MAX BENDING LENGTH: 2180 MM

BUILDING TECHNOLOGIES

STEEL FURNITURE

CATERING & FOOD EQUIPMENT

Over 4000 installations in 76 countries, the largest manufacturing plant dedicated entirely to panel benders and 40 years of experience and expertise. salvagninigroup.com

SHOP FURNITURE

Set new benchmarks

with 12 kW Impressive dynamics and flexibility. With 12 kilowatts, the new ByStar Fiber cuts steel, aluminum, and non-ferrous metals from 1 to 30 millimeters with high precision. Thanks to Swiss quality in fiber laser cutting, you benefit from up to 20 percent higher productivity at minimum costs per part.

Cutting | Bending | Automation bystronic.com