MART October 2015 by MART INFOMEDIA PRIVATE LIMITED

Volume 12 Issue 4 October 2015 ` 100

The New Wave of

Industrial Revolution Additive Manufacturing with SLS and its Applications Additive Manufacturing Vs Metal Injection Molding Additive Manufacturing In Finished-Part Quality Product Development is Crucial to Manufacturing

3D Printing: the New Wave in Manufacturing! 3D Printing: Growth is Endless

Art Of Resolving Complex Engineering Problems A Practitionerâ&#x20AC;&#x2122;s View October 2015

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October 2015

Meistermacher. Made in Germany.

Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding.

German champion with Borussia Dortmund 2002 English champion with Arsenal London 2004

Dominic Schneider, Service Specialist – Clamping Technology

Held more than 10,000 times under maximum tension Jens Lehmann, legendary German goalkeeper

Used more than 10,000 times worldwide in lathes ROTA-S plus 2.0, manual chuck from SCHUNK

www.gb.schunk.com/rota-s-plus

First time buyers, please contact ‘+91 - 9632200040’ to avail special discount offers www.martupdate.com

October 2015

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October 2015

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October 2015

foreword Attitude, Altitude! Hi Readers, The recent economic slump in the Chinese stock market is creating a lot of buzz in the international market when we are yet to get out of the Euro crisis created by the Greece bust. There were several reports in the frontline media how Chinese fall out is going to bring more foreign investors to Indian market and a report about a Chinese article titled ‘China’s economic pain can’t be India’s gain’. It’s a fact that we cannot compare the both economies, as they are not at the same level and what happening currently in China is the correctional measure which was expected as per their economic restructuring and industrial upgrade. Almost a decade ago, China with its industry friendly policy, was able to bring manufacturers across the world to China and made it a global manufacturing destination, cost being one of the major factors. India’s growth in the manufacturing was very slow, and a little steady, around 10-15% of the GDP, used to have its share of leading foreign manufacturers in various industry segments setting up their plants targeting the domestic market. In China, today the scenario is changing with middle class becoming financial stronger, and labour costs are on the rise. In future China will be venturing into manufacturing critical machines and components where the chances of cost oriented industries shifting to other favourable countries will be minimal. There is a lot of reason for the current economic slowdown witnessing across almost all global economies including variations in the supply and demand, terrorism, global warming, insecure living conditions etc. When developed economies are suffering due to the lack of demand in their local market, emerging economies like India, China, Russia, Brazil and some of the African countries are the future where investments in logistics and infrastructure developments are expected to flow. Where ever you are going to produce your products, the bigger consumer markets like India or China cannot be neglected by manufacturers and service providers and that’s currently our strength, which is just natural. Apart from the Modi Factor, and a feel good factor created by him in the global arena, and specially his “Make in India and Sell Global Campaign” nothing much is changed in our policies and a lot of constructive effort needs to be put in place to develop manufacturing in India. Identifying future market prospective, inspire young engineers into manufacturing and creating budding entrepreneurs is the need of the hour. We don’t have any reliable studies made on this front and have no adequate measures to apply in different steps from the grass root levels in the academy and industry. Front pages of Indian and US newspapers are covered with PM Modi’s ongoing successful trip, with global IT companies offering their support to his Digital India campaign, just another example for us to see where India stands in their business plans. India is the future and if Indians need to take a bite of that success, need to identify the opportunities and start working towards it. If we think our Prime Minister or other elected representatives will do magic and fill our wallet, or some other country will lose and we are going to gain, it’s the right time to wake up from those day dreams, and start doing our responsibility, and show our real attitude the altitude it can reach. I am sure you will have a great read with our current edition of MART, one of the best editions of recent updates, articles and case studies about Additive Manufacturing - making products fun and easy. We look forward your suggestions to make MART, SMART! Signing Off.

October 2015

Hari Shanker hari@martinfotech.in

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28 MAIN FEATURE

CASE STUDY

10 INNOVATIONS

18 24 28 32 36 54 58 60

Additive Manufacturing with SLS and its Applications Additive Manufacturing vs Metal Injection Molding Additive Manufacturing by using Big Data Analytics 3D Printing: The new wave of Industrial Revolution 3D printing, the next leap in manufacturing! Additive manufacturing of gripper fingers saves time and costs An Intelligent Strategy for Achieving Excellence Pioneering additive manufacturing reshapes patientâ&#x20AC;&#x2122;s face Volume 12 Issue 4 October 2015 Annual Subscription `1200 Member INS Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre

MediaMart Infotech

Siji Nair

Sandeep Hingne

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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manne the Publisher no any of its employees accept any responsibilities for any errors or omissions. ÂŠ All Rights Reserved October 2015

CONTENTS 68 Eric Purushothaman Managing Director, Beko ON FACE

Image Source: DMG MORI

Columns

72 76 78

Facing audits of Customers and Third Parties Essentials of Business Email Art of resolving complex engineering problems

82 Feature Article

90 97

MART UPDATE THE LAST LEAF

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• One Year (12 issues) at `1200 Send your subscriptions to: The Circulation Manager - MART Mediamart Infotech, N o: 313, Dorikal Byelane, Jheel Avenue Dum Dum Road, Kolkata - 700 074 Tel: + 91 33 2560 4052 Mobile: +91 9038 000711 Email: mart@martinfotech.in Web: www.martupdate.com & www.martonline.in

IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post. m. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 er whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither October 2015

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Eplan Harness proD 2.5 Wire harness engineering: From schematics through to production

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A preview function helps users to achieve correct positioning at the first attempt avoiding the need for subsequent adjustment.

An Assistent supports users in the extrapolation of 2D symbols for the nail board drawing from the existing 3D model.

Version 2.5 of Eplan Harness proD is in the start blocks. In combination with Eplan Platform’s central parts management system, users benefit from continuous and optimised workflows. A wide range of enhancements for nail board design, cable routing and project management guarantee effective wire harness engineering. Version 2.5 of Eplan Harness proD is available from October. Development has focused on optimising user workflows and a major new highlight is the coupling of the 3D wire harness engineering system to the Eplan Platform’s central parts management. This represents a milestone in integrated data management. Users then have only one central parts management system which they are able to access over the entire course of a project. This significantly reduces the effort in maintaining master databases and enables continuous workflows from schematics through to production documentation.

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Master data workflows have been further optimised through the derivation of 2D symbols – required for nail board drawing – from existing 3D data. This is particularly efficient because 3D component data is already required. Existing data therefore gets reused – manual creation of component symbols is unnecessary. Simple component positioning in 3D Eplan Harness proD aims to provide a user-friendly 3D system for wire harness design. Electrical engineers generally have limited experience in operating complex MCAD systems and therefore benefit from a user friendly approach. For example, by positioning a component, such as a connector, within the 3D space enables the selection of reference point, edges and areas. This simplifies the positioning process. A preview function helps users to achieve correct positioning at the first attempt avoiding the need

for subsequent adjustment. Users who use AutoCAD symbols can look forward to a much improved import function. Imported DWG and DXF drawings can be edited in Version 2.5 with all the relevant content being extracted. This greatly speeds up the process of creating parts. Faster cable routing Version 2.5 of Eplan Harness proD includes many new features – for example, the fixing of a 3D object’s positioning, the option to position the starting point of a new bundle in a wire harness into existing bundles, and the automatic routing of cables. To support production, wire colourings can be displayed in the connector symbol on the nailboard. Production can then use the drawing to identify the correct positioning of a wire at a connector. Searching wire lists for the necessary information is no longer required and the production process becomes faster.

Flexibility in nailboard design There are also many new features in the nailboard design to interest users. Eplan Harness proD 2.5 has separated the “data layer” from the “display layer”. This might sound technical but it gives users massive flexibility in nailboard design. Display configurations enables a drawing to be viewed differently without having to change the data – e.g. according to a company’s internal drawing standards. This gives greater flexibility. Batch processing of updates has been added to project management section of Eplan Harness proD. The need for evaluation or drawing updates is detected and then batch processed to further reduce project management effort. Features such as the automated updating of library parts or the newly supported CAD formats are among the many enhancements to increase the efficiency of wire harness projects and to speed up customer workflows.

October 2015

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October 2015

SMART FOCUS

Plasma Cutting Units

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The new Minis now Compatible with the Hainbuch Modular System

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Set-up for any draw tube position with three versions of the Spanntop mini chuck

The mini product series with Hainbuch’s tried and trusted modular system.

Sometimes small things turn out to be a big success. And that’s true for the mini chucks. But one thing they haven’t had until now was compatibility with the Hainbuch modular system. That’s no longer the case, and of course this includes both series of chucks: the round Spanntop and the hexagonal profile Toplus. Because of its reduced interference contour, to be able to use the modular system the Spanntop mini chuck comes with an adapter ring. The existing Mando Adapt mandrel and jaw module work perfectly with the new Spanntop mini. The Toplus version does not use an adapter ring, instead it has ring of

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attachment holes for fixing the jaw module, and next year it will get its own Mando Adapt series of adapters. And finally, as another piece of good news, Spanntop and Toplus minis both have full through-bore and are available in three standard lengths to suit all machines and drawtubes. Reduced clamping device interference contour and less mass These two factors play an ever more important role in any machining process. Tool accessibility and low energy consumption are key criteria for modern workholding making them ready for the challenges

of the future. Increasingly parts have smaller dimensions and higher tolerances than in the past, So the emphasis is no longer on the chuck size but rather on the complete process. Thanks to greater tool accessibility, the mini chucks can use shorter and therefore more stable tools on the main and counter spindles. This again has a direct influence on the surface finish. Not only is the mass reduced by over 38%, the chuck diameter and the total lengths have also been considerably reduced [by a third or a quarter]. So the “little” chucks make a “big” difference. The reduced interference

contour makes it easier to choose the right tool and this helps with the issue of reduced space especially in counter spindle machines. The reduced mass is also results in lower energy consumption especially in mass production. Because spindle acceleration and deceleration are more dynamic this shortens the cycle times, and all this contributes to lowering the cost per workpiece. For more details write to M´la Sales Corporation, 5, Yeshwantnagar, Telco-Century Enka Road, Pune - 411018 Tel: +91 20 27477405 Email: info@ mla-sales.com

October 2015

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Infineon Digitizes Power for energy-efficient LEDs

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Every fifth kilowatt hour of electricity around the world is used for artificial light. LED technology, however, is making significant savings possible. About 13 million tons of CO2 could be saved in Germany alone, equaling the emission of about seven million cars; in German office buildings, the electricity bill could be reduced by more than Euro 500 million. But how can we make introducing the technology easier for industry and end users? With .dp digital power 2.0™ Infineon Technologies AG (FSE: IFX / OTCQX: IFNNY) has developed a digital platform for power supply with which the LED lighting systems can be controlled intelligently, thus making maximum energy savings possible.

The step into the digital world with all its advantages is made possible by digital controllers and a special software that the manufacturers of lighting systems can use to configure individual parameters according to their requirements. “This allows our customers greater flexibility because it eliminates the need for costly development of new designs for product variants, since specifications can be defined at the end of the production line,” says Ulrich vom Bauer, who is in charge of Marketing for Lighting ICs at Infineon. “With .dp digital power 2.0, the development time can be reduced by up to 70 percent – therefore, the customer can bring new products to the market significantly faster.” In addition, the digital approach makes innovations possible that can’t be realized using analog components. The ICL8105 is a digitally configurable flyback controller with Power Factor Correction

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(PFC) for constant power LED drivers from 10 to 80 W. Thanks to the high level of integration and the control on the primary side, only a few external components are required. This allows for a cost reduction of up to ten percent. The controller has powerful algorithms and supports multiple operating modes. Advantages are a high efficiency and power factor correction plus low distortion. This produces a high quality of light with no flickering. The controller has an input for 0 to 10 V dimming; there is no need for an oscillator including power supply. An active burst mode significantly extends the dimming range, while preventing undesirable effects such as flickering or shimmering. To protect the LED driver in case of overtemperature, the ICL8105 automatically reduces the output current in case of overload.

configurable buck controller and is designed as a constant current source with output current control (backlash) for LED drivers in the range from 10 to 150W. Thus, the regulator addresses diverse commercial LED applications. The ILD2111, too, requires only a few external components. The output current can be set easily and accurately by a resistor, and is also compatible with the LEDset interface. The IC provides flicker-free PWM dimming down to one percent. The component automatically selects an operating window in order to optimally regulate different loads, depending on the switching frequency and the ripple of the output current. The output voltage is specified with 15 to 55 VDC. Extensive, user-configurable features protect the component at undervoltage and overvoltage, short circuits, overcurrent or high temperatures.

The ILD2111 is a digitally

Both driver ICs offer the

advantages of the digital world which includes the ability of the LED power supply to be configured by the customer on site using software. In addition to high flexibility, this also means savings in material costs. This plays a big role in today’s highly fragmented lighting market. Availability Both the ICL8105 and the ILD2111 are available as samples and can be ordered in high volume. Development boards, the .dp Interface Board and the .dp Vision GUI software are offered for both controllers. Further information about the controllers is available at.dp digital power 2.0.Those interested can register to get more product information in the range of the .dp digital power platform. For more details write to www.infineon.com

October 2015

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Delcam makes modelling easier, simulation faster in $149 ArtCAM Express CADCAM

ArtCAM Express can now export reliefs for 3D Printing

Delcam has made a number of enhancements to its ArtCAM Express software, including changes to make modelling easier and to speed up machining simulation. The price of this entry-level version of the company’s ArtCAM artistic CADCAM system, which is designed for hobbyists and users new to CNC machining, remains at US$149, £99 or 125 Euros. ArtCAM Express 2015 R2 offers 2D drawing, over 600 free pieces of relief clipart, and 2D and standard 3D machining functions. It provides an ideal introduction to computerbased manufacturing for companies and hobbyists involved in engraving, routing and signmaking, or other areas of decorative metalworking and woodworking. A range of modules are available to add

October 2015

extra design and machining functionality. Two options have been added in the 2015 R2 release of ArtCAM Express to help users to design with vectors. Firstly, snap hints now appear to help in spotting

to overlap and intersect reliefs has been enhanced with a new option to interactively blend the reliefs. This allows relief clipart to be pulled up or pushed down in the Z axis to give a better blend with an overlapping3D design.

hard-to-find snap points within vectors when creating designs. Secondly, the thickness of vectors can be changed, in either the 2D or 3D view, making it easier to visualise the design. Accuracy will also be helped by the addition of rulers in the 3D view to make it easier to create precise artwork and to position elements of the piece. A combine/replace mode was added in ArtCAM Express 2015 for customers creating 3D designs from imported models or the relief clipart included with the software. The ability

The main machining enhancement in the 2015 R2 release is significantly faster machining simulations thanks to a new algorithm that uses the specialist processor in the computer’s graphics card to calculate thousands of operations simultaneously. This is a significant improvement over standard multi-threading. Another area of improvement is corner machining, where fillets can be added to vectors to allow more accurate machining of slots. In a related development, loops can be added for creating corners with

knife cutting. A further change to ArtCAM Express is the ability to export reliefs for 3D Printingas well as to machine them. Before, this was only possible with other members of the ArtCAM range. As well as the updates to the main ArtCAM Express program, the optional ‘Vector Tools’ module has been enhanced with better layer management. Firstly, multi-coloured vectors can be imported from DXF files as a single vector layer or as separate layers. Similarly, several layers can be exported simultaneously. Secondly, working on complex models with multiple layers can be simplified by merging any layers not being used and placing them in the project tree. For more details visit www.artcam.com/express

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A Building Energy Management System (BEMS) is a computerbased system that automatically monitors and controls a range of building services, including air conditioning, ventilation, heating, lighting and other consumers of energy within the building or sometimes groups of buildings. The functional aim of BEMS is to manage the environment within a building, so that energy use perfectly balances the way in which the building is used.

Building Energy Management System ElMeasure provides a unique technique to integrate cuttingedge mechanical, electrical and building automation system technology into real-world solutions. Our goal is to design buildings and systems that will have a smaller energy footprint and a much smaller impact on the environment. There are a number of important benefits associated with use of a Building Energy Management system. It provides energy analysis, management and control information. It enables equipment, air conditioning, lighting etc to be switched on and off automatically. It optimises space heating within the building. It allows

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monitoring of equipment status and environmental conditions. The amount of wasted energy is minimized. This saves money and reduces carbon emissions. With the advent of the Smart Grid, these Building Energy Management Systems can help businesses better manage their electricity demand. With a varying price of electricity, the BEMS can program the system can turn on and turn off loads without sacrificing occupant safety, comfort, and productivity. BEMS can be used in different sectors such as, Health Care: Large savings can be made by installing BEMS to optimize efficiency, while still

delivering the best comfort conditions for occupants. Retail: Inefficient energy use can lead to over-heating and over-cooling causing over consumption and spending. Manufacturing: Rising energy prices and the cost of raw materials are making it hard for manufacturers to keep their production costs down and make a profit. Managing energy consumption across a manufacturing site with an effective BEMS can remove inefficiencies and reduce costs. Educational Institutions: Energy intensive equipment, such as computers, lighting and air conditioning, are often used inefficiently, e.g they are left

turned on overnight or at weekends, adding unnecessary cost to the bottom line. BEMS can be programmed with occupancy set points and calendar schedules, to ensure lighting and heating are not over-used during unoccupied times. Commercial/ Residential: The desire for comfort can often reduce the efficiency of the building, due to inefficient settings and programming of your building controls. BEMS can control lighting and cooling effectively to avoid unnecessary use of energy outside normal working hours or when ambient daylight levels are adequate. For more details write to marketing@elmeasure.com or visit www.elmeasure.com

October 2015

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MAIN FEATURE

Additive Manufacturing with SLS and its Applications Additive Manufacturing has evolved over years and now promises to be an alternate, competitive manufacturing process. There are few more methods of building a part ‘additively’ and are often misunderstood to be processes for “Additive Manufacturing”. This article gives a simplistic account of what Additive Manufacturing really means and also mentions briefly its applications in few industry segments.

Ajay Deshkar ajay.deshkar@3dengg.com

During academics and all along their careers in manufacturing engineering, Designers and Engineers are tuned to ‘Subtractive Manufacturing’ as a process to produce a product. As a student of Tool engineering, I remember creating ‘Process Sheets’ for manufacturing products and all sheets made in my manufacturing career referred to machining processes such as turning, drilling, milling,

grinding, EDM, etc. to reach the final ‘net‐shape’ of the product. Referring to the Indian manufacturing scene, this ‘subtractive’ method of manufacturing changed only marginally during the period when I graduated in 1987, until as recent as 2005. The books we referred to learn manufacturing engineering had editions dated couple of decades earlier. Effectively, for 50+ years, manufacturing

technology had not changed drastically, apart from the CNC machines probably! The advent of Additive Manufacturing has revolutionized the way manufacturing is seen in the current and next decade. AM is as revolutionary to manufacturing as was Internet for the IT & communications world. There is an immediate need to consider Additive Manufacturing as a mainstream

manufacturing process rather than alternate. Known to a few friends of mine who know me to be working in AM space, I get calls that have questions revolving around the technology with reference to its existence around them. There are confusing messages and claims which I try eliminating by sharing some of the knowledge I have gained on this technology. For example, the other day, I had

Stage wise Additive Manufacturing Process using Selective Laser Sintering

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October 2015

Sample process of manufacturing Die Insert with traditional manufacturing. There are two processes – one for manufacturing of the part and the other for copper electrode for die sinking

a call from a friend in Delhi who had known my company to be selling machines for AM that are ‘quite high valued’ (in the range of few millions of Rupees). Obviously concerned if I was in right hands he was referring to a machine he saw that was available for a few thousands. That’s what prompted me to write this article which could give a simplistic account of the extremely hyped and captivating process of Additive manufacturing. There are few acronyms and names AM is represented with – RPT, 3D Printing, Functional prototypes, Additive Manufacturing, etc. RPT or Rapid Prototyping which has been around for about 25 years now, refers to making physical parts from virtual 3D CAD files. The purpose of making these

parts is to get a feel of the parts, ergonomically, before starting to manufacture on a larger scale. These parts so manufactured are not dimensionally stable and do not have properties for it to be put to physical use. Most of such RPT parts are made from epoxy resins or molten plastic filaments that are fragile. 3D Printing is a general term used to represent the technology, yet it also is a process of making such Prototypes. The prefix ‘functional’ make the prototypes functionally usable so that parts so produced can be used for a few cycles. 3D Printing processes such as FDM (Fuse Deposition Modelling), SLA (Stereo Lithography), LOM (Laminated Object Manufacturing), DLP (Digital Light Processing), etc. are either generating

from extrusion or light polymerization and are used for Rapid Prototyping.

products which are injection moulded (plastics) or machined (metals).

Processes which use powder beds such as SLS (Selective Laser Sintering) and EBM (Electron Beam Melting) are more often used for Additive Manufacturing.

AM is being used by OEMs (Original Equipment Manufacturers) and their suppliers to make series production of components that could have geometries that are impossible to be made using traditional processes or made in matter of hours against lead times as high as few weeks in case of traditionally made parts.

Additive manufacturing refers to a more accurately manufactured production technique that produces parts that can be used is real world applications. The process involves use of digital 3D data to build a component by melting selective regions of layers constructed over one another, bottoms‐ up. A range of plastic or metallic powers can be used to produce parts that have physical properties very close or even better than the traditionally manufactured

The SLS process for Additive Manufacturing: The Selective Laser Sintering process starts by applying a thin layer of powdered material on the building platform. A powerful laser beam fuses the powder at exactly the points defined by the computer‐

Sample process of manufacturing Die Insert using Direct Metal Laser Sintering (DMLS)

October 2015

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generated design data of the component being built. The platform is lowered and another layer of powder is spread on the earlier layer. Once again the material is fused by melting using the high power laser beam so that it bonds with the layer below, at predefined points. Layer‐ by‐layer the building process completes when the desired part geometry is produced as the building platform lowers to the height of the part. Layer thicknesses vary from a low 20 microns to as high as 70 microns, based on the finish and productivity requirements. The part so built is ready for use in case of a plastic parts and metal parts need to undergo few finishing and post processing to be able to use ‘live’. Advantage AM: Additive Manufacturing is strong in areas where conventional manufacturing

reaches its limits. It enables design‐driven manufacturing, meaning – ‘what can be designed can be manufactured’ and not the other way round as it used to be conventionally. A drill can only drill a straight hole, but using AM we could produce a spiral hole for example. Building complex shapes is one of the most important benefit that AM brings on table. Another aspect that makes AM compelling is the turnaround time. As soon as we have a 3D Model ready, a ‘print’ command is all what is required to produce the part. An average part can be produced within 24hours thereby saving immense time and cost associated with the saved time. Advantages of making assemblies of plastic parts as one single part replacing many is one advantage that a proper reengineering of design can bring about. Alternate materials can be used to produce geometries in low

volumes without tooling. In summary, Additive Manufacturing provides a high degree of design freedom, optimisation and integration of functional features, manufacture of small batch sizes at reasonable unit costs and a high degree of product customisation even in serial production. I often give example of a stark comparison between a typical net‐shape manufacturing cell for Conventional and Additive Manufacturing. See illustrations: Though the example is only illustrative, it speaks a lot for the ease of manufacturing with AM. Obviously there are few post processes for the insert manufactured using DMLS such as removal of supports and finishing, yet, the ease is evident. Applications of Additive Manufacturing:

Additive Manufacturing using Selective Laser Sintering finds applications in following areas: Aerospace Applications: Aerospace parts need to be lighter so as to improve the efficiency. There is no other manufacturing method for a honey comb structured part made in titanium other than Additive Manufacturing. Additive manufacturing has revolutionized how Jet engine parts are being made. AM also plays important role in making parts for aerospace interiors. AM has been used to manufacture UAVs (Unmanned Aerial Vehicles). Automotive applications: Since automotive applications generally run in larger quantities, direct part manufacturing for automotive applications is not common. However AM makes a big impact on the tools required to manufacture parts for automotive applications. Development of functional prototypes

Graphic of conventional design of the assessed steel cast bracket (left) and titanium bracket with optimised topology made by using DMLS technology (Source: EADS) – taken from EOS website

Tool insert and injection‐moulding component: Thanks to conformal cooling, the time required for cooling reduced from 14 to just 8 sec for each production cycle and the quality of the final part improved (Source: Salcomp) – taken from EOS website.

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October 2015

from dmg mori

Open House Bangalore 8th â&#x20AC;&#x201C; 11th December 2015

October 2015

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during development stages of automotive design and testing phases, especially engine parts that go through iterations to meet emission & safety norms is a classic example of how AM is being used for Auto‐making. Customized parts of engine and body of racer cars look for every opportunity to save even a gram off its weight. Industrial applications: Additive manufacturing allows Maintenance and overhaul of worn parts, saving expensive replacements in early stages of the life cycle of the product, especially high valued products. Plastic assemblies with clearances between joint parts can be made as single part using AM. Parts in machines and equipment can be made in low quantities and alternative geometries & materials with the help of AM. Tooling applications: AM has changed the way injection moulding inserts are constructed. Conventionally, injection moulding cycle consumes a lot of time for cooling between the injection of molten plastic and ejection of parts. Inserts

manufactured with AM can have conformal cooling lines that reach closest to the walls of the inserts allowing as high as 50‐60% saving in the cooling time thereby reducing the overall moulding cycle by about 15‐35% depending on part geometry. Products that have very high production requirements can benefit by higher production rates from lower number of machines being deployed. Parts so manufactured are dimensionally more stable. AM can also be used for construction of ‘hybrid’ inserts where a complex shape is built over a traditionally made part, delivering the best of both the worlds. Medical applications: Additive manufacturing is a boon for the medical applications, especially the orthopaedic line of medical sciences. No two people are same in construction and hence there cannot be ‘off‐the‐shelf’ availability of dental copings and bridges or Orthopaedic implants such as hip and knee joints. Scanning of individuals allow personalized and better fitted body parts made in bio‐ compatible and lightweight

materials allowing humans to make their lives better. Even skull damages can be repaired using implants made using Additive manufacturing. AM can be used for making medical devices, particularly due to their complex shapes and lower production volumes. Lifestyle applications: And off course! Additive Manufacturing finds applications in making personalized gadgets, footwear, sports equipment, lighting and home interiors and not to forget jewellery, watches and many such personalized products. The key to the advancement of the additive Manufacturing technology is a paradigm shift in the way products are designed. Designing to take the advantage of the power of this technology needs a completely different approach. So instead of designing for manufacturing feasibility the era we are now in is ‘you design and we’ll make it’! Think differently! The author Ajay is the CEO of 3D Engineering Automation LLP. Ajay has expertise in

Manufacturing, Engineering and Special Machinery, Products & Tool Design. Ajay graduated in Mechanical Engineering from Government College of Engineering, Aurangabad in 1987 and Post graduated in Tool Engineering from Tool Room & Training Center, Delhi, in 1989. In his current profile, he heads implementation of engineering product solutions from Siemens PLM, ANSYS & EOS GmbH to the manufacturing industries in India. Earlier he cofounded the engineering (products and services) divisions of Expert Global in 1999 of which he was a member Board for 15 years & headed design and development of Tools and SPMs at, Paramount Tools for 10 years. Ajay has presented technology papers at International summits and has managed Engineering Design, Design Automation & PLM projects for clients in Europe, US and India. Ajay is a consultant to few manufacturing companies in India. Ajay’s hobbies are music & graphic design.

Thin cross‐sections of alloy powder are sequentially melted by a laser driven by this geometry, automatically building complete 3D restorations with structural fixtures not yet snapped off.

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October 2015

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MAIN FEATURE

Additive Manufacturing Metal Injection Molding

Additive manufacturing is buzzword in the manufacturing industry today, and has been looked at, as the best solution considering saving of time, and realizing the design and creative ideas to be converted into reality. There are a large variety of processes that are being used in various industries and have given a good success to innovative concepts. The SLM (Selective Laser Melting) additive manufacturing technologies like DMLS (Direct Metal Laser Sintering) & EBM (Electron Beam Melting) are the popular AM methods for manufacturing the metal parts.

Sachin Malgave sachin.m@indo-mim.com

An alternate manufacturing technology, MIM (or Metal Injection Molding), has been used by all industries since more than two decades. It has played a key and significant role in bringing down both time and costs, thereby benefitting the OE manufacturers. As a

technology, it is a Designerâ&#x20AC;&#x2122;s Dream, given the flexibility on material as well as design that it offers. Harnessing parts through a Mold, is the key to facilitating manufacture of complex-shaped three dimensional and asymmetrical parts using this emerging

technology. The unique and competitive advantage of this technology is the ability to ramp-up volumes in a short time, and hence it finds wide acceptance and popularity in applications where the â&#x20AC;&#x153;GoTo-Marketâ&#x20AC;? targets are low. Typical examples are wearable

devices, smart phones and tablets, single-use medical devices, etc. Customers have been able to embrace MIM even with an input of a sketch / concept. There have been manufacturers like Indo-MIM, based at Bangalore, India,

Courtesy: Sandvik Osprey, UK

Metal Powder Additive Manufacturing Methods

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October 2015

Courtesy: Sandvik Osprey, UK

Net Shape Manufacturing Processes

Additive Manufacturing Methods complete with MIM & HIP different ends of the PM spectrum

who have revolutionized the “reach” of this technology to newer application areas. This company has enabled designers and application experts to conceive MIM at an early stage of a product, thereby enabling a very smooth transition to mass manufacturing. OE manufacturers have been able to outsource their worries to Indo-MIM, and solicit technology-based solutions, that have helped them meet their customer deadlines, and launch dates. The following picture shows the various metal powder additive manufacturing technologies used & representative machines for

October 2015

the respective technologies. Metal Injection Molding (MIM) is a near-net shape metal forming technology which allows three dimensional complex shaped metal components to be made with great ease, in large quantities. The main forte of this technology is its consistency & repeatability. The below picture explains the process flow of Metal Injection Molding (MIM) process. The below graph explains the weight range of the parts that can be produced by various Net Shaping Processes. MIM can produce the parts with the weight up to 200 gm. MIM is

typically most suitable process for large quantity production requirement. Nowadays prototyping is a must for most of the complex part design validation. Even though MIM is most suitable for high volume production requirements, MIM has an advantage of making a low cost single cavity tool with the soft steel called as “proto tool” which can be made initially for part design validation & development. Few components can be produced for functional testing before it gets a go-ahead for high volume production. As the same manufacturing process is used for high volume

production, the manufacturing process validation will be done during prototype stage, which avoids the additional production process validation at mass production stage. Thus, prototyping and manufacturing process established through the MIM route will have lesser product development lead time. Metal Injection Molding (MIM) has following advantages over Metal Additive manufacturing (AM) for prototyping – 1. Good surface finish : MIM produces the parts with surface of 1-2 micron Ra which is quite smooth & there is no further surface finishing

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required for most of the parts & they can be used in “asMIM” condition. However, the metal AM part have rough with surface of >5 micron Ra. 2. Narrower dimensional tolerances : The parts can be manufactured via MIM with dimensional tolerance of +/- 0.5 % nominal tolerance. Typical tolerance achieved on Metal AM part is ~ +/- 0.1 mm. 3. Near net shape part with minimal finishing process requirement : Typically MIM produces the parts with all the required features which requires least secondary finish machining. On the other hand, the Metal AM parts have supports which need to remove by secondary machining. When production volumes are small, the removal of support material is usually not a big issue. However, when the volumes are much larger, it becomes an important bottleneck. 4. Wide material choices : Most of the metal & alloys available in powder can be processed via MIM hence it offers wide material choices.

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MIM can manufacture most of the alloys offered by wrought and cast route. At present, 3D printers can work with approximately 100 different raw materials. This is insignificant when compared with the enormous range of raw materials used in traditional manufacturing. Also, materials and their properties (e.g., tensile property, tensile strength, yield strength, and fatigue) have not been fully characterized. More research is required to devise methods to enable 3D printed products to be more durable and robust. 5. Lower energy consumption per part production : When melting plastic with heat or lasers, 3D printers consume about 50 to 100 times more electrical energy than injection molding to make an item of the same weight, according to research by Loughborough University. In 2009, research at MIT’s Environmentally Benign Manufacturing program showed that laser direct metal deposition (where metal powder is fused together) used hundreds of times the electricity as traditional casting or machining. Because of this, 3D printers are better for small batch runs.

6. Cost effective manufacturing for low volume production : The cost of most materials for additive systems (Powder) is slightly greater than that of those used for MIM. 7. No manufacturing process validation required for high volume production in MIM : As the same manufacturing process is used for high volume production, the manufacturing process validation will be done during prototype stage, which avoids the additional production process validation at mass production stage. Thus, prototyping and manufacturing process established through the MIM route will have lesser product development lead time. 8. Lower residual stresses : MIM produces the stress free annealed microstructure in asMIM condition. Residual stresses can be “very high” in metal parts produced using laser-based additive manufacturing methods due to higher melting & cooling rates. 9. Homogeneous microstructure & Isotropic

material properties : MIM produces the homogeneous microstructure & isotropic material properties. The Metal AM parts will have non-isotropic material properties. The author Sachin Malgave is the Manager (R&D) at INDO-US MIM Tec Pvt Ltd, Bangalore. He has expertise in Metal Injection Molding (MIM) materials & process development. Sachin is graduated Production Engineering from Walchand Institute of Technology (WIT) in2000 & Post Graduation in Metallurgical Engineering from Indian Institute of Technology (IIT),Chennai, Madras, in 2004. He is Certified Six Sigma Black Belt from ASQ (American Society for Quality). He has published various articles on “Metal Injection Molding (MIM) “in Industrial Business Mart. He has presented paper on “Metal Injection Molding (MIM) “at M& MT 2011, Mumbai, India. He has presented paper on “Value Engineering through MIM” at Medtech China 2011 at Shanghai, China. He has given seminars on “Metal Injection Molding – Technology awareness “ at various other customer places.

October 2015

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MAIN FEATURE

Additive Manufacturing by using Big Data Analytics Additive Manufacturing refers to a process by which digital 3D design data is used to build up a component in layers by depositing material. The term “3D printing” is increasingly used as a synonym for Additive Manufacturing.However, the latter is more accurate in that it describes a professional production technique which is clearly distinguished from conventional methods of material removal. Instead of milling a work piece from solid block, for example, Additive Manufacturing builds up components layer by layer using materials which are available in fine powder form.

Rajesh Angadi rajesh_angadi@hotmail.com

A range of different metals, plastics and composite materials may be used.The technology has especially been applied in conjunction with Rapid Prototyping - the construction of illustrative and functional prototypes. Additive Manufacturing is now being used increasingly in Series Production. It gives Original Equipment Manufacturers (OEMs) in the most varied sectors of industry the opportunity to create a distinctive profile for themselves based on new customer benefits, cost-saving potential and the ability to meet sustainability goals.

Benefits from Additive Manufacturing

manufacturing reaches its limitations. The technology is of interest where a new approach to design and manufacturing is required so as to come up with solutions. It enables a design-driven manufacturing process where design determines production and not the other way around. What is more, Additive Manufacturing allows for highly complex structures which can still be extremely light and stable. It provides a high degree of design freedom, the optimization and integration of functional features, the manufacture of small batch sizes at reasonable unit costs and a high degree of product customization even in serial production.

The strengths of Additive Manufacturing lie in those areas where conventional

Additive manufacturing is the process of building complex three dimensional parts from

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their CAD models rapidly in a layer by layer manner. CAD models are sliced to obtain tool path and layer information which are used by the additive manufacturing equipment. Material is deposited in a layer form one over the other and fused to the previous layer to form a cohesive bond. In the past, rapid prototyping technologies were primarily used to make parts to check for form, fit, and aesthetics but, with limited functional capabilities.However in the recent past there has been a push to use these prototyping technologies to make end products with more functional applications in mind. Many researchers have successfully shown that additive manufacturing technologies can be used to manufacture end products

and have termed them rapid manufacture and rapid tooling. Rapid manufacturing exhibits significant advantages over conventional manufacturing processes includes • Reduced lead times • Zero tooling costs • Design and redesign flexibility • Material flexibility • Part complexity These advantages enable their use in a multitude of direct manufacturing applications to produce parts used in aerospace, medicine, research, defense, and other sectors. It is believed that many of the component items in a modern sonar transducer can be produced using these methods.

October 2015

Many researchers have successfully shown that additive manufacturing technologies can be used to manufacture end products and have termed them rapid manufacture and rapid tooling

The roles of additive manufacturing technologies include 1. Embedded sensors 2. Print labels/EPCs 3. High performance temperature sensors 4. Fabricate on demand 5. Part DNA 6. Designing and producing conforming transducers 7. Tissue, organ production and other medical applications 8. Manufacture of assembled actuated mechanism 9. Manufacture of micro – sensors and micro - actuators Additive manufacturing in Cyber Enabled Manufacturing can also lead to sustainable mass production of smart fabrics and other wearables with applications in many areas, such as electronics to provide versatility without recourse to a silicon foundry, and the processing of emerging

October 2015

materials such as carbon fiber and polymers that offer the potential to combine capability for electrical andoptical functionality with important physical properties including strength, durability, and disposability. Big Data Analytics with Additive Manufacturing Organizations that know where they are in terms of analytics adoption are better prepared to turn challenges into opportunities. We need to segment respondents based on how they rated their organization’s analytics prowess, specifically how thoroughly their organizations had been transformed by better uses of analytics and information. Three levels of analytics capability emerged — Aspirational, Experienced and Transformed — Aspirational- These organizations are the furthest from achieving their desired analytical goals. Often they

are focusing on efficiency or automation of existing processes and searching for ways to cut costs. Aspirational organizations currently have few of the necessary building blocks — people, processes or tools — to collect, understand, incorporate or act on analytic insights. Experienced- Having gained some analytic experience — often through successes with efficiencies at the Aspirational phase — these organizations are looking to go beyond cost management. Experienced organizations are developing better ways to collect incorporate and act on analytics effectively so they can begin to optimize their organizations. Transformed- These organizations have substantial experience using analytics across a broad range of functions. They use analytics as a competitive differentiator and are already adept at organizing people, processes and tools to optimize and

differentiate. Transformed organizations are less focused on cutting costs than Aspirational and Experienced organizations, possibly having already automated their operations through effective use of insights. They are most focused on driving customer profitability and making targeted investments in niche analytics as they keep pushing the organizational envelope. Transformed organizations were three times more likely than Aspirational organizations to indicate that they substantially outperform their industry peers. Executives want better ways to communicate complex insights so they can quickly absorb the meaning of the data and take action. Over the next two years, executives say they will focus on supplementing standard historical reporting with emerging approaches that make information come alive. These include data visualization and process simulation as well as text and voice analytics, social media

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analysis and other predictive and prescriptive techniques. New tools like these can make insights easier to understand and to act on at every point in an organization, and at every skill level. They transform numbers into information and insights that can be readily put to use, versus having to rely on further interpretation or leaving them to languish due to uncertainty about how to act. It takes big plans followed by discrete actions to gain the benefits of analytics. But it also takes some very specific management approaches. Based on data from our survey, our engagement experience, case studies and interviews with experts, There is a methodology for successfully implementing analytics-driven management and for rapidly creating value. The recommendations that follow are designed to help organizations understand this “new path to value” and how to travel it. While each recommendation presents different pieces of the information-and-analytics

value puzzle, each one meets all of these three critical management needs: Reduced time to value- Value creation can be achieved early in an organization’s progress to analytics sophistication. Contrary to common assumptions, it doesn’t require the presence of perfect data or a full-scale organizational transformation. Increased likelihood of transformation that’s both significant and enduring- The emerging methodology we’ve identified enables and inspires lasting change (strategic and cultural) by tactically overcoming the most significant organizational impediments. Greater focus on achievable steps- The approach used by the smartest companies is powerful in part because each step enables leaders to focus their efforts and resources narrowly rather than implementing universal changes — making every step easier to accomplish with an attractive ROI.

Speeding Insights into Business Operations Compared with other respondents, Transformed organizations are good at data capture.

4. Advanced statistical techniques, such as regression analysis, discrete choice modeling and mathematical optimization.

(“What Data-Transformed Companies Do.”) Additionally, Transformed organizations are much more adept at data management.

Organizations expect the value from these emerging techniques to soar, making it possible for data-driven insights to be used at all levels of the organization.

In these areas, they outpaced Aspirational organizations up to tenfold in their ability to execute.New methods and tools to embed information into business processes — use cases, analytics solutions, optimization, work flows and simulations — are making insights more understandable and actionable. Respondents identified trend analysis, forecasting and standardized reporting as the most important tools they use today. 1. Data visualization, such as dashboards and scorecards 2. Simulations and scenario development 3. Analytics applied within business processes

Additive manufacturing, 3-D, animated maps and charts can simulate critical changes in distribution flow or projected changes in consumption and resource availability. In the emerging area of analytics for unstructured data, patterns can be visualized through verbal maps that pictorially represent word frequency, allowing marketers to see how their brands are perceived. Innovative uses of this type of information layering will continue to grow as a means to help individuals across the organization consume and act upon insights derived through complex analytics that would otherwise be hard to piece together.

Advance standard methods for identifying business problems to be solved with analytics.

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October 2015

New techniques to embed insights will gain in value by generating results that can be readily understood and acted upon: Dashboards that now reflect actual last-quarter sales will also show what sales could be next quarter under a variety of different conditions — a new media mix, a price change, a larger sales team, even a major weather or sporting event. Simulations evaluating alternative scenarios will automatically recommend optimal approaches — such as the best media mix to introduce a specific product to a specific segment, or the ideal number of sales professionals to assign to a particular new territory. A centralized analytics unit can provide to build advanced skills within the organization, providing both advanced models and enterprise governance through establishing priorities and standards by these practices: Advance standard methods for identifying business problems to be solved with analytics. Facilitate identification of analytic business needs while driving rigor into methods for embedding insights into endto-end processes. Promote enterprise-level governance on prioritization, master data sources and reuse to capture enterprise efficiencies. Standardize tools and analytic platforms to enable resource sharing, streamline maintenance and reduce

licensing expenses. Manufacturers looking to shorten supply chains eliminate shipping costs and reduce lead times can benefit from additive technologies. Additive manufacturing technologies create a world of possibilities that can take an organization in an entirely new direction and help launch new businesses and business models.3D printing and 3D imaging are causing design and manufacturing professional to rethink their approach to new product development. Designers and manufacturing engineers are extending their capabilities as additive manufacturing offers highly complex, geometric shapes and features.It is found that additive manufacturing, owing to its advantages of low manufacture time, easy customizability, material flexibility, and greater tolerance of part design complexity, is a viable option for use in cyber physical systems to bring about cyber enabled manufacturing by using Big Data Analytics. The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.

Creating the world’s first 3D printed metal bike frame

Unlock the potential of additive manufacturing The bike frame has been additively manufactured from titanium alloy powder using an AM250 laser melting system. This project highlights the benefits of Renishaw’s technology: • Rapid design iterations - shorter development times • Weight reduction - use material only where required • No investment in tooling • Complex, thin walled, and internal features • Choice of high performance alloys What can Renishaw do for your products?

For more information visit www.renishaw.com/bike

Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com

www.renishaw.com October 2015

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MAIN FEATURE

3D Printing: The New Wave of Industrial Revolution We all have heard the buzz about 3D printing called the 3rd or the 3D industrial revolution. What exactly is 3D printing how big of an impact will it have on our future? Everything from pills to houses is been 3D printed paving way to the new wave of industrial revolution. No doubt Indian companies and consumers will heavily invest in 3D printing in the coming years and many analysts predict that this industry is expected to grow in a whopping 300% growth until 2020.

Chithrarth Manoharan chithrarth@3ding.in

We all have heard the buzz about 3D printing called the 3rd or the 3D industrial revolution. What exactly is 3D printing how big of an impact will it have on our future? The concept is quiet simple much like a printer prints ink on a page, 3D printer spit a bit of material like plastics, nylon,

ceramic, cement or even wood to form a 3 dimensional object instead of printing one layer of ink a 3D printer does multiple layers by stacking upon each other to create a 3 Dimensional object, think of it like making a sliced bread but in reverse after putting one layer down another on top of that and so

on until whole of the bread is put together. This is achieved by an additive process whereby layers of materials are laid down in different shapes. This method differs vastly from traditional machining techniques that rely on the removal of materials either by cutting or drilling which are

subtractive processes. 3D printing technology has found varied uses and benefits ranging from rapid prototyping to applications in construction, architecture, engineering, medical industries, fashion, jewellery, defence, automobiles, aerospace and in a host of other fields. In the

3D Print Architectural model

3D Printed Winterfell

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“The increased sale of 3D printers over the past few years has taken additive manufacturing mainstream more than any other single development globally and the same wave has started to take place in India, Low cost 3D printers are catalysts for the professional as well as consumers.” Surendranath Reddy Founder ,CEO, 3Ding.in

near future it is expected that 3D printers would become easily available consumer goods, thanks to the fact that they can offset the capital costs in procuring them by enabling people to “print” common household items rather than purchasing them from the market. Manufacturers looking to shorten supply chains eliminate shipping costs and reduce lead times can benefit from additive manufacturing technologies.

Additive manufacturing technologies create a world of possibilities that can take an organisation in an entirely new direction and help launch new businesses and business models. 3D printing and 3D imaging are causing design and manufacturing professional to rethink their approach to new product development leading to a drastic reduction in time for product development.

hardships for many Asian

Despite a decade of financial

technology more accessible to

manufacturers, additive manufacturing technologies offer a way for companies to get started on a shoestring (relatively speaking, depending on what you are making). If you have an existing company, it doesn’t take much to add a rapid prototyping machine into the mix. Low-cost 3D printers have helped create visibility for the industry, making the

students, researchers, do-ityourself enthusiasts, hobbyists, inventors and entrepreneurs. Designers and manufacturing engineers are extending their capabilities as additive manufacturing offers highly complex, geometric shapes and features. The development of highperformance polymers and metal-based systems offer unlimited possibilities for the production of end-use parts.

3D scanned and 3D printed

October 2015

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The Chennai based startup 3Ding.in manufactures 3D printers for price as low as 20,000 INR backing up with a one year warranty. The founder CEO Mr Surendranath tells us â&#x20AC;&#x153;The increased sale of these machines over the past few years has taken additive manufacturing mainstream more than any other single development globally and the same wave has started to take place in India, Low cost 3D printers are catalysts for the professional as well as consumers, giving birth to the Fab X series of printersâ&#x20AC;? he proudly claims. 3Ding.in currently sells two variants of the Fab X series of printers namely Fab X v1 and Fab X v2.0 the later retails for 30,000 with features like autobed levelling, easy to use one touch auto print and much more. They also have bigger

machines in pipeline which they might launch later this year. Traditionally, full-size injectors take months to make because a lot of measuring must be done and it has to be exact. Should someone make a mistake, everything must be machined all over again, which can take several months. The use of additive manufacturing, time between iterations will drop to weeks. Not only has it given an edge over the time factor but most importantly on the developmental cost. A bottle manufacturing company in Chennai which designs and develops beverages, glue bottles for it clients has saved 20-30 lakhs or about 70-80% in total cost and 75% save in time for the design and development phase which goes on an average of 15- 30 iterations for each designs before their clients give a final

go for the mass production. Investing in 3D printing this year has been about as fun as drinking battery acid despite the unabated promises of it being the next industrial revolution. Everything from pills to houses is been 3D printed paving way to the new wave of industrial revolution. No doubt Indian companies and consumers will heavily invest in 3D printing in the coming years and many analysts predict that this industry is expected to grow in a whopping 300% growth until 2020. This is good for industries, entrepreneurs and even consumers as the overall cost of the product will reduce and new designs meeting customer specific products will hit our markets rapidly than ever before. The author Chithrarth Manoharan Born and raised in

Chennai, India Chithrarth was passionate about technology right from his childhood and this led him to purse his engineering in Electronics and communication. Some of his development includes unmanned ariel vehicles, fully autonomous rovers with vertical locomotion for Non destructive evaluation and surface mapping during his college days. His burning urge led him to grab some elite competition titles from IIT-M, NIT etc which eventually led him to join REDD robotics as an R&D engineer. As a research and development engineer he is responsible for the development and fine tuning of some of the products developed by REDD Robotics a.k.a 3Ding.in. Redd robotics is focused towards research and development of various domains like Robotics, Automation, Embedded systems, Internet of things, Consumer electronics and 3D printing.

The Manufacturing industry prototypes machinery parts using industry grade 3D Printers before manufacturing

2D Printed vs 3D Printed

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October 2015

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MAIN FEATURE

3D Printing, the Next Leap in Manufacturing!

Guruprasad Rao Director – Technology & Operations, Imaginarium India Mr. Guruprasad Rao is the Director – Technology & Operations, Imaginarium India Pvt Ltd, one of the largest 3D printing company in India. He has over 28 years of diverse Industrial and academic experience having worked in Titan, Tanishq, Crompton Greaves, and was a professor of Design at IICD, JSSATE and besides design consulting. He has been promoting AM applications through talks, seminars and as a member of many task forces and national consortiums. He is a task force member FICCI on 3D printing. As an accomplished product designer, has bagged 3 Gold medals and a number of patents, Design registrations to his credit. He is currently working on building Imaginarium Academy to augment skill needs for a better 3D ecosystem and on medical applications of 3D printing. Excerpts from the discussions MART had with Mr. Guruprasad Rao on the future of 3D printing and its opportunities in India, follows:-

From product prototyping, the Rapid Prototyping industry has witnessed revolutionary changes and now offering user based products through Additive Manufacturing and 3D Printing. Can you please throw some light about the technology shift?

an end product. That is indeed a great shift!

Well, the early 3D printing technologies offered coarse build and were mostly used for product mock-ups for aesthetic evaluations. Today, due to advancement in technology, we have very accurate model-building capability with multiple materials which can be used not only for aesthetic evaluation but also functional testing and in certain cases as

‘Onestop shop’ is how we would like to put it in one word! Imaginarium offers 3D print services in more than 30 industry segments. Our state of the art facility at Mumbai, boasts of different technologies such as SLA, SLS, Polyjet, Multijet, DLP with post processing including painting, apart from facilitating small batch production with vacuum casting. We

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Imaginarium is one of the pioneer in the field of Additive Manufacturing in India. What are the solutions in your offer to the Indian Manufacturing Industry?

also offer plastic and metal products for aerospace, automotive,medical, FMCG,white goods,electrical & electronics, tool room, foundry, jewellery,toys,trophy,art, and architecture segments. What is the application procedure of 3D printing in various arenas of manufacturing? We believe ‘if you can think it, we can make it’. 3D printing uses a file format called stereo lithography format or stl built via CAD. The technology is widely used in new product development processes such as concept development, mechanism testing, design

validation, overall appearance testing or prototype evolution, and development of jigs and fixtures. Medical applications include study models, surgical guides and implants. Organ printing could be reality soon. Foundry sector uses patterns which can be made by 3D printing. Today people are using it in every field possible such as art, architecture, toys, trophies, jewellery and hobby related projects. Imaginarium introduced CAD/ CAM as well as 3D printing in the Indian jewellery sector. Can you brief about these initiatives which was instrumental in changing the conventional manufacturing?

October 2015

Architectural Model

3d Printed Jewelry Prototypes

Yes, in fact it was Imaginarium which made 3D printing popular in jewellery segment. Earlier hand drawn sketches were used by skilled artisans or karigars, who used to carve designs out of wax or silver. That, however was an inaccurate, time consuming and costly process. With the advent of CAD/CAM technology, the sketch is first converted into a 3D model and then is ‘printed’ directly. The process, therefore, has led tozipping the timehighly, to market. Imaginarium was associated

with the Academy creating awareness about Additive Manufacturing among the budding engineering students. Can you brief about the results generated through these programmes?

of Imaginarium Academy, which focuses on skilling India in 3D printing and allied technologies.

3D printed fashion show.

Major achievements by Imaginarium?

Yes, since our inception, we have been educating markets to adopt this technology. We believe that it’s essential to build a sound ecosystem around technology for it to get adopted widely. In order to get started with the process of creating anything using 3D printing, we need a 3D model and someone to create it.So, we came up with the idea

We made 3D printing a defacto standard for Jewellery Manufacturing!

We are proud of our growing customer base which stands at 5000 now!

We are Asia’s largest 3D printing setup offering multiple solutions. We created Indian Oscar, Film fare trophy through 3D printing. We participated in Asia’s first

We have largest machines in the country.

We have supported more than 100 start-ups in their product innovations. We have more than 10,000 visitors in the past 3 years. We have improved / saved more than 10 lives through our 3D print support for medical domain.

Filter Manifold

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We have India’s most skilled 3D print domain experts. We have grown to be an employer of choice in our domain. Imaginarium has become synonymous to Design and 3D printing! How ‘Make-in-India’ can change the course of manufacturing in our country? Make in India is not about a slogan but needs hard work! We need to put in a lot of hard work, to skill ourselves, get updated on technology, and rise to global quality levels. We need to compete with the best in class in every field. Even more important is the rate of innovation that should increase. It’s highly important for us to adopt 3D technologies to make leap forging to reach to global levels

and be competitive. So, it is a movement of making a new industrial India.

better SOPs for the sector. Imaginarium has been pushing for policy through FICCI and other industry bodies. We still lack a united sector voice due to the inadequate professional bodies. We have been working on it and hope for success soon. Imaginarium Academy is one such platform to reach out and create skills needed to fill the gap.

When it comes to Additive Manufacturing, India is still lagging behind its global counterparts. What are the measures Imaginarium has initiated to fill this gap? Yes, we as a nation lag when it comes to adoption of 3D technologies. Thanks to internet revolution, we can read about its advancement across the world and are slowly inching towards its adoption. Imaginarium was conceptualized when there were few believers and we had to educate users to survive.

Where do you see Imaginarium in the next five years? Imaginarium will be a household name! Imaginarium will grow to be a nodal agency helping India in 3D skills.

The Indian market potential is estimated at 3000 Cr while current total supply is around 200 Cr. What can boost our growth is need for national policy on 3D printing with

It will be one of the top 10 in the world for its services. Tell us about the inception of Imaginarium and your success story?

Imaginarium was born out of several years of incubation and deep insights and well planned market research by a team of Individuals who took it as their passion. They left no stone unturned on the subject as they were not domain experts. It was a bold dream by this team which resulted in creation of a brand, Imaginarium. AnkitMehta ,Dipak Shah, Kamlesh Parekh are true founders of this wonderful institute. My first brush with this technology was in 1993 and by 2000 I was hands-on user at my alma matter, IISc. I was fortunate to continue my journey when I joined the Imaginarium team in 2011. Soon many technocrats were on board to form a sound organization as we stand today.

Formula Racing Car - SLS model

Titanium Cranial Implant

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Innovative Automation Products

B/24, MIDC Satara 415004 India

+91 2162 246509 +91 2162 245966 sales@innovativedro.com www.martupdate.com 39

MAIN FEATURE

Product Development is Crucial to Manufacturing Varun Gadhok Head Manufacturing, Autodesk India and SAARC

Varun Gadhok with over 18 years of experience in the industry, currently leads the manufacturing business of Autodesk India and SAARC and drives the overall growth strategy for the segment. Varun is an established thought leader in the automotive domain with rich cross cultural experience. During his career, he has held various positions in the technology & automotive industry, with significant contributions in the fields of strategic planning, sales & marketing, business development, key account management and team management. He discuss in details about the future of Additive Manufacturing and the offerings Autodesk extend to the industry.

Additive Manufacturing is the key word in todayâ&#x20AC;&#x2122;s manufacturing. Can you brief the changes industry witnessed from Rapid Prototyping to 3D Printing and Additive Manufacturing? 3D Printing includes various related design technologies which fabricate physical objects directly from 3D digital models. These digital models are created using Computer Aided Design data that are generated using CAD technologies that can capture this data. Itâ&#x20AC;&#x2122;s a unique method

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that works by adding and bonding specialized materials in various layers eventually forming the objects. While 3D Printing is a more popular term, rapid prototyping and additive manufacturing also represent significantly different processes as well. Rapid prototyping refers to the fast development of prototypes for different purposes. It helps make the manufacture of complex objects manageable, straightforward, and speedier. This has resulted in their wide

use by engineers as a way to reduce time to market in manufacturing, to better understand and communicate product designs, and to make tooling to manufacture those products. Additive Manufacturing is a process of building a component from digital 3D design data in multiple layers by adding or depositing material. It is a manufacturing technology that uses layerby-layer or drop-by-drop processes. The process is advantageous for producing an

object of complex geometry. However, in recent years, more and more additive manufacturing technologies are being used for final parts especially when the geometries are complex or for the incorporation of special functionalities. What is 3D Design? Tell us about your innovative products. 3D Design/Modelling covers not only CAD(computer aided design) Design/Modelling but also highly complex organic

October 2015

Autodesk 3D Printer

shapes for more creative applications. It is the process of modelling a ‘subject’ with three-dimensional appearance from a graph or two-dimensional image to be projected on screen. Autodesk 3D design software and apps are used by more than 100 million designers, engineers, architects, creative artists, students and hobbyists to unleash their creativity, build better products and solve critical challenges impacting the world. Autodesk 360 - a cloud-based platform helps improve the way users design, visualize, simulate, and share work with others anytime, anywhere - and host of 3D Printing apps like 123D Catch, a free app that lets you create 3D scans of virtually any object. We are deeply involved with our customers to bring the cutting edge design technologies like data driven manufacturing to the market. Fusion 360–Autodesk Fusion 360 allows design and engineering professionals to more easily create 3D product designs and collaborate with others in the cloud. The cloud technology behind Autodesk Fusion 360 offers anytime,

October 2015

anywhere access, from virtually any mobile device or web browser and puts essential data at the center of the design experience. It also supports an open design environment, allowing designers to readily incorporate and modify CAD data from virtually any source. Autodesk Fusion 360 leverages the Autodesk 360 cloud-based platform and adds to Autodesk’s cloud portfolio for manufacturers, which includes Autodesk PLM 360, a cloud-based product lifecycle management offering, and Autodesk Simulation 360, a comprehensive set of simulation tools delivered securely in the cloud. A comprehensive product design tool geared toward small business professionals, Autodesk Fusion 360 capabilities span all aspects of industrial and mechanical design, melded with anytime, anywhere access to data, collaborative and social development capabilities the cloud has to offer. Autodesk Fusion 360 also connects to advanced capabilities such as large scale mockup, simulation, PLM and rendering. Autodesk Fusion 360 offers a radically different user experience

through an intuitive interface that conforms to the role and level of user expertise. Autodesk Fusion 360 provides built-in guidance to novice users to speed the learning curve, and the ability to turn off guidance and access deeper functionality for design experts. Regardless of their level of expertise, users can start designing in a matter of minutes and begin to leverage Autodesk Fusion 360’s integrated social collaboration tools. Can you brief more about “SPARK” Last year, Autodesk launched an open software platform for 3D printing called Spark, which simplifies printing the 3D models, and makes it easier to control how that model is actually printed. Spark offers a common and open platform that shortens that path between digital content and hardware. This facilitates a much improved information exchange between design software and the printer, so software can address and offer automated fixes and optimization to the design before production begins. In addition, the APIs that will be

included with Spark will enable a broad group – from materials science companies to crowdfunded start-ups – to access and innovate the 3D printing pipeline. Spark is closely integrated with Autodesk’s cloud-based design software for product development or personal design and fabrication, including Autodesk Fusion 360 and Autodesk 123D. Later, we launched the Spark Investment Fund worth of $100 million to be invested in helping and nurturing 3D printing companies over the next several years. The Fund, which is operated within Autodesk, is the first of its kind for the 3D printing industry and invests in entrepreneurs, startups and researchers who push the boundaries of 3D printing technology and accelerate the new industrial revolution. How India can give a fight with its global partners in this new concept of 3D manufacturing? Product development is crucial to manufacturing. The management of the entire production process determines the quality of a product in terms of its sustainability, feasibility and

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also marketability. If we look at product manufacturing some steps involved include Prototype Design, Prototype Testing, Product Manufacturing, Simulation of the final product and testing it in real world conditions. 3D Design technologies are increasingly helping manufacturers worldwide in developing innovative products and also bring these products to market faster. Enthusiastic adoption of 3D Design technologies will help Indian manufacturers to become competitive internationally. Today 3D manufacturing is used to make components for aircraft and automobiles, medical prosthesis and also human organs. Taking this cue, even Indian automakers have begun using it to make entire car parts such as dashboards, tail-lamp covers etc. Indian orthopedists and dentists are using it to get accurate models of their patientsâ&#x20AC;&#x2122; bone structure to better diagnose their problems; and Indian jewellery makers are adopting it because of the customizable aspect of 3D printing.

The proliferation of cloud and mobile technologies has added another dimension to the product development process. Design in Cloud will help the designers collaborate in a much efficient way which will reduce time wastage and improve efficiency in the processes. Inclusion of customer opinion in the planning phase of projects is another important aspect that seems to be emerging. Indian manufacturers will do well to keep abreast of such latest trends which will disrupt the entire traditional manufacturing process. In the recent years we have seen a growing interest which would help in the growth of this market. Trends like 3D printing and mass customization are slowly gaining a foothold in the Indian manufacturing industry. For example, one of the fastest expanding countries for the adoption of 3D printing within healthcare is in India, which is forecast to report strong growth totalling 26.15 CAGR during the period 2012 to 2018. The 3D printing market is set

to increase rapidly over the next few years and especially in re-creating and manufacturing complex parts which contain complex geometries and surfaces. 3D printers are ideal for manufacturing low volume although high value products and their application within the healthcare sector is important for manufacturing complex parts in a short time scale. 3D printing is particularly in high demand in the orthopaedics sector. As well as in other sectors like Aviation (a recent example of Airbus making over 1,000 3D printed parts for its aircraft), prosthetics, construction and automobiles, etc. The possibilities with 3D manufacturing are endless! What are the services Autodesk offers to the Indian Manufacturing industry? Autodesk, foresees Cloud as the future for the design industry as well as its own business growth in India. A holistic strategy, aligned with the industry requirements and key stakeholders, including the partners and customers is the way forward for the

company in India and all other international markets. While our involvement is strong we understand and value the fact that presence of competition in the market gives customers more options and this is what keeps us nimble. Our Go-To-Market strategy constitutes of having a strong and expansive partner ecosystem spread across multiple cities. With the aim of democratizing technology, we provide the best of design innovation solutions to large, mid-size and SMBs. We also ensure that our partners are trained requisitely with the apt skills to provide these solutions to the customers. We have been advocating Distributed Manufacturing as the key to the Next Industrial Revolution and encouraging companies, individuals to developing ground-breaking hardware, software, materials, marketplaces and maker spaces through 3D technology. The FY16 Design Suites, which were launched earlier this year, address the requirements of the industry to push the

Today 3D manufacturing is used to make components for aircraft and automobiles, medical prosthesis and also human organs.

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October 2015

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boundaries on how products are designed and made and how products are manufactured. The new suites enables collaborative processes in more ways than ever before, with expanded cloud services and flexible ways to license the software. The suites address the entire workflow: from capturing reality and iterating on a design, to physically making that design through 3D printing or other forms of fabrication. The 2016 range of software comes with deeper integration with cloud services, flexible subscription options and enhanced collaborative processes that will considerably accelerate the future of how things are built or made. The tighter integration with Autodesk 360 will provide our customers faster rendering, visualization, simulation, and collaboration capabilities through design in the cloud. We recently announced that after July 31, 2016, new commercial licenses of most Autodesk Design & Creation Suites and individual products will be available by subscription only. When this takes effect, the company will provide new, simplified subscription options so customers can access multiple products and share licenses as they do today — while gaining the simplicity, accessibility, and flexibility of subscription.Our customers have been asking for greater flexibility and more value from their software investments. This allows Autodesk to deliver both, as well as an improved user experience and easier access to a broader portfolio of technology. Your take on ‘Make in India’. India is a key growth market for Autodesk and our major

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focus is on Automobile design, Manufacturing, Architecture, Infrastructure and the Media & Entertainment sectors. Autodesk technology can be a key ingredient in enabling the components of the “Make in India” campaign. With a new supportive government we expect the journey to be even more exciting, especially the opportunities in manufacturing. We at Autodesk believe that Innovation, R&D and skills are the key drivers for the growth of manufacturing Sector and will give boost to Make in India. The success of this initiative will depend on the amount of innovation and R&D happening in the country. Off late, various auto component manufacturers have moved up from built-to-design towards designing own products.This has been possible because of the investments in innovation and capacity development by the companies. Creativity & Innovation are integral part of any business process to produce new ideas with an objective to deliver value. India also has more than 51 million SMBs which contribute to more than 17% of National GDP and have 45% share in manufacturing output. We need to cater to these entrepreneurial zeal with modern technology to make India a hub for global manufacturing. Autodesk’s global turnover and India’s contribution in it. Autodesk has been performing consistently in India and we continue to drive profits bolstered with strong business growth across various industry sectors. For the quarter May-July 2015, global revenue was $609.50 million, up 21%

year-over-year. As one of the key emerging market, India contributes a sizable portion to this revenue as we finished the last year on a very strong note. Autodesk invests US$500 million on R&D annually. This makes us the biggest R&D spender among US companies of a similar size. (During the last fiscal year, FY2013, Autodesk spent 25.4% of net sales on research and development, the largest percentage among U.S. software or Internet companies that have a market value above $5 billion and an annual R&D budget of at least $300 million.) Additionally, Autodesk has two R&D centres in India – Pune and Hyderabad working on different projects. We continue to look for talent, and are excited by the opportunities India has to offer. R&D spends in India are a part of our global investments in this segment. As stated earlier, Autodesk spends nearly half a billion annually on R&D. Autodesk 360 and Fusion 360 are two indigenous cloud solutions that originated from India and India is also among top 5 users of Autodesk consumer products in the cloud through mobile and smart devices. Indian Industry faces tough challenge when it comes to ideal manpower. How much you get the right talent with knowledge of 3D Design? What are the policies to retain them? The Indian manufacturing industry faces the challenge of having a readily available skilled workforce. We are definitely moving to acquire the required skill set as the government and private players are doing their part in achieve the milestone of a Skilled India.

Autodesk has partnered with more than 12,000 institutions in India, including almost all the engineering colleges and institutions such as AICTE, Directorate of Employment and Training Karnataka, Directorate of Industrial Training Kerala and Directorate of Vocational Education and Training Maharashtra. This move has benefitted more than 19 million students in India. In 2013, Autodesk signed a MoU with NIIT and NIIT University to offer design related programs. Under this MoU, NIIT and NIIT University will leverage design tools of Autodesk to offer a host of design programs and setting up a design lab and launch masters programs in design to support research and innovation. In addition, various specialized design programs will be launched for college students in verticals such as interface design, application design and media & entertainment design with an aim to create a pool of skilled manpower for these specific industries. In 2014, Autodesk partnered with National Programme on Technology Enhanced Learning (NPTEL), a joint initiative by the seven Indian Institutes of Technology (IITs) and Indian Institute of Science (IISc), to enhance access of engineering students to professional 3D design tools, industry-relevant curricula, multimedia and web technology. This move aimed to increase the number of skilled and industry-ready engineering graduates nationwide. Late last year, Autodesk tied up with leading educational institutes to provide software free to students, instructors and academic institutions not

October 2015

just in India but worldwide. Through this action, more than 680 million students and educators from over 800,000 secondary and post-secondary schools in 188 countries can take advantage of free access to Autodeskâ&#x20AC;&#x2122;s professional software and services for use in classrooms, labs, and at home. Can you brief about Autodesk India, its start, success story and the future plan? Autodesk started its operations in India in the last decade. Since then we have come a long way from being known as the makers of AutoCAD to a major 3D design company with product offerings in not only Manufacturing but also in Media and Entertainment

October 2015

(M&E) as well as Architecture, Engineering and Construction (AEC) space. Autodesk in its journey has been a part of several iconic projects. To name a few, Autodesk was the design partner in the Mumbai Monorail, the Mumbai T2 International airport, Khed City in Maharashtra, the Golden Quadrilateral as well as the conservation of heritage monuments. Almost every major automobile manufacturer today uses Autodesk software at some stage of their production process. Autodesk has a strong presence in the R&D space in India with two facilities in Pune and Hyderabad. Our education programme is going

exceedingly well with over 19 million students benefitting from our products through our various partnerships with educational institutions. Lately, we have also begun to focus on the thriving Makersâ&#x20AC;&#x2122; community in India in order to make India a manufacturing hub.

under one roof. The event was

Out flagship event, Autodesk University has been organized in India for the past 2 years and the event has become the largest gathering of designers, engineers and as well as professionals users of Autodesk products outside the US. The 2015 edition of Autodesk University in Mumbai recorded an attendance of more than 3000 budding designers and industry experts

moved the needle from a

also attended by the Honorable Chief Minister of Maharshtra, Shri Devendra Fadnavis who inaugurated the event as well. This goes to show the success that Autodesk has achieved in its stint in India. We can say that we have product focussed company to a more value focussed one that emphasises on resolving business problems. As of now, the company is focussing on its transition to cloud and to offer simplified subscription options to customers to access our diverse product portfolio. We are upbeat about India and the exciting opportunities it offers!

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MAIN FEATURE

Additive Manufacturing: Transforming Prototype Development

Rajiv Bajaj General Manager, Stratasys India Rajiv has extensive experience in the manufacturing industry, serving as an expert speaker at industry forums across India, such as the Confederation of Indian Industry (CII), the Indian Machine Tool Manufacturers’ Association (IMTMA) and the Global Manufacturing Cluster Vision (GMCV) 2020, driving thought leadership and promoting efficient factory design for manufacturing excellence. Rajiv completed his Leadership and Strategy program from the Indian Institute of Management Lucknow and holds a Bachelor degree in Mechanical Engineering.

Stratasys is a big name in the field of Additive Manufacturing. What are the solutions in your offer to the Indian Manufacturing Industry? For over 25 years, Stratasys has been the trusted leader of 3D printing and additive manufacturing innovation, offering an unmatched suite of 3D printing systems, specialized applications and solutions to address various design and manufacturing requirements. Apart from concept modeling and functional prototyping for design validation, Stratasys offers advanced manufacturing solutions such

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as Direct Digital Manufacturing (DDM), facilitating local and international businesses in optimizing manufacturing efficiency while minimizing production cost. The production of customized jigs and fixtures, injection molds, or end-use production parts allow companies to benefit from effective production processes, flexible manufacturing schedules, as well as higher creativity in their offerings to their clients. What is the application procedure of 3D printing in various arenas of manufacturing?

Additive Manufacturing which is also referred to as 3D printing, is transforming prototype development manufacturing processes and is displacing certain segments of traditional, or subtractive, manufacturing methodologies such as metal extrusion, CNC machining and manual fabrication techniques. While 3D printing has historically been focused on design and rapid prototyping applications, it is now beginning to show signs of broader adoption with solutions across complete “design through manufacturing” process. Manufacturers are increasingly

using 3D printing systems to:visualize and communicate product ideas and designs, verify the form, fit and function of prototypes, manufacture tools, jigs, fixtures, casts and injection molds used in the process of manufacturing end-products, manufacture customized and short-run end-products more efficiently and with greater agility and, produce objects that could not otherwise be manufactured through traditional manufacturing methodologies. Can you brief about the 3D Printing Webinars you are organizing and how much effective it’s to create the right

October 2015

The modeling and support filament used in the FDMbased 3D printers and production systems features a wide variety of production grade thermoplastic materials.

awareness in the market? Stratasys hosts webinarson latest 3D printing trends, applications and industry specific solutions to not only raise awareness, but educate targeted markets and provide quick references to customers and prospects for their design and manufacturing challenges. Our experts share their experiences such as the benefits of 3D printed manufacturing tools, 3D printing trends in the aerospace or automotive industry etc. with the audience. Tell us about theMaterials used by Stratasys? We offer a broad range of 3D printing materials, consisting of 38 Polyjet/FDM cartridgebased materials, 138 non-color digital materials, and over 1,000 color variations for use in our 3D printers and production systems. The modeling and support filament used in the FDMbased 3D printers and production systems features a wide variety of production grade thermoplastic materials. We continue to develop

October 2015

filament modeling materials that meet our customers’ needs for increased speed, strength, accuracy, surface resolution, chemical and heat resistance, color, and mechanical properties. Our resin consumables, which consist of our PolyJet family of proprietary acrylic-based photopolymer materials, are designed for use with our PolyJet printing systems and enable users of those products to create highly accurate, finely detailed 3D models and parts for a wide range of prototype development and customized manufacturing applications. The wide variety of resins within the PolyJet family is characterized by transparent, colored, or opaque visual properties and flexible, rigid or other physical properties. Which are the key industries Stratasys offers solutions to? Stratasys offers solutions to a wide array of Industries like Manufacturing, Aerospace, Defense, Dental, Medical, Education, Auto and R&D, to name a few. Manufacturers use Stratasys 3D Printers to create models and prototypes for new product design and testing,

and to build finished goods in low volume. Educators use the technology to elevate research and learning in science, engineering, design and art. Hobbyists and entrepreneurs use Stratasys 3D Printing to expand manufacturing into the home — creating gifts, novelties, customized devices and inventions. Government, Military and Defense manufacturers use Stratasys 3D printers to quickly create low-volume tooling, or build complex, precise prototypes when customized equipment is vital and deadlines are non-negotiable. 3D printing is shaping medicine by improving healthcare delivery for complex surgical procedures, personalizing prosthetics as well as driving innovation in medical devices. What are your views on ‘Make-in-India’? The Government’s recent Make in India initiative is a welcome step to boost the Indian manufacturing sector, which has the potential to account for 25-30% of the country’s GDP by 2025, as per a recent report by Mckinsey and Company. As the Indian government aims to increase

the share of manufacturing in the GDP of the country and to create smart sustainable cities where manufacturing will be the key economic driver, we believe local businesses will be more ready to adopt 3D printing technology too. Stratasys is looking forward to working with Indian companies to accelerate their go-to-market plans with the aid of 3D printing solutions and applications. Additionally, continued Research & Development efforts to improve existing technologies, while discovering new ones like 3D printing, will help provide optimized solutions for businesses and allow Indian industries to reach new heights. When it comes to Additive Manufacturing, India is still lagging behind its global counterparts. What are the measures Stratasys has initiated to ensure Quality Solutions in AM? As a leading industry player, Stratasys has always been at the forefront of the global and local 3D printing markets, and India is one of our key focus regions in Asia Pacific. We

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see additive manufacturing as part of the Next Industrial Revolution that empowers both personal manufacturing and customization in products. Stratasys focuses on the professional market in India, but through our subsidiary, MakerBotÂŽ and GrabCAD, we provide a very comprehensive ecosystem to serve different customers and their needs. We aim to challenge the status quo in manufacturing, health care, defense research and development by allowing innovation early and thereby broadening horizons of traditional manufacturing processes. Where do you want to see Stratasys in the next five years? We believe that the proliferation of 3D content, advancements in AM

technology platforms and the introduction of improved materials will continue to drive growth in 3D printing. We intend to invest in the identification of new applications (especially DDM applications) for which our proprietary printing technologies and materials are appropriate. In addition, we seek relevant niche applications where Additive Manufacturing can provide substantial value, and develop a comprehensive solution to address these opportunities. We also intend to encourage existing and potential customers to identify new applications in part by increasing awareness of the features of our technology and product offerings across healthcare, manufacturing, aerospace, automobile and other sectors.

Tell us about the inception of Stratasys Ltd as well as Stratasys India. Stratasys was the merger of two leading 3D printer manufacturers, Stratasys Inc. and Objet Geometries. Founded in 1989 by Scott Crump in the U.S., Stratasys first developed FDM (Fused Deposition Modeling) technology which was patented in the U.S. in 1992. A few years later, Objet Geometries was established in 1998 in Rehovot, Israel, offering high-resolution PolyJet 3D printing solutions. Stratasys and Objet merged in 2012 to combine efforts in bringing a wider range of 3D printing solutions to customers. The company acquired MakerBot Industries, a leader in desktop 3D printing, in 2013 and set up Stratasys Direct Manufacturing,

a merger of three leading 3D printing service bureaus that became another strong arm of Stratasys, offering advanced manufacturing solutions to the market. Together with two cloudbased collaboration platforms, Thingiverse and GrabCAD, Stratasys provides a complete 3D printing ecosystem to serve different needs of professional enterprises, local companies and individuals. Stratasys has been doing business in India for over 15. The establishment of its Experience Center in Bangalore in April 2015 further exemplifies Stratasysâ&#x20AC;&#x2122; commitment to the fast-growing Indian market, allowing our customers to see our innovative technologies in action and realize the values and advantages of 3D printing technology.

3D Printing Solutions to Customers

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October 2015

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MAIN FEATURE

3D Printing: Growth is Endless

Harsh Juthani Co-Founder, Trikolaa Mr Harsh juthani is an Indian entrepreneur and the Co-founder and CEO of Trikolaa tech. At the age of 22 he completed his B-tech in mechanical from Symbiosis and then later he worked in HP for a year and then he realized job never Intrigued him. So that’s is how he ventured into business and started his entrepreneur journey at the age of 23.Since the very start he was interested in new technologies and various electronic gadgets so he came up with 3D printers.

Can you brief about the endless opportunities of 3D Printing? Rapid prototyping was invented way back in 1980’s. Since than this industry is been evolving rapidly with new process & techniques. Every invention is like birth of child, after which just as

child evolves so does the technology. Considering 3d printing technology it’s like upbringing a celestial & immortal child , this is where the term endless comes. It simply means endless research-development-growth which leads to opportunity.

In few years of time you will see 3D printers in every Industry and every home for endless use. From product prototyping the Rapid Prototyping industry witnessed revolutionary changes and now offering user based products through Additive Manufacturing and 3D Printing. Can you please

throw some light about the technology shift? Rapid prototyping (RP) process was originally conceived as a fast & more cost effective method for prototyping. In real terms 3d printing can be traced back to 1986, when the first patent was issued for STEREOLITHOGRAPHY

3D Printing Started From Industrial Use Then To Commercial Use & Now This Open Source Technology Is Consumer Stuff.

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October 2015

Architectural Modeling

3d Selfies

(SLA). This patent belonged to Charles Hull, who 1st invented in 1983. Hull went to co-found 3D SYSTEMS CORPORATIONone of the most profiled organisation in 3d printing sector today. In 1987, Carl Deckard, filed patent in Us for SELECTIVE LASER SINTERING (SLS) RP process. In 1989 Scott Crump, cofounder of Stratasys Inc. Filed a patent for FUSED DEPOSITION MODELLING (FDM). In this way things started from prototyping i.e 3d printing started from industrial use

then to commercial use & now this open source technology is consumer stuff. And off course growth is endless. The solutions Trikolaa is offering on 3D Printing in various arenas of engineering manufacturing like Casting, Moulding etc? TRIKOLAA TECH is the leading manufacture of 3D printers and service providers in India. After effectively assessing various needs of customers, our firm TRIKOLAA got incorporated in the year 2014. We offers our own line of 3D printers & filaments -

We provide latest generation technology products for industrial and related areas. This gives us an edge over the conventional technologies in inspection & design. These presented products are easy to use and do not require maintenance up to several years. Hence, we can proudly say that, we have well defined processes to ensure high efficiency, high productivity and faster response time. We Believe in quality thus we provide the best end product to the customer with all the process done by us from the design to product development and then post process. Our services :

1. Rapid prototyping 2. Architectural modeling 3. Jewellery model making 4. 3d selfies 5. Workshops for 3d printing technology. 3D printing opens more vistas for progress in content creation and engineering. Can you please more about this? 3D printing is Ideas to Reality. A machine of a size of microwave can create wonders. This is a serious boon for designer because now they can actually see their products done with modelling at considerably less cost with same fit & finish as designed.

â&#x20AC;&#x153;In the end, all business operations can be reduced to three words: People, Product, and Profits and for me good design is good businessâ&#x20AC;? Luv Dedhia Partner, Trikolaa Tech

October 2015

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Architects can create their miniature models with complete interior presentation saving their time, money & most important efforts. In current generation everything is practical and people want to see and feel the product rather than looking in computer or just an image thus 3D printing has created this arena of content creation. Major achievements by Trikolaa? Trikolaa has conducted various workshops all over India and have sold Printers all over India. We have made our awareness not only in west India but even North and East. In service Industry we Work for lot of big companies and have help them in creating new technology and new products. We have made various architecture models of size around 15’ Ft and we have even worked with Local Hospitals to create model of bone and vertebrae, Still we have lot to do as we think we have lot to achieve. How ‘Make-in-India’ can change the course of

manufacturing in our country? Our hon. Pm initiated this epic run. Unfortunately according to me real initiatives & not been taken to prove the word. Government is trying to bring more & more FDI & MNC’S instead of supporting our national industrialists & making some special policies of dying small scale & suffering medium scale industries & organisation. FDI will surely increase & national revenue & create job opportunities, but in search of light one can surely not burn his house. Similarly progress of our people is real progress of nation. Off course main turn on is youths are motivated & many of them are striving to have their own start-ups. This is really good positives of make in India. I wish our company become milestone in this make in India event & become motivation for budding entrepreneurs. When it comes to Additive Manufacturing, India is still lagging behind its global

counterparts. What are the measures Trikolaa has initiated to fill this gap? Problem in India is change which is not accepted easily. Another thing is industrial atmosphere in India is not designer friendly, purpose is more valued than the way object looks. But our consumer is really getting smart & is craving for looks & performance as package. Thus we are acting as bridge between consumer & industry for which we are focusing on marketing & publicity of 3d printing technology.

and thus our journey started we went on to create our own firmware and our own line of Printers and then after finding success with our product we started to push ourselves in service industry were in we found a huge opportunity to capture the market thus we set ourselves in service sector and as time passes we have put our grooves in service industry. The journey Is on and so is our passion for our work and as far as success is considered I don’t find myself successful until I achieve my goal and my goal would be my success and then we will be having our success story.

Where do you see Trikolaain the next five years? SKY IS THE LIMIT...we give our best efforts rest is karma ;) Tell us about the inception of Trikolaaand your success story? Trikolaa was a dream of two students who thought to create technology in India itself and thus we started our journey and formed Trikolaa which got incorporated in 2014

We Have Even Worked With Local Hospitals To Create Model Of Bone And Vertebrae.

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October 2015

Submit Your Application Now for the International Additive Manufacturing Award Prize-giving ceremony at the METAV 2016 in Düsseldorf

The application procedure for the International Additive Manufacturing Award (IAMA) – the international award in the field of 3D printing – has begun. For what is already the second time, the two trade associations, the AMT and the VDW (German Machine Tool Builders’ Association),will be honouring fit-for-purpose innovations in additive manufacturing for industrial use. These include developing machinery concepts and important components, progress in machining processes and in material machining, new applications, data processing and measurements for quality assurance. The closing date for applications is 7 December 2015.

The application procedure for the International Additive Manufacturing Award (IAMA) – the international award in the field of 3D printing – has begun. For what is already the second time, the two trade associations, the AMT and the VDW (German Machine Tool Builders’ Association), will be honouring fit-forpurpose innovations in additive manufacturing for industrial use. These include developing machinery concepts and important components, progress in machining processes and in material machining, new applications, data processing and measurements for quality assurance. The closing date for applications is 7 December 2015. The accolade will be awarded under the aegis of the METAV 2016 – 19th International Exhibition for Metalworking Technologies –in Düsseldorf during

October 2015

February 2016.The application documents can be downloaded from the internet under www.additive-award.com System manufacturers, users, component suppliers, data modellers and international academics are invited to apply.The applications will be scrutinised by an international jury with high-ranking representatives from the industrial sector, the academic community, the important customer grouping of medical technology users, media and trade associations. The winner receives 20,000 US-dollars in cash, plus a media package worth 80,000 US-dollars for publicising the innovation concerned. “Additive manufacturing will be one of the trends radically transforming the production processes of the future: it has meanwhile evolved into an autonomous technology

that opens up new options to the industrial sector for manufacturing complex parts, in series if necessary,” said Dr. Wilfried Schäfer, Executive Director of the VDW. “With the IAMA, we are aiming to position current innovations and creative solutions in the field of additive manufacturing from an international viewpoint. Following a successful debut this year, we are already looking forward to numerous national and international project submissions on all subjects involved in the value creation chain,” emphasised the AMT’s President Douglas K. Woods.

thus enables metalworking,

The winner of the first IAMA in 2015 was the American firm Hybrid Manufacturing Technologies. The company’s innovation is a hybrid kit that can be integrated into any metalworking CNC machine: laser deposition welding

network for bringing together

finishing and checking of parts to be performed in a single machine. Here, conventional CNC technologyis combined with additive production processes, thus opening up new scenarios that hitherto neither of the two technologies was able to offer by itself. The AMT and the VDW joined forces to inaugurate the IAMA in 2014, since the USA and Germany are key markets in the field of additive processes. This applies for the creation, use and researching of the process. Both partners possess the requisite competence and the the international sector within the framework of this initiative and supporting mutual feedback between experts. Further information under: www.additive-award.com

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MAIN FEATURE

Additive Manufacturing of Gripper Fingers Saves Time and Costs

The expense for the design and manufacture of application-specific gripper fingers is still often underestimated. Depending on the component geometry, an experienced design engineer often needs several hours for one pair of fingers. The production process itself can also be complex and costly. A patent pending web tool from SCHUNK shortens this process to a fraction of the time previously required. SCHUNK eGRIP needs only minimal data for the fully automatic calculation of the optimal 3D contour, the price and the delivery time. Once the order is placed, the additively manufactured fingers are delivered within only a few days - faster and less expensive than ever before.

Online shop for gripper jaws The expense for the design and manufacture of applicationspecific gripper fingers is still often underestimated. Depending on the component geometry, an experienced design engineer often needs several hours for one pair of fingers. The production process itself can also be complex and costly. A patent pending web

tool from SCHUNK shortens this process to a fraction of the time previously required. SCHUNK eGRIP needs only minimal data for the fully automatic calculation of the optimal 3D contour, the price and the delivery time. Once the order is placed, the additively manufactured fingers are delivered within only a few days - faster and less expensive than ever before.

SCHUNK has been exploring the (virtually) unlimited capabilities of additively manufactured gripping system components since 2005. The company thoroughly examined the different generative production methods to determine how they can be used in handling and assembly. Series of tests were conducted to analyze the behavior of flexure mechanisms, the

dependency of the mounting direction, and the recovery properties. In cooperation with the Fraunhofer IPA, SCHUNK also tested and optimized robot grippers manufactured with generative processes. The result is convincing: additive manufacturing produces gripper components that are lightweight, wear-resistant,

Additive manufacturing of SCHUNK gripping system components offers new capabilities in handling.

After uploading the STEP or STL files the patent pending web tool automatically generates the optimal 3D contour of the gripper fingers.

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October 2015

Just a few days after placing the order the additively manufactured gripper jaws are delivered

The SCHUNK eGRIP gripper fingers are equally suitable for assembly applications and machine loading.

and extremely adaptable. They allow room for creativity in the development of standard modules and custom, application-specific solutions. Complex geometries can be implemented Undoubtedly the biggest advantage of additive manufacturing is the enormous freedom with respect to the component geometry. Design engineers do not have to watch out for draft angles or undercuts, which allows them a high degree of design creativity. For example, the channels for power supply, signals or compressed air can be integrated directly in the grippers. Complex components that would require a great deal of cost and effort to implement using conventional methods are comparatively easy with

the additive method. And even moving parts such as hinges can be manufactured as one piece. Direct generation of the components in the CAD system also significantly reduces the production time. The advantages of additive manufacturing with respect to time and costs are especially evident in the case of custom solutions produced in small quantities. The low weight of the polyamide modules also generates other effects: the lightweight components provide optimal conditions for the reduction of cycle times and energy consumption and for the use of smaller robots and handling systems. For several years already SCHUNK has been using modern laser sintering systems

to manufacture diverse modules from lightweight and wear-resistant polyamide 12 in a non-cutting process. The product spectrum includes grippers with a closed drive membrane for hygiene-critical applications, individually formed and on request also flexible fingers, quick-change systems that can be directly integrated in grippers or gripper fingers and that can even be equipped with media feed-throughs, as required. Even complex contours or individual labeling are possible at no additional cost. Since polyamide is resistant to chemicals and suitable for use with foods, it can also be used reliably in connection with aggressive media and in the food industry. Automated customization

While SCHUNK gripper components produced with additive manufacturing processes so far have had the character of custom solutions, the browser-based SCHUNK eGRIP 3D design tool now automates the entire process, from engineering to the completed finger. Similar to using an online photo service the user configures the desired gripper fingers by uploading his own file (STEP or STL) and specifying diverse variables, such as gripper type, weight, installation position of the gripper and finger length. Before completing the order the tool displays the exact price and delivery time, therefore guaranteeing maximum transparency of the order process. Users can either order the top jaws right away or save the offer for later retrieval to

â&#x20AC;&#x153;From numerous projects we know how much engineering design and production time is needed, especially for complex gripper fingers. Depending on the component geometry, an experienced design engineer needs from two to eight hours for one pair of fingers.â&#x20AC;? Ralf Steinmann Business Unit Manager Gripping Systems, SCHUNK

October 2015

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place an initial or follow-up order. In addition, the outer contour of the generated assemblies, consisting of the gripper, top jaws and workpiece, can be downloaded in STL format for immediate use in the system design. The first version of the design tool, which went online in early 2015, includes top jaws for the SCHUNK PGN-plus 40 to 125 universal grippers, the SCHUNK MPG-plus 20 to 64 small component grippers, and the SCHUNK EGP 25 to 40 electric small component grippers. The attractively priced top jaws are manufactured within a matter of days of lightweight, wearresistant polyamide 12, either in the colors white or black. For use in pharmaceutical and medical applications, top jaws are also available in FDAapproved polyamide 12. Since polyamides are resistant to chemicals and suitable for use with foods, they can also be used reliably in connection with aggressive media. Three-fold savings potential “From numerous projects we know how much engineering design and production time is needed, especially for complex gripper fingers,” explains Ralf Steinmann, Business Unit

Manager Gripping Systems at SCHUNK. “Depending on the component geometry, an experienced design engineer needs from two to eight hours for one pair of fingers.” SCHUNK eGRIP should now reduce the time needed to about 15 minutes. The knowhow and the software for design of the gripper fingers are entirely from SCHUNK. A patent on the underlying process has been applied for. The actual additive manufacturing is performed by Materialise GmbH, one of the world’s leading pioneers in 3D printing, with whom SCHUNK has concluded an exclusive contract. The two companies have invested about one year of development time, and a six-digit figure in the tool. The result is convincing: the design time for gripper fingers is reduced by up to 97%. The production and delivery time are reduced by up to 88 %. In addition, the finger price is reduced by up to 50%. SCHUNK eGRIP is especially worthwhile in assembly systems requiring numerous grippers with different geometries. “In the case of a rotary table with 12 stations and 12 different pairs of fingers, savings between € 2,400 and € 9,600 are possible,

SCHUNK eGRIP finger designer Program language:

English

Gripping modules:

- SCHUNK PGN-plus universal grippers, sizes 40 to 125 - SCHUNK MPG-plus small component grippers, sizes 20 to 64

3D data:

STEP or STL

Software:

browser-based, no installation necessary

Material:

- Polyamide 12, white or black, extremely wear-resistant - Polyamide 12, food-safe, with FDA approval for use in medical and pharmaceutical applications as well as food handling

Savings potential:

- Reduces the design time for gripper fingers by up to 97% - Reduces the delivery time for gripper fingers by up to 88% - Reduces the price for gripper fingers by up to 50%

Planned configurations:

Other series from the SCHUNK gripper portfolio

Tutorials on YouTube:

www.bit.ly/1M05a7j

depending on the geometry and individual requirements,” Ralf Steinmann explains. Over a period of six months test customers, including experienced SCHUNK design engineers, tested the system thoroughly. On the basis of their feedback it was possible to further optimize the user interface, the intuitive operation and the logic of the program. The program flow is now structured so that the user

is guided step-by-step through all required actions. Attractive terms additionally facilitate the introduction to the software. The experience with SCHUNK eGRIP is so promising that SCHUNK is already considering offering the design tool in multiple languages and expanding it to include additional gripper series. For more details visit www.in.schunk.com

In the first phase, the design tool is available for the SCHUNK universal grippers PGN-plus 40 to 125 and for the SCHUNK small component grippers MPG-plus 20 to 64.

SCHUNK eGRIP reduces the engineering design and ordering time for individually shaped gripper fingers to only 15 minutes.

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October 2015

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MAIN FEATURE

An Intelligent Strategy for Achieving Excellence: MTU Relies on Additive Manufacturing for its Series Component Production

15 % less fuel consumption – this is the primary benefit that the manufacturer Airbus wants to give customers with its A320neo, a new short- and medium-haul aircraft. Achieving the goal requires, above all, more efficient engines. MTU Aero Engines is a primary supplier to the US engine manufacturer Pratt & Whitney and plays a key role in Airbus reaching its objectives. In order to remain at the forefront of technology, the Munich-based experts in aircraft engines actively supports the use of innovative production processes. Additive Manufacturing plays an important role here, as shown in the manufacture of borescope bosses - access points for inspecting turbines - a product for which MTU relies on EOS technology.

Challenge The aerospace sector is one of the most innovative in the world. Airbus applied for over 380 patents for the design of the A380 alone. New materials and technologies that are suitable for series production have an important role to play in this industry for reasons

that include cost, weight and func-tion. Because of this, both manu-facturersand suppliers are testing the performance capabilities of Additive Manufacturing processes, by which components are produced when a powder is hardened, layer by layer, using a laser. This method was originally used in the manu-

facture of prototypes as it allows for the fast production of individual parts. Due to its many advantages, however, the technology has since establisheditself as a staple in series production. The advantages associated with this process include increased design freedom as well as a wide range of useable raw

materials, from extremely light, fire resistant/flame retard-ant plastics to a variety of metals. Generally, the moment an aircraft takes to the skies, both cost and safety pressures become significant driving forces. It is therefore important to choose the right middle ground when introducing new technologies. MTU Aero

Additive manufactured borescope bosses from MTU Aero Engines for the high-speed, low-pressure turbine of the Geared Turbo Fan engine PurePower® PW1100G-JM, which will power the A320neo (courtesy of MTU Aero Engines).

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October 2015

Manufacturing at MTU: One of the seven EOS systems that produces series components for engine construction (courtesy of MTU Aero Engines).

Engines, Germany‘s leading engine manufacturer, took a strategic step-by-step approach towards the use of Additive Manufacturing. The company currently uses seven EOS machines. “About ten years ago, we began with the manufacture of tools and development components,“ says Dr. Karl-Heinz Dusel, Director of Rapid Technologies at MTU. “In order to optimise capacity u tilisation and implement our phased plan, we went in search of further areas where we could apply the technology.“ The principal challenge consisted of cost and safety considerations on the one hand, and the pursuit of strategic innovation on the other. Solution Borescope bosses will be used on the latest generation of engines – the Geared Turbo Fan (GTF) – and they will be manufactured using EOS machines. “At the beginning of the second phase we started to produce raw components, which replaced existing parts. The bore-scope bosses for the low-pressure turbines of the A320neo-GTFs fell into this

October 2015

category,“ explains Karl-Heinz Dusel. These small add-on components allow technicians to check the condition of turbine blades inside the engine using endoscopes. The parts are riveted to the turbine housing to create an opening for the e ndoscope, which in the aerospace sector is termed a borescope. Heat resistance and durability are the key characteristics of the nickel-based alloy that was used. This high-quality material achieves the best results demanded by the compo-nent, but it is difficult to machine. Fortunately, a problem like this is easily overcome with Additive Manufacturing. As MTU is also a producer of raw materials, the company was able to develop a new process chain, which has been approved and integrated into the manufacturing system. The entire manufacturing pro-cess is underpinned by a control system specifically developed by MTU. Online monitoring captures each individual production step and layer. In addition, new quality assurance procedures were intro-duced, such as optical tomog-raphy. The German

Federal Aviation Authority even certified the EOS machines. In the past, the borescope bosses were cast, or milled from a solid, but the low-pressure turbines for the A320neo’s Geared Turbo Fan are the first turbines to be serially equipped with borescope bosses produced using Additive Manufacturing. Above all, it was the cost advantages of the EOS technology that were the decisive factor, both in the production itself and in the development stages. Results The strategic approach paid off for MTU, as did the close and positive collaboration with EOS. Preparations for the series production of the borescope bosses have now begun. 16 parts per job are envisaged, totalling up to 2,000 parts per year. The savings in percentage terms, com-pared to previously established processes, is expected to be in double figures and quality is already at a high level. MTU and EOS are working together to further optimise the finishing for the component, especiallythe smooth surfaces, with the aim of achieving perfection in the struc-tural mechanics.

For Dusel, the advantages are clear: “The EOS technology is characterized by its virtually unlimited design freedom and the significantly shortened develop-ment, production and delivery times. In addition, development and production costs are dras-tically reduced. Components of lighter weight and greater com-plexity can be made a reality and production requires less material and minimal tools.“ MTU sees a lot of potential for the manufacture of further series components for aero engine construction, such as for bearing housings or the blades for turbines – both of which need to meet the highest demands in terms of safety and reliability. MTU‘s aim: Within 15 years a significant proportion of compo-nents should be manufactured using industrial 3D printing. The EOS technology thus contributes to the competitiveness of the company, which is active in one of the most demanding sectors in the world. For Further details visit www.eos.info

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MAIN FEATURE

Pioneering Additive Manufacturing Reshapes Patientâ&#x20AC;&#x2122;s Face Additive manufacturing (3D printing) is changing and improving many traditional industries and processes. Healthcare is no exception with reconstructive surgery being particularly prominent. A horrific motorcycle accident left Stephen Power with multiple skull fractures that changed his life and meant he would require reconstructive surgery.

Samina Khalid Samina.Khalid@renishaw.com

Professor Adrian Sugar, a consultant in Cleft and Maxillofacial Surgery at Morriston Hospital in Swansea, UK was keen to push the boundaries of his profession and embrace new techniques

and processes, in order to

on recovery rather than

for Applied Reconstructive

help Stephen.

appearance, Stephen would

Technologies in Surgery

require subsequent surgery to

(CARTIS) in South Wales, to

restore symmetry to his face.

develop surgical guides.

to reconstruct his face.

Renishaw worked in

Soft tissue incisions and

However, with an emphasis

collaboration with the Centre

bone positioning can involve

Stephen had already undergone emergency surgery

Stephen Power and Professor Adrian Sugar in front of a Renishaw AM250 machine

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October 2015

Figure 1. Cutting guide

Figure 2. Repositioning guide

freehand incisions making this type of surgery more complex than perhaps it might otherwise be and with less predictable outcomes. Surgical guides were created to overcome this. Although the surgical procedure itself was still time consuming and onerous, professor Sugar felt that the guides, which were

manufactured on a Renishaw

presents. This planning,

Stephen’s response was even

AM250 metal 3D printing

together with the surgical

more emphatic: “It is totally

machine, made the surgery

guides, made for a near perfect

life-changing.”

quicker and more accurate.

fit for two permanent implants

Prior to surgery plans were

and a more efficient operation.

Surgery took place to put Stephen’s cheek bone back

drawn up to decide where

Professor Sugar felt that the

into place. The use of custom

to make bone incisions, and

guides resulted in a more

surgical guides is still in its

custom made guides were

predictable outcome and said,

infancy with a number of steps

made in order to remove

“I think it’s incomparable - the

required to reach the final

results are in a different league

outcome.

some of the guess work that this type of surgery inevitably

from anything we’ve done before.”

In order to achieve symmetry

Figure 3. Repositioning guide with implants in place

October 2015

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in Stephen’s face, the surgical team took computerised tomography (CT) scans of his head. The CT data allows the surgeons to assess the state of his skull and plan the surgery. This “pre-operative” CT data was fed into a powerful computer aided design (CAD) package which allowed the team to design the “postoperative” bone structure that would achieve the best symmetry. Using the pre-operative and post-operative design data, two metal guides were designed and produced for each stage of the surgical process: a cutting guide and a repositioning guide. The

cutting guide (figure 1) was

were removed. The additive

used to cut the zygomatic

manufacturing process allowed

(cheek) bone, in specific

Professor Sugar more flexibility

locations, so the bone

in the design of the guides and

sections could be used in a

implants.

cheek reconstruction. The repositioning guide (figure 2) allowed the bone sections to be placed in their final location before placing a zygomatic implant and orbital floor (figure

Stephen commented that he would “be able to do day-today things, go and see people, walk in the street, even go to any public areas.”

3). The zygomatic implant

The project was the work

holds the repositioned bone

of the Centre for Applied

sections in position and allows

Reconstructive Technologies

them to heal, whilst the orbital

in Surgery (CARTIS), which

floor lifts the eyeball so that it

is a collaboration between

is level with Stephen’s other

Abertawe Bro Morgannwg

eye. The titanium implants,

University Health Board’s

printed in Belgium, remained

Maxillofacial Unit at Morriston

in place once the guides

Hospital and the National

After emergency surgery

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Centre for Product Design and Development Research (PDR) at Cardiff Metropolitan University. Renishaw supplied the cutting and placement guides which were 3D printed in cobalt chrome alloy on a Renishaw AM250 additive manufacturing machine. Renishaw is the only UK manufacturer of a metal 3D printing machine. Designing and developing the machine at its Stone (Staffordshire) and Gloucestershire sites, and manufacturing the machine at its site in Miskin near Cardiff. For more information visit www.renishaw.com

After implant surgery

October 2015

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MAIN FEATURE

Additive Manufacturing In Finished-Part Quality In times of ever shorter product life cycles and increasingly more complex and more individualised bespoke components, additive manufacturing processes can help companies to manufacture produce new and innovative products more quickly. Additive manufacturing processes enable complex geometries and workpieces to be produced. The unique technology combination of laser metal deposition by means of a powder nozzle and milling gives the user completely new application and geometry options. With the LASERTEC 65 3D, SAUER LASERTEC offers a hybrid solution for combined laser deposition welding and 5-axis milling. This method uses a deposition process by means of a powder nozzle, which is up to 20 times faster than generation in a powder bed.

Ankur Agarwal ankur.agarwal@dmgmori.com

The market for additive processes has grown rapidly in the past. However, up to now, these have been restricted to the production

of prototypes and small parts, which otherwise could not have been manufactured using any other conventional method. With the

combination of the two processes, metal deposition and chip removal, on one machine, additive technology supplements and enhances

traditional machining methods. For generative manufacturing, the LASERTEC

LASERTEC 65 3D

With the LASERTEC 65 3D, DMG MORI presents a machine, which is currently unique and incorporates laser deposition welding into a fully-fledged 5-axis milling machine

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October 2015

65 3D is equipped with a

component geometry, to be

2 kW diode laser for laser

machined to final accuracy.

deposition welding, while the fully fledged 5-axis milling machine from DECKEL MAHO in robust monoBLOCK® design also enables highly accurate milling operations to be carried out. “Thanks to the fully automatic changeover between milling and laser operation, the LASERTEC 65 3D is suitable for the complete machining of complex components with undercuts as well as for repair work. It is also ideal for the application of partial or complete coatings for mould making and mechanical engineering or even medical engineering”, explains Friedemann Lell, Sales Director, SAUER LASERTEC, in Pfronten. Producing large parts generatively In contrast to laser melting in a powder bed, laser deposition welding enables large parts to be manufactured using a metal powder nozzle. With a deposition rate of up to 3.5 kg/h, this process is up to approx. 10 times faster than the laser generation of parts in a powder bed. The combination with milling opens up completely new

The hybrid machine combines the advantages of milling, such as high precision and surface quality, with the flexibility and high deposition rate of laser welding. “In the case of some components, where today 95 % of the material is removed by milling, with additive processes, material is only built up where it is needed. As result, material loss is reduced to 5 %. This leads to significant raw material and cost savings”, explains Friedemann Lell. The laser, complete with powder deposition head, is fitted into the HSK toolholder of the milling spindle. It can be automatically parked in a secure docking station while milling operations are being carried out on the machine. The machine is controlled by means of a 19” ERGOline® with Operate 4.5 on SIEMENS 840D solutionline. The controller for the laser process is mounted in a separate electrical cabinet, which makes it easier to integrate this system into other DMG MORI machines. Production of 3D contours

applications. The component

By means of a laser diode, the

can be built up in several

metal powder is deposited in

steps, whereby milling can be

layers onto a base material,

interspersed with deposition

and fuses with it without

welding in order to allow

pores or cracks. In doing so,

areas, which the cutter

the metal powder forms a

would no longer be able to

high-strength welded bond

reach when the component

with the surface. A coaxial

was finished due to the

inert gas prevents oxidation

October 2015

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during the build-up process.

successively build up layers

many interesting options for

After cooling, a layer of metal

of different materials in lines

lightweight components,

which can be mechanically

of 1.6 mm and 3 mm are

prototypes or small batches

machined is produced.

possible depending on the

production – particularly in

nozzle geometry. Complex

the large-part manufacturing

3D contours can also be

sector where other additive

generated in layers without

manufacturing processes

supports.

cannot be used due to limited

As laser deposition welding has long been established as a stand-alone technology, it is ideal for incorporating into

space.

DMG MORI’s high-quality CNC

The individual layers can

machines. “The combination

then be accurately machined

of chip-removal and additive

before the areas become

processes will become more

inaccessible to a cutter

important in future, as it

or other tools due to the

opens up many new options

component geometry.

and advantages for the user”,

The combination of the

the energy or aerospace

says Lell.

two processes is a sensible

industries, tend to be

choice for repair work and

expensive. If roughing,

the production of mould

deposition and finishing are

tools. However, it also offers

reduced to a single machine,

One strength of this process is the option to

Economical solution Large machines, such as those used for machining bulky components in

this represents a financially advantageous solution for the customer. Furthermore, in the energy and oil industry, components often have to be coated with corrosion-resistant alloys to protect against wear. Deposition welding provides protection for products such as tubes, fittings, flanges and special products which are used in aggressive environments. With a hybrid machine, machining of the base material, coating and finishing can be carried out on one machine. This results in cost savings and a reduction in throughput times.

• Unique combination of laser metal deposition and milling provides optimum surface finish and component precision • Laser deposition welding with powder nozzle: approx. 10x faster than powder bed processes • Ability to produce complete components • Many 3D geometries, including undercuts, can be realised without supporting structures • Repair of turbine components and in tool/mould making • Application of wearing surfaces • Complete machining with fully automatic changeover between milling and laser operation • Large work area for workpieces up to Ø 500 mm, 360 mm in height and max. 1,000 kg • Accessibility and ergonomics: Door opening 1,430 mm, optimum access from the front • Low space requirement with 7.5 m² footprint

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October 2015

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ON FACE

Energy Conservation is the Mantra of the Day

Beko as a world leader in Air & Gas technologies believes in innovation and constant changes in the offerings of its new products. In India, Beko is trying to meet the challenges to offer cost effective products without compromising with its quality. Today Bekoâ&#x20AC;&#x2122;s product portfolio is broadly classified into Condensate management, Filtration, Drying system and Measurement & Process instruments. Excerpts from the conversation with Mr. Eric Purushothaman

Eric Purushothaman Managing Director, Beko

Berthold Koch invented BEKOMAT in 1982 the first step of Beko. Can you put some light on your inception and the start of Indian operations? Beko, being a high technology company, believes in constantly offering new technology to the market. Since its inception by late Mr. Berthold Koch to name

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a few innovations like deep cooling systems (BEKOBLIZZ) for the blow moulding industry and the Catalytic Convertor (BEKOKAT) based oil removal from compressed air, which in turn delivers totally oil free compressed air. The Indian operation started in January 2002 in a very small

way. The BEKO Technologies GmbH, Germanyâ&#x20AC;&#x2122;s success story across the globe was a motivating & inspirational factor, which helped BEKO India, grown into a company, what it is today. Today BEKO India is a leader in the high pressure business in the country. We also dominate the major industrial segments like

pharmaceutical, CNG, Defence etc. The challenges Beko India faced to establish its operations in the price competitive Indian market? One of the goals of BEKO India was to offer high technology compressed air

October 2015

BEKO Compressed Air Technologies

& gas treatment products at a reasonable & affordable price to the Indian market. The currency and the market conditions were not at all conducive. Hence we embarked on an aggressive localization plan which then made our prices highly competitive in the market place. This had a twin benefit of being competitive in the price sensitive market & also making our products attractive for a buy back arrangement with our Principles in Germany. Can you brief about your current organizational strength in India? Over the years we built a very sound & strong Engineering, Supply Chain Management, Marketing team. BEKO India has always believed in providing its employees training programmes to enhance their skills, which help the Organization to reach high efficiency levels. All our employees at the

October 2015

Senior Management & Middle management levels have been trained in BEKO Germany. With regard to our Engineering team, we design & develop products which are released in the Indian & Global Market.

quality systems and are the only dryer manufacturer in the country to have an in-house pneumatic testing facility of 450 bar.

Beko stands for Safe, Clean, more Effective – optimised compressed air technology. Can you brief on this and your product portfolio?

Moisture Separators Micro Air filters High pressure Micro Air filters

Every product in the BEKO range is engineered to be a energy saving product be it the zero air loss level sensor auto drain ,micro filter or the dryers. In terms of safety and cleanliness, we treat condensate to ensure safety to the environment.

BEKOMAT-No air loss electronic level sensor based condensate drain

Today our product portfolio is broadly classified into Condensate management, Filtration, Drying system and Measurement & process instruments. Our organisation is a ISO 9001 2008 company. We have invested a lot on

DRYPOINT Drying Systems:

Filtration (clearpoint):

Condenste technology:

OWAMAT- Oil Water Separator” BEKOSPLIT- Emulsion Splitting Plants

Air dryers – Heatless regenerative type, up to a dew point of -60 deg.C Air dryers – Refrigeration type, up to a dew point of + 3 deg.C

Air dryers – Membrane type suitable at point of use with a compact space METPOINT Measuring Instruments & Process Instruments: Dew point meters Flow meters with METPOINT BEKO Data Logger (BDL) METPOINT LKD -Compressed Air Leak Detector METPOINT OCV –Online Oil Monitoring System BEKOBLIZZ- Deep cooling systems” BEKOKAT- 100% Oil removal systems Your market share in India and major clients? In the organised sector we enjoy a 12% market share in the entire range of products whereas in high pressure systems we enjoy a market share of 90%. The major customers are in the

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Pharmaceutical, Automobile, CNG, defence, Compressors manufacturing OEM Segment. Manufacturing industry is going through a rapid transformation globally as well as in India. What innovative initiatives Beko has implementing in its production facility to stay ahead in the competition? To make ourselves more efficient & competitive we have made changes in our manufacturing by going for automation. The process in certain areas has been changed to ensure higher efficiency. Indian industry, on a large extent, comprised of SMEs who cannot provide high end technologies. What cost-

effective products are in range from BEKO to this segment? Going by the market requirement our products are designed & developed to meet the market’s requirements. The products are highly efficient. Every product has a quick return of investment & hence SMEs buying those products know that they would make their money back within a very short time and hence this return of Investment brings in a lot of interest in SME’s though they have initially higher investment to make in certain cases. ‘Make in India’ has created a lot of buzz in Indian manufacturing. What are the steps BEKO is planning to take to seal this positive sentiment?

Make in India is a very positive

Your advice to budding

initiative taken by the Indian Prime Minister Shri. Narendra Modi. This has clearly evoked a lot of response from the existing Multi-Nationals in India who are ramping up their production as well as looking at setting up green field projects. We at Beko have always been looking at indigenising the BEKO Products ensuring that more & more products are available to the customers at a reasonable price.

engineers in India?

Where you see Beko India in the next five years? BEKO: We are working on well-defined goals. We should see ourselves as leaders in the other business segments like engineering, power etc.

Our advice to the young Engineers is to stay in our country and work towards building this great nation rather than going out of India to stay and contribute. The country offers good opportunity for aspiring engineers to realize their dreams. Eric Purushotham is the Managing Director of BEKO Compressed Air Technologies Pvt Ltd. He did his graduation in Management and possesses two & half decades of experience in the filtration & drying industry/ Pneumatic industry. For more details you can visit: www.bekoindia.com

Today our product portfolio is broadly classified into Condensate management, Filtration, Drying system and Measurement & process instruments.

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October 2015

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MANUFACTURING EXCELLENCE

Facing Audits of Customers and Third Parties Managing a SME in India - Part 34

Auditing is an art as well as science. With practice, it can be learnt. As a continuation of last article on facing audits of customers and third parties, we will discuss on few more points in this second part in our regular series of managing SME’s better in India.

P S Satish gotopssatish@gmail.com

46. Facing audits of Customers and third parties – Part 2 Having understood types of audits, difference between audits & assessments and various purposes companies want to undergo these processes, let us understand in detail process of audits and tips for facing Customer audits. If the Auditee is familiar with the way the Auditor thinks and techniques he follows, it is easier to face the Audit and Auditor. Auditee should put himself/ herself in the shoes of Auditor. Auditing is an art as well as science. With practice, it can be learnt. Let us look at some the qualities the good Auditor should acquire – • Ethics – Integrity, credibility and honesty of Auditor

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should be unquestionable. He or she will access to many company’s sensitive information and these should not be misused • Keen Observer – Auditor should be able to see things which others cannot see. Also ability to evaluate the situation beyond appearance • Independent – Must have his or her own opinion without getting influenced by the environment • Patience and cool headed – Many times Auditor will be shown some irrelevant information. He or she not lose his cool and continue the audit with focus • Persistent – with the objectives without getting distracted by the situations which may distract sometimes

• Versatile – Ability to move from one situation to another without losing the direction • Decisive – Should be able to make a clear decision without ambiguity • Diplomatic – In many situations, Auditor have to explain bitter things about the company which may not be taken in right spirit by the Auditee. Auditor should explain diplomatically • Open minded – Should be willing to listen, learn and accept new ideas. Patient listening is a very important quality for an Auditor. Auditing Techniques Questioning The best in Audit will come out by asking proper questions. This is a skill Auditor has to acquire. He

may start with closed ended questions where answer would be either yes or no. For example, ‘Is this the latest revision?’, ‘Did you contact Customer?’, ‘Did you test this before delivered? ‘. With this, the Auditor can go further with open ended questions where answer would be more of descriptive. For example, ‘What process were followed in revising?’, ‘What was the feedback received from Customer?’, ‘What parameters were checked before delivering the product?’ Another type of questioning that helps the auditor is funneling type. Here you start with a broad based question and keep narrowing till the right answer is obtained. Use of 5W & 1H The auditor should use

October 2015

extensively 5W & 1H namel y,Why?,Who?,When?,Where ?,What? and How? Usage of these in funneling questions will help to get to root of situation. Fixing the Audit Date o Audit of a system or process is not typically by surprise. Give enough notice to the company to be audited o Ensure suitability of date to the Auditee and all required members are present on that day from Auditee side o Let agenda be clear with purpose, timings and members required and any other preparations needed o Indicate in brief how auditing process is going to happen o To save time, some specific questions may be sent in advance to the Auditee Company for a self -audit. After all, audit is an open book examination. o Ensure the Auditee does not have any other Customerâ&#x20AC;&#x2122;s visit on the same day of Audit o Prepare well from your side with drawings, specifications, earlier audit reports and with recent issues if any o Clarify to the Auditee on other members joining you in the Audit o Clarify on the transport arrangements, lunch, coffee arrangements o Inform in advance if there is a plan to visit a sub-supplier

October 2015

Before start and during the Audit - Start on time with an opening meeting with all concerned along with the management team to explain the purpose and process of audit - Give them a message that your visit is on fault finding but finding ways for improvements - Do not hesitate to move across departments if needed - Ensure that the audit process will not stop their day to day work - Smile and show confidence - Do not make any sarcastic remarks - Convince them by explaining properly any deficiency observed - While comparing do not mention name of other company and you may say as Industry standard - Do not pin point at a particular person but focus on process - Be friendly with the team and they will share more points openly Beginning of the Audit Starting point is important to set a tone for the rest of the process. Better to start with results or reports of previous audit if any. The effectiveness of closure of actions will give lot of hints for further probing.

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When a complete manufacturing line is audited which involves many manufacturing processes, focus could be based on process dominance and characteristics matrix. Each process has some parameters as dominant which has high influence on quality. For example, In plastic injection moulding process dominant parameter is Set up of moulds, Machine has dominance in soldering and electronic soldering of PCB, In drilling process fixture playsa major role, in sheet metal components manufacture of tooling is dominant, in assembly operator is the key, in some processes humidity and dust have great influence etc.

then those characteristics are to be controlled closely. APQP manual of AIAG gives guideline on selection of process and characteristics for the process audit.

in our mind. Documentation is not required

Typical remarks from Auditee in Audits

o We wanted to do but we were busy with other Customers

There are some typical remarks that comes out from Auditee to Auditor and these are more of reactions than responses. o We think paper work will not be useful o What is the need for specific process audit when we are already certified for TS16949? o This will work only in big corporate and not for small and medium companies like ours

After clear observations of dominant factors influencing in quality of processes, next step of measures taken to control dominant factor to be probed.

o We have not understood the question. This comes up some often, though questions are sent in advance and known to them

Similarly, it is good to start with observations of characteristics which gets altered in the processes. If a characteristics gets altered in many processes,

o We understood the questions wrongly o We have experience in the process for many years. All are

o Concerned person who implemented the system has left the company

o There is no issue or complaint? Why talk of process and document for this now? o In Indian scenario, it does not work o Thanks for input. We will definitely input ( Positive remark) Typical situations seen in Audits • Last minute preparations with required signatures taken with back dates. • Window dressing made for the audit purpose • Sometimes a doubt will come whether systems are there for the people or the other way round

• Phobia of audits • Sudden change of Auditee who is not mentally prepared • Internal audit done as a fault finding mission in another department • People taking a lawyer approach justifying what is done is correct • Varying interpretation of standards from auditor to auditor • Conflict of interest especially in 3rd party. It is possible that 3rd party auditor may be lenient considering future assignments for them I will continue the series of article in the next issue. Please send your inputs,remarks,suggestions to P S Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q 103, MantriParadise Apartments,Bannerghatta Road, Bangalore-560076. Do visit www.satishps.com. Have a good day.

Auditing is an art as well as science, So let us understand in details process of Audit and tips for facing customer audit

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October 2015

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TALENT MANAGEMENT

Essentials of Business Email Research has found that the average employee spends about a quarter of their time at work combing through the hundreds of emails they send and receive each day. And yet, according to research, over 60% of professionals still don’t know how to use email appropriately.

Pavan Sriram pavan@ittige.com

Despite the growing prevalence of texting, instant messaging apps and social networks in the business world, e-mail remains one of the most popular high-tech ways for modern professionals to communicate. But at the same time, email has always been an insensitive medium. Its mechanical tone of voice has led to humans evolving a whole other language of emoticons to try to reinstate some form of positive emotional contact with their recipients. Positive emotions are an

essential part of humanity and positive morale is good for business. Business leaders place great value on building a healthy team spirit. Even in today’s budget conscious times organizations still invest reasonable sums on so-called team-building days. Yet all this can be undermined in an instant, thanks to a single thoughtless email.

mistakes that could be detrimental in a professional interaction. For example, you can easily miss a spelling error while typing out an email on your smartphone or tablet, or you may come off as too casual or unprofessional in tone or content.

In a 2014 survey looking at all forms of business communication, conducted by CPP, publisher of the MTBI Because people send and receive assessment, they found email so many messages a day, many is the biggest offender when it end up making embarrassing comes to creating resentment

and confusion in the workplace. According to 43% of the survey respondents, of all the communication technologies in the workplace, email is most likely to create resentment between senders and receivers. While 92% agreed email is a valuable communication and collaboration tool, 64% reported having either sent or received an email that resulted in unintended anger or confusion. Top reasons for this include: failure to respond (51%), too many “Reply Alls” (25%), messages that were

Business Email Etiquette Equals Success

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October 2015

An email is a reflection of your thoughts, personality and professionalism

confusing or vague (19%), emails that are too long (12%) and too much email in general (18%). Although over 300 billion e-mails are estimated to be sent every day, however, a surprising number of executives still struggle to grasp fundamental rules of netiquette. In the interest of enhancing interactions with clients, colleagues and customers, following are 10 basic principles of professional e-mail etiquette, all of which can help you better connect and interact with others we encounter in corporate or commercial environs. 1) Keep your subject line to 50 characters or fewer: For courtesy’s sake, subject lines should be short, sweet and directly relate to e-mail contents. Misleading or false statements, or needlessly open-ended or misleading questions or out of topic will be poorly received. 2) Mirroring your email sender is very important: If you are responding to a message from a professional correspondent, follow their lead. If they use, “Dear X,” then you answer with “Dear Y.” If they start with “Hi, X,” then you can use “Hi, Y.” Sign-offs follow the same sort of logic. “Sincerely” can work, but if the correspondence continues

October 2015

with more than one email, you need to get more friendly, moving toward “Warm Regards” or “All the best.” 3) Grammar and abbreviations that have originated in the realm of instant messaging and texting have made their way into email. Even if your co-workers and clients don’t call you out on your use of such shortcuts, avoid using them. An email could get forwarded to another client or a senior manager who may be appalled at your seemingly lack of written communication skills.

7) Proof read and Proof read: Make it a habit to read over every email you ever write before pressing “Send.” read carefully, too, looking for more than just typos. If you are sending the email to someone who is important to you professionally, you might even clean it up by deleting extraneous material from the bottom, or, if it makes sense in the correspondence, start fresh with a new email and a new subject line instead of just hitting reply.

4) Once written, e-mails cannot be undone: Watch what you say, whom you copy, and always think twice before sending them along.

8) When away from your desk for travel or vacations, set an out of office response stating when you’ll return, and the conditions under which you may or may not be checking your inbox.

5) Don’t write anything in an e-mail that you wouldn’t be comfortable saying: in person or in public. Easily forwarded and shared, and/or monitored by employers, inappropriate commentary may come back to haunt you. Professionalism is imperative.

9) If you don’t have an efficient email management in place to tame your inbox, you will be subjected to regrettable phenomenon of people waiting for your long-delayed response to assume you’ve either moved out of the role or don’t like them.

6) Business e-mails should, wherever possible, be confined to working hours: unless you’re working in different time zones and/or continents, recipients may be understandably perplexed to receive emails from you at midnight.

10) Decide Phone or Email: Before sending off yet another email, ask yourself if email is really the right platform to communicate your message. Maybe a phone call or face-toface meeting would be more suitable. If your email is more

than two to three paragraphs, you probably need to talk. Few people, by the way, are going to read your long emails. We may be evolving alongside technology, but there are still a few ways in which computers just can’t compete. I have yet to find a combination of fonts, embellishments, and emoticons that truly represent the range and complexity of human emotion. Words communicate a lot, but we miss out on crucial information when we can’t hear the tone of voice or the brief pause in someone’s response. In person is best; there is much to be learned from the crossing of arms and legs, the look in someone’s eyes. When there is something important on the line - whatever that may be for each of us - it deserves more of ourselves than we can offer electronically. I look forward to hear from you at pavan@ittige.com on how you are setting yourself apart as a professional brand using your communication skills to your advantage. Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to improve learning outcomes.

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COLUMN

Art of Resolving Complex Engineering Problems A Practitioner’s View (40 Man Years Of Learning) Issue was one of the subsystems used to get stuck and system needed a hard reboot. This specific subsystem was interacting with the other subsystems (many subsystems) for information exchange. Hard reboot refers to the power off/on, which meant it was a service impacting issue and it was very annoying to the customer. This issue was existing for the last 5-6 years in the system and it was not reproduced in our test lab which qualifies it as a complex problem.

Ravi Raghavendra ravi.raghavendra2002@gmail.com

What is a Complex problem? Any problem which is recurring multiple times (even after a fix), not reproducible without an elaborate setup, not fixed for a long duration of time (complexity has further increased due to the changes to the system) A six step practical formula to solve any complex engineering problem We will be walking you through the steps with the help of the following example:

reboot refers to the power off/ on, which meant it was a service impacting issue and it was very annoying to the customer. This issue was existing for the last 5-6 years in the system and it was not reproduced in our test lab which qualifies it as a complex problem. Step 1: Breaking down the problem Study the history of the problem, where has it occurred, how many times, and what data is available about it now.

This example is about one of the problems which we had faced while working on a product used in field from last 12 years.

Identify the area broadly as to where the issue could be arising from.

Issue was one of the subsystems used to get stuck and system needed a hard reboot. This specific subsystem was interacting with the other subsystems (many subsystems) for information exchange. Hard

• scalability issue or one of issue,

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Check if there is a pattern

• design related issue – multiple occurrences, • same version or across multiple versions,

Anil Kaushik anilkaushik@rediffmail.com

• when did it happen for the first time • Has it been reproduced in the test lab or not In our example: All the data collected from multiple customers place and existing repository of issue was searched to dig the history about the issue form the past. After collecting the data, we figured out that most of the time it happened while many subsystems interact with this specific subsystem which was having the issue. Also from the data it was noticed that the issue does not occur immediately, it used to take some time. So it was concluded that scale and duration could be the base for reproduction. Step 2: Create an environment in the lab which simulates the customer’s environment to the closest possible.

Ensure that the same set of hardware, software and any other specific environment aspects of the customer are setup. MAKE NO ASSUMPTIONS of what can be relaxed from the customer site. If there are any specific setup at the customer’s site and not possible to replicate in the lab, then have the simulation of the setup. In our example: Second step was to get high number of subsystems and make them interact with the subsystem with the issue over period of time. Also just to reduce the reproduction time, one set of simulated subsystems were also used. Step 3: Study the architecture, design and code around the problem area and experiment in identifying the problem. Once a broad path in which the problem could exist is identified. Develop short stubs

October 2015

for test, create test data and start experimenting. Start instrumenting the code to create the errors intentionally and check if the pattern matches with the original problem. Based on the outcome tweak the stubs, introduce new stubs or change the data set. This is the most trying time of identifying the problem, many people give up during this time. It is very important, that one should persist and should NOT entertain the thought that the problem cannot be found. This is the most critical step towards resolving the problem, as it is said that “Half of the problem is solved, once it is reproduced in a controlled manner”. Since the product has a problem and is occurring somewhere, also that we have developed the product, it is not acceptable that the problem cannot be reproduced.

architecture and design in depth, simulated subsystems were changed and frequency of interaction with the subsystem was increased. After one week of step2 and step 3 iterative process, issue occurred (during week end) Step 4: Hooray! We are ready to solve the problem Identify at least 2 ways to solve the problem, don’t be convinced that there is only way. In our example: While we were executing the step 2 and step 3, we had kept required tools to collect the data in case issue occurs. Once the issue occurred, we collected the required data using our tool and root cause was done. Issue was identified and there were multiple iteration for proposed solution to the fix the issue. Step 5: Find the side effects!! Otherwise you haven’t resolved the problem yet!

Step 2 and Step 3 are iterative till the problem is found.

Do a thorough Impact analysis of the solution

Also find if there are similar situations or other situations where a similar problem could occur.

Review with sub system owners if there can be any possible impact on their sub systems due to a fix on this particular sub system (Check for the interface specifications

In our example: After studying

October 2015

and see if anything is getting impacted) If we are not confident that we have unearthed all the impacts and still feel that there could be some residual impact which can give rise to further defects in the future, establish stubs in the probable areas where the problem can occur and create a data collection mechanism when the problem occurs. This way we will be able to get a more refined test data. IMPORTANT: Let the customer know that there could be a risk of some residual defects, but is currently addressed by placing test stubs so that the occurrence can lead to identifying the root cause quickly. In our example: Once the solution was finalized, we interacted with owner of those subsystems which interacts with the troubled subsystem and asked them to review the changes which had done. After couple of iterations there were few adjustments which were made to remove the impact on other subsystems.

make it work!!) Learn if the solution has not worked (What did you not do, because of which the solution didn’t work) Learn about your own thought process when you were resolving the problem In our example: There were quite a few leanings. We need to have lots of patience and wait for longer after running tests. There were times where we changed the tests within couple of hours which resulted in waste of time. There needs to be fine balance for running the tests and results. This would depend on the problem but patience needs to be applied for resolving complex problems. Also we need to have required tools to identify the problem even it is reproduced in the test lab. We were very cautious of having subsystem with all the required tools in case problem occurs to collect all the data.

Step 6: Learn! Learn! And Learn!

One of the key factor of resolving this issue was our determination and continuous effort as well.

Learn if the solution has worked (what did you do to

Beware of the following Pit falls:

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1. Settling for temporary solution without adequate root cause analysis

THERE ARE NO QUESTIONS

2. Succumbing to the urgent need for a solution

Ensure that you consistently keep focusing on the problem, and not allow to get worried, upset or frustrated whenever the results do not appear early. Complex problems do take time!!

3. Not investing in time towards simulation or reproduction of the issue 4. Solutions are more oneof based and tend to be randomized rather than scientifically deduced 5. Not enough time spent in data collection and studying the issue, to gain expertise over the problem Personal Traitsthat are really critical for every person solving a complex problem.

Working closely with the Quality Assurance team, Field Engineers, Design team, System Engineers Communication with the Management and Customer:

You should be prepared to take pride in your work, and be ready to give your time completely.

Establish a milestone plan for the problem resolution and keep reporting periodically to the Management team.

Sometimes you may have to sacrifice your personal time in lieu of finding the problem.

Identify one of the Management team member to work with you on the communication front with the rest of the Management team and the Customer Honesty in Engineering – Accepting that we don’t know something and we are not ignoring something that could probably occur in the field which is not evident right now, and that which the resolver only knows and the others do not.

Technical Inertia (Leading to “Laziness in Engineering” – Coinage under patent), this is exhibited as

Confidence:

- Jumping to solutions mode without analyzing the problem completely

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Collaboration with Team members:

Passion:

From our experience through years of resolving complex problems,we have found that there are a certain personal traits that we will have to have when we are pursuing solving complex problems

Have enough faith in your knowledge and skills that you can resolve the problem.

Mind control:

solution that it probably may resolve the issue

- Habit of taking short cuts without complete study of the problem

- Betting on a half confident

The author Ravi B Raghavendra is an entrepreneurial facilitator with 20 years of experience to make organizations to

rethink, and successfully identify their most impeding systemic constraint to achieve the most important goal; an experienced consultant driving strategic application of process excellence methodologies in product realization, including a people-centered focus, to successfully remove systemic bottlenecks, and enable attainment of outcomes that sustain business growth (order to cash), enhance quality and improve profitability(remove wastes). The coauthor Anil Kaushik possess more than 20 years of experience in the wireless and networking industry. Currently working as Senior Architect of Embedded systems in Fortinet Innovation India Center, Bangalore Architecting/ Managing the Embedded systems, Locationing, BLE, WLAN infrastructure and security solutions. He is WLAN Patent committee member WiFi Alliance and WBA member and done researches in the following dimensions - Wireless, networking and security domain, Location techniques and in IoT

October 2015

Driving Manufacturing Processes of the Future www.spsautomation-india.in

7 â&#x20AC;&#x201C; 9 April 2016 Helipad Exhibition & Convention Centre Gandhinagar (Near Ahmedabad), Gujarat, India

For further details, kindly contact: Anand Nair +91 11 6676 2310 anand.nair@india.messefrankfurt.com Talat Shekasan +91 22 6144 5957 talat.shekasan@india.messefrankfurt.com

International trade fair for automation in production and assembly

International trade fair for quality assurance

www.motek-india.com

www.control-india.com

October 2015

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FEATURE ARTICLE

When Versatile Milling Makes the Grade A key part of any indexable insert is its grade. Dormer Pramet’s recently launched M8340 PVD milling grade was a landmark development within the company’s overall insert programme and is set to be a central figure for future R&D projects.

Karel Tiefenbach, indexable milling product manager at Dormer Pramet, takes a look at the key elements in what makes up a grade, its main components, the impact a coating can have and what needs to be considered when creating a new design. The development of Dormer Pramet’s new M8340 grade was the culmination of a two-year programme to create a new grade, investing a significant amount of time and resources into it. An extensive period of planning preceded this project, which included numerous new experimental procedures, a

thorough evaluation process and involved more than 20 technicians. The result was one of our most successful development projects in the last 10 years and the M8340 is now the leading grade used to support most general milling applications, particularly when machining steels, stainless steels and under certain conditions cast iron. It has become our ‘go to’ grade for customers. Key qualities of versatility and durability within an insert are driven by the composition of its grade. As there are so many operations possible within

milling (face, shoulder, slot, plunge, progressive and ramp milling to name but a few), it is important to have a grade which can be used across as many applications as possible. The focus when establishing a new grade is to determine what the main aims are and ultimately what the cost will be to customers. When Dormer Pramet began the development of its M8340, the aim was to create a grade which would support both wet and dry milling, with a specific requirement to increase reliability of the cutting edge, minimise cracking and improve performance when using

coolant. Created under the Pramet indexable range, the M8340 would support our existing 8215 and 8230 milling grades to offer a complete programme of options for the end-user. Reviewing the capabilities of these existing grades offers an insight into their structure and how they differ from what was required from the M8340. We began by looking at the basic element of the insert, the substrate. This is made of cemented carbide - a powdery metallurgical material made up of a combination of tungsten carbide (WC) particles and

The microscopic structure of a milling grade.

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October 2015

A range of Pramet inserts which feature the M8340 Grade.

The M8340 Grade within Pramet’s LNGX12 milling cutter.

metallic cobalt (Co). Varying the type, size and proportion of particles within the substrate can significantly influence the make-up and ability of the insert. For example, Pramet’s 8215 grade has a low content of Cobalt (Co) offering high hardness and considerable toughness, more suited to high cutting speeds with a focus on performance. The 8230 has a medium content of Cobalt (Co) offering a balance of hardness and toughness. M8340 focussed on the other end of the spectrum, having a high content of Cobalt (Co) offering the highest toughness of all Pramet’s grades with considerable hardness, more suitable to unfavourable cutting conditions and reliability. The amount of cobalt used, mixed with additional company specific materials, can make every substrate unique to the next and provides a core foundation to deliver a successful performance from the insert. However, it is the addition of the coating which can make the most significant difference to the composition of a grade and give it the additional benefit of being durable in tough machining conditions.

October 2015

The coating protects the insert from abrasion, corrosion and heat – all of which impact on the life of the cutting tool. Coated cemented carbide constitutes up to 85 per cent of all inserts since it was introduced to the industry more than 40 years ago. Key to adding a coating is to make sure the most suitable material is used to combine it with the substrate, ensuring a perfect match. The order of applying the coating, its thickness and the processes involved, are all variables which impact on overall performance. In the case of the M8340 grade, a Physical Vapor Deposition (PVD) coating was added. This is achieved by evaporating a metal after it reacts with nitrogen to create a hard nitride coating on the cutting tool surface. This is performed at the relatively low temperature of 400-600°C. PVD coatings are a popular way of providing wear resistance while its compressive stresses also add edge toughness and comb crack resistance, all required to combat against the grade’s hardness. It is ideally suited to deal with instability and high chip evacuation from the cutting area. Recommended for tough,

sharp cutting edges and appropriate for a wide range of general applications for drilling, grooving, threading and milling, PVD is also particularly used for finishing applications. Modern coatings are combinations of sequenced layers and/or lamellar coatings, which have numerous thin layers, in the nanometre range, making it even harder. Pramet’s M8340 substrate is surrounded by NANO-layers of TiN (Titanium nitride) and TiAlN (Titanium aluminium nitride) for increased thermal crack and wear resistance. It then has a layer of TiN (Titanium nitride). Titanium nitride has all-round properties to provide wear resistance and is often a golden colour, while Titanium aluminium nitride has high hardness in combination with oxidation resistance, which improves overall wear resistance. To use multiple layers of different coating materials enables us to combine all the benefits each one offers. It is this combination of the type H sub-micron grain size of the substrate and the multi-layer PVD coating which enhances wear resistance – in particular, preventing the initiation and propagation of thermal cracks and in turn increasing tool life.

Following the development of the M8340, an extensive evaluation period commenced both at our production facility in Sumperk in the Czech Republic and at selected sales units around the world. Tests were completed with and without coolant against an existing grade and similar ones from competitors. It was clear at the outset that the M8340 was the grade we had been aiming for. It achieved on average: • A 50 per cent improvement in performance compared with the previous generation grade • An increase in life span between 30-60 per cent • An increase in productivity by 30 per cent with improved reliability Thermal crack initiation and propagation was minimized and while it was designed for operation with coolant, it also achieved greater performance in dry cutting conditions. The success of the trials led to the M8340 being released into the market in November 2014 as part of a wide range of products being launched and was made available across almost 150 inserts within Pramet’s indexable programme. For more details visit www.dormerpramet.com

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CASE STUDY

San Marino Company Invests in Haas UMCs Two Haas UMC-750 five-axis universal machining centres recently acquired by a San Marino-based manufacturer of industrial profiles have provided a welcome boost in capacity. Within two months of arrival, the machines, which are configured in a two-machine cell with one operator attending to both, are already working 21 hours a day across three, 7-hour shifts.

Alluminio Sammarinese is a company that specialises in the production and design of custom-made industrial profiles, in particular, for the automotive, electronic, furniture, and construction sectors. The business was founded in 1981, and has grown steadily, thanks in part to a planned programme of investment in the latest manufacturing technologies, which includes two Haas UMC-750 five-axis universal machining centres.

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The company is located in San Marino, which is entirely surrounded by Italy and claims to be the oldest surviving sovereign state and constitutional republic in the world. Starting out as an extrusion company, predominantly serving the window manufacturing industry, Alluminio Sammarinese has subsequently diversified into a number of other sectors and activities. Today, the company views itself more as an engineering

business than an extrusion business. In fact, the window industry now only represents 1 percent of current output. Despite its success, however, the company’s business owners and managers are aware of the need to keep moving forward. The CEO at Alluminio Sammarinese, Stefano Ceccato, whose father started the company, says increased competition from low-wage economies is the biggest threat to the future of

the firm. “Around 10 or 20 years ago, our main competitors were from Italy,” he says, “whereas now, they are from Eastern Europe, Turkey, and sometimes China. To overcome this, we have to raise our level of technology, and take on more complex machining and more complex extrusions. Also, the products need to offer greater precision and surface finish, particularly in sectors such as automotive.”

October 2015

Mr. Ceccato says the Haas UMC-750 five-axis machines are part of the company’s plan to produce more complex parts. “We bought the Haas UMC750s because of the very attractive quality-to-price ratio. We make a lot of complex automotive parts, and needed five-axis machines that weren’t too expensive. The components tend to be big, so we purchased two Haas UMCs – one is running while the other is loading and unloading. They are arranged in a small cell, with one operator to run both.” Although only installed a few months ago, the Haas

machines already work 21 hours a day across three 7-hour shifts (not the more traditional 8 hours, due to an agreement with the unions). Alluminio Sammarinese reports that the machines have worked perfectly since the outset, aside from one technical issue relating to the use of bespoke fixtures that was easily solved by the local Haas Factory Outlet, a Division of Celada, in Italy. Celada, which is part of the very highly regarded machine tool supplier, R.F. Celada Macchine Utensili SpA, provides expert sales, service, and support across Italy, including San Marino. “The service we receive is

excellent,” says Mr. Ceccato, “and the Haas UMC-750s work well. We are currently testing more precision parts to put on the machines, and we are very happy with the results. In fact, we would ideally like a bigger version of the UMC-750. We are always investing, and a machine such as that would be very attractive for us.” Unsurprisingly, 100 percent of the output from Alluminio Sammarinese’s 10,000-squaremeter facility is exported, 60 percent to Italy, with the remaining 40 percent to the rest of Europe. The automotive sector, for which the Haas machines were predominantly acquired, accounts for 20 to

25 percent of the company’s customers. “In all cases, we like to help our customers create a better product, whether that’s taking out cost or enhancing quality – adding value in some way,” concludes Mr. Ceccato. The Haas universal machining centres will no doubt have an important role to play in ensuring this ethos continues for a long time to come. Alluminio Sammarinese has since ordered two more Haas UMC-750s. Both new machines will be Super Speed (SS) models, each with 15,000rpm spindles, and are due for installation in October 2015.

Haas UMC-750 five-axis machines are part of the company’s plan to produce more complex parts

October 2015

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CASE STUDY

Winning at Titanium Machining What does production superiority mean to aircraft manufacturers? In a word: billions. In the land of the giants, US-based Boeing beat European rival Airbus in net new orders and deliveries in the first quarter of 2015. While the first quarter is the traditionally slow quarter for new orders, it’s deliveries that generate the most revenue, and Boeing handed over a record number of jets for the period. For manufacturers of all sizes and types of aircraft, and their entire supply chain of components and parts suppliers working in difficult-to-machine materials, production delays can mean order cancellations, and cancellations can mean shifts to better-equipped builders. Machine builder Fives Cincinnati finds Kennametal’s KM4X™ spindle connection key to achieving new levels of metal removal on industry-leading “super-profilers”

One technology provider that knows this better than most is Fives Cincinnati, whose Hebron, KY, plant produces Cincinnati machining centers, composites fiber-placement systems, and multi-spindle Cincinnati profilers. With over 650 profilers in the field all over the world, there isn’t a commercial aircraft flying that hasn’t been touched by a Cincinnati profiler, the company says.

Available in three- and fivespindle gantry configurations, the latest-generation of these powerful giants, the Cincinnati XTi Profiler, is impressive on many scales. Designed for manufacturers that process multiple materials, 7000-rpm spindles can cut aluminum and steel and high-torque (2523 Nm) spindles are available for processing titanium and other hard alloys. Called ‘the only multi-spindle platform available for titanium

roughing,” company literature states the XT sets the MRR (metal-removal rate) record for machining titanium at more than 100 cubic inches per minute. These massive machines, with 4267 mm of X-axis travel (expandable in increments of 3658 mm), 3683 mm in Y, and 711 mm in Z, now are setting new records with optional KM4X100 spindle connections from Kennametal Inc.

From Weakest Link to Strongest Feature Whether profiling on large gantry machines or milling on smaller machining centers, processing tough material like titanium is a constant challenge. Machining hard alloys while adding the pressure of improving production efficiencies means maximizing metal removal in the face of low cutting speeds and significant cutting forces. Machine tool

The Fives Cincinnati XT profiler with five spindles for titanium milling.

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October 2015

The business end of a five-spindle XT profiler.

builders like Fives have responded with specialty milling and profiling centers that feature improved stiffness and damping on spindles and sizable machine structures, all to minimize undesirable vibrations that deteriorate part quality, throughput, and tool life. Although these advances have added to greater productivity, the weakest point historically has been the spindle connection. The tool-spindle connection, the “handshake” between the machine tool and the cutting tool, determines how much material the machine can remove on a given operation. This is because this interface must withstand high loads and yet maintain its rigidity until tool deflection is too high or the onset of chatter is reached. Spindles may be able to transmit a considerable amount of torque, but cutting forces also generate bending moments that will exceed the interface’s limits prior to reaching torque limits. This becomes obvious in end-milling applications, where projection

October 2015

lengths are typically greater -- the limiting factor is the spindle interface’s bending capacity. As an example, an indexable helical cutter with 250mm (9.84 in.) projection from spindle face, 80mm (3.15 in.) in diameter generates 4620 Nm (3407.5 ft. lbs.) of bending moment and less than 900 Nm (663.8 ft. lbs.) of torque when removing 360 cm3/min of Ti6Al4V at RDOC of 12.7mm and an ADOC of 63.5mm. By combining high clamping force and optimized interference levels, Kennametal’s next-generation spindle connection KM4X provides a robust connection, extremely high stiffness, and bending load capacity. For titanium processors, this means greatly improved performance in machining high-strength alloys and other materials, enabling extremely high metal removal rates and more completed parts per day. Adds More to Machine Design Together with Kennametal senior account manager

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The KM4X100 spindle connection is vital in determining maximum metal removal rate.

Passed the “bobsled” test cut with ease: KM4X spindle connection.

Mike Malott, Fives Cincinnati applications engineer Robert Snodgrass began evaluating KM4X approximately four years ago. “The engineering is impressive – it definitely allowed us to start thinking that there’s more to machine design, that a stiffer spindle helps meet customer demand for more effective metal cutting and increased throughput.” “Remember, typical aero structure components

start out as forgings with much of the material being removed to achieve finished part specifications,” says Kennametal Vice President Mark Huston. “The “buy-tofly” ratio -- the weight you buy in raw material vs. the weight that flies in finished form can be 4:1, 8:1 or more depending on the component.” First-generation Cincinnati profilers achieved an MRR of four cubic inches per minute in titanium, due to machine

structure and tool-spindle connection limitations. With the XT-generation of Cincinnati profilers and face-contact HSK 125 spindle connections, the MRR increased to 50 cubic inches per minute. With the KM4X100, the MRR doubled to 100 cubic inches per minute. “Even at a 100 cubic inches per minute, our benchmark testing for the XT profilers using the KM4X were well below the machine’s theoretical limits for bending moment resistance,”

Snodgrass adds. He noted that previous-generation tests employed large CAT60taper toolholders that, when compared to 50-taper versions are like driving a tank versus an SUV. The KM4X achieved double the metal removal rates versus the 60-taper toolholder. Compared to CAT50, HSK100, or KM4X100 the CAT60 is almost twice the weight. “This changes spindle and machine design a ton,” says Ken Wichman, Fives Cincinnati

Profiling in Action.

A challenging “bobsled” test cut designed to max out torque and cutting forces is accomplished with ease on the Fives Cincinnati XT profiler with KM4X spindle connection.

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October 2015

product manager. “Many gantry machines have manual tool exchange even though automatic tool exchange/ storage is available. The enhanced bending moment resistance of the KM4X allows lighter tooling when compared to a CAT or HSK tool with an equivalent bending moment resistance. Ergonomically, this is a huge benefit to the operator. For customer’s choosing automatic tool exchange/storage, the smaller KM4X can accommodate more tools in a given footprint.” “We pride ourselves in keeping customers productive,” adds Fives Cincinnati Vice President Mark Logan. “Not only is a more powerful spindle connection like KM4X changing new machine design, it also can be a significant boost for existing machines in the field. This gives us the chance to offer a notable upgrade in retrofits while still pushing the limits on profiler models to come.” “The industry needs to set new standards for producing titanium parts at the lowest cost per piece, and the XT Profiler provides that capability and more,” says Chip Storie, Fives Cincinnati executive vice president. “With a massive cross-rail, robust spindle design, dedicated foundation, and high-pressure coolant system, we expect to exceed 100 cubic inches per minute metal removal. This is going to change the way the industry approaches titanium machining.” SIDEBAR: Analyzing the Bobsled Cut

October 2015

Mike Malott, Kennametal senior account manager, has spent years in the field to where he had been granted “family” status on the Fives Cincinnati production floor. He also has noticed that the FIVES “bobsled cut” for establishing cutting-tool performance has been making its way around the industry. “To truly put a new configuration through its paces, we had to develop an extremely challenging test – truly something for which the tool was not intended,” says application engineer Robert Snodgrass. The result was forcing a tool through a titanium workpiece following a deep and continuous curve, similar to a bobsled track. “We wanted to max out penetrating depth and torque in a simultaneousmotion cut, all the time subjecting the machine tool and the spindle/cutting tool to extreme forces in every possible way.” Experienced titianium processors may wince thinking of the screams that would come from the workpiece prior to either the machine tool or the cutter failing. But as the Fives video on YouTube proves (https://www.youtube. com/watch?v=-0pcocy4IsE), a small mountain of chips from a deep and wide test cut can be processed efficiently at a pleasant hum, even on five separate spindles. The proof is in the performance, and further improvements are on the horizon. For more details visit www.kennametal.com

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MART UPDATE

Red Lion’s Rugged Graphite HMIs receive ABS Approval for Maritime Applications Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced that its rugged Graphite®Human Machine Interface (HMI) operator panels have been tested to meet ABS (American Bureau of Shipping) standards. ABS approval assures equipment is safe for operation in amanner that protects life, property and the marine environment when used in shipboard and offshore settings. Red Lion’s modular Graphite HMIs have been ABS tested and approved to monitor and control equipment in maritime applications that range from workboats to offshore

energy and gas vessels. In these marine environments, Graphite HMIs provide reliable functionality that helps drive operational efficiencies as well as adhere to international standards for environmental performance. In addition to ABS approval, Graphite HMIs are Underwriters Laboratories (UL) Class I, Division 2 listed for hazardous locations and ATEX and IECExzone 2/22 approved for potentially explosive environments. With rugged aluminum construction, a wide operating temperature range and flexible plug-in modules, Graphite HMIs enable customers to connect, monitor and control processes in several industries to meet

varying industrial automation requirements in both factory and extreme locations. Since its launch in July of 2013, Red Lion’s Graphite platformhas receivednumerous global accolades, including Automation World’s “First Team Supplier, HMI Hardware” award, the “Industrial

Control Award” from Plant Engineering Chinaand “Best Product of the Year” from Control Engineering China. For more information on Red Lion’s modular Graphite HMI platform, visit www.redlion.net/Graphite

Grundfos India Promotes Discussion on Smart Cities Grundfos Pumps India Pvt.Ltd (Grundfos India) partnered with CII-ITC Centre of Excellence for Sustainable Development on its 10th Sustainability Summit and sponsored a session on ‘Smart Cities: Transforming Life, Transforming India’. With the central government’s

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recent announcement on the list of cities included under 100 smart cities program, there is a lot of expectation and excitement around the development of these smart cities in the country. This session on Smart Cities had industry leaders including Ranganath N K, Managing Director, Grundfos India

“The development of smart cities can be made possible only through the partnership of government and industry. It is therefore critical that we have such platforms where industry and Government can come together to discuss key aspects of how efficient implementation and sustainable solutions can help make the Smart Cities initiative a reality. Energy and water efficiency will play a critical role in the success of the smart cities and we hope that this session has highlighted the same.”

discuss the challenges, opportunities and solutions that can ensure that the Smart Cities initiative succeeds. Mr. Rajiv Ranjan Mishra, Joint Secretary (Housing), Ministry of Housing & Urban Poverty Alleviation was also one of the key members of this panel discussion.

Mahathi Parashuram Head – Public Affairs & Marketing, Grundfos India

Ranganath N K also chaired the session ‘Water for Life’ at this Summit.

October 2015

Ingersoll Rand launches Smart Citizen 3.0 Ingersoll Rand, a world leader in creating comfortable, sustainable and efficient environments, announces the launch of its new interactive microsite Smart Citizen 3.0 that will educate its audience on conserving natural resources in their day to day living. The platform will allow people to enrol themselves in an engaging activity on energy conservation while providing insights on various natural sources of clean energy and their conservation.

Smart Citizen 3.0 like its predecessors will be based on the principles of REDUCE, REUSE and RECYCLE. However,

October 2015

in the present day scenario where the natural resources are depleting rapidly, adopting these 3 Rs are not enough. This year the initiative goes a step further and adopts the 4th R - ‘REFUSE’. The microsite will educate the audience the ethos of prevention by simply ‘REFUSING’ to accept products, services and routines that are harmful for the environment. Smart Citizen 3.0 through its interactive design and content, aims to propagate about these 4 Rs by embedding them intelligently in the contest. Smart Citizen 3.0 will focus on the technologies and requirements that go into

building a smart SMPS DC/DC Converter Water Proof SMPS city while setting optimum rules for a sustainable society in order to maintain a balance between the energy consumed and conserved by Adaptor using 3 Phase Transformer LED Drivers innovative methods by ahousehold, at a workplace and at an individual level. The contestant will need to complete 1 Phaserelated Transformer Battery Charger Solar Lartern the scenarios to planning the city, setting the 27, 2015 and is open to all 65, Laxmi Vihar, Jandli, Ambala City (Haryana) India. Tel: +91-171-2801711/3291897 laws and optimizing individual LinkedIn, Facebook or Google+ Fax : +91-171-2801289 Mobile : +91-9416020078/9215720078 energy consumption by choosing users in India. Emailenergy : nacei@rediffmail.com / naceiamb@gmail.com Website : www.nacei.com the most efficient option in the shortest possible time. The For more details visit www.smartcitizen.co.in contest commenced on August

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New mounting system boosts Seco’s Square T4-08 Helical cutter strength, stability Seco recently expanded its Square T4-08 Helical milling cutter line to include a new innovative insert mounting system for specially designed inserts with four cutting edge capabilities. The product line also now includes a new MS2050 insert grade. Ideal for 2D directional contour milling applications, the Square T4-08 Helical excels in machining challenging materials such as cast iron, steel and stainless steels. Its strong, reliable pocket seats combined with multi-edge inserts optimise cutting stability and allow for clean 90-degree walls. The inserts mount tangentially in the cutter so that the cutting forces impact the thickest

parts of the inserts, allowing

Weldon, Arbor and

manufacturers to achieve the

Combimaster™

required levels of strength for

heads.

increased depths of cut with small diameters.

The tool has cutting

In addition to its high metal

range from 25 mm

removal rates and cost

(1.0”) to 54 mm

effective operations, users will

(2.0”) and depths

also benefit from the Square

of cut between 22

T4-08 Helical’s versatility.

mm (0.87”) and 64

Variations include normal pitch

mm (2.52”). Corner

for slotting and contouring

radii ranges from

operations and close pitch for

0.02” (0.4 mm) to

contouring only. The Square T4-08 is available in M08 and MD08 insert geometries, and four grades including the new MS2050, which joins the MP3000, MK2050 and F40M options. Various mounting types include Seco-Capto™,

diameters that

0.063” (1.6 mm). Furthermore, the entire Square T4-08 Helical range has integrated through-coolant channels to provide extended tool life.

For more details visit www.secotools.com/en-IN/ Global/Products/Milling/Squaresholder-milling/Square-T4-08/ Square-T4-08-Helical/

Intelligent sensor technology of the future SICK at SPS IPC Drives 2015 - Hall 7A, Stand 340 The safety technology of the future and solutions for vision and identification tasks are the focus of SICK AG’s presentation at the SPS IPC Drives trade fair in Nuremberg which will be taking place on November 24– 26, 2015. SICK will be using this event to gather information about current trends and as an opportunity to present its products and technical innovations. The leading manufacturer of intelligent sensors and sensor solutions will also be demonstrating its wide range of solutions for the

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many industrial applications. On the subject of “Industrial Security Systems”, SICK will be presenting the safety technology of the future. In the future, SICK safety sensors will be even more closely connected to one another. The challenges of the future include a rapid commissioning for significantly faster system effectivity and continuous production for increased system efficiency. In the future, SICK’s smart sensors in the context of Industry 4.0 will not only be used to

ensure the safety of people, but also the implementation of ever-increasing production specifications.

process optimization using global data transparency, which facilitates industry-wide networked communication.

More than a vision

At the SPS IPC Drives trade fair, SICK will be demonstrating what is already possible and getting Industry 4.0 off the ground. The innovative solutions face up to the requirements and trends associated with Industry 4.0: Flexibility for custom batch sizes, seamless transparency for traceability, and increased performance for shorter processing times.

SICK will also be using the trade fair as an opportunity to show itself as a pioneer for vision and identification applications and will be presenting its wide range of solutions that do more than “just” see. These solutions are already prepared for the requirements of Industry 4.0: They visualize process data and use it to create continuous

October 2015

Bonfiglioli’s RPS Endurance inverters are now ready to tango RPS Endurance inverters with new parallel operation feature – available in 20 ft “ICON ND” stations up to 2.25 MWac new

parallel operation feature – available in 20 ft “ICON ND” stations up to 2.25 MWac

With the introduction of the new tandem feature, two units operate seamlessly in parallel on a single medium-voltage transformer winding. This makes the performance and ease of handling of RPS Station ICON ND – The perfect home for RPS Endurance RPS Endurance inverters inverters now fully available for megawattscale PV stations.

Electrical Schematic of RPS Station ICON ND with 2 x 2 units of RPS Endurance

Thanks to the further extended power range of single RPS Endurance units of up to 563 kWac at 50°C ambient temperature, the new features allows the effortless realization of 1MW+ tandem configurations with a common

ac connection, paired with the best-in-class 15 % permanent overload capacity (up to 648 kWac) at reduced ambient temperatures. Constructed with a record footprint and designed for maximum productivity even in the toughest conditions, these ratings make the RPS Endurance a truly compact powerhouse. A unique feature for indoorrated PV inverters, the innovative two-zone ambient RPS Endurance is a robust, compact protection system distinguishes powerhouse with a rated power of up to the RPS Endurance from 563 kWac for each inverter unit. other solutions and makes it a preferred choice wherever harsh conditions for plant installation and operation are present, such as in the “sunND series integrate 2 x 2 units belt” regions of the world. The of RPS Endurance inverters intelligent encapsulation design into a compact 20 ft container maximizes uptime through a design, achieving an excellent full IP54 ambient protection power rating of up to 2.25 degree of active components. MWac per station. This great Thanks to advanced air compactness is paired with a cooling technology, the proven and easy-to-maintain inverter design ensures forced-air cooling system. outstanding reliability and ICON ND stations are delivered serviceability. With numerous ready to connect to an external self-protection functions and three-winding medium-voltage grid management options, transformer, helping customers the RPS Endurance is built to to significantly reduce project satisfy your power control execution times. requirements in the fast For more details write to developing global PV market. ameet.rele@bonfiglioli.com or The new RPS Station ICON visit www.bonfiglioli.com

Quick and simple ordering of product samples Shipped within 24 hours of

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eCatalogue online product

Tangible samples are an important decision making aid for developers and designers

October 2015

For more details visit www.harting.com

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Kjellberg establishes subsidiary in India Support of Indian customers is intensified; Smart Focus meets requirements After more than 50 years’ experience and activities Kjellberg expands its presence on the Indian with its subsidiary Kjellberg Cutting and Welding India Pvt Ltd in Pune. From 1st of April 2015 the subsidiary near Mumbai in the federal state Maharashtra will take care of all activities concerning sales and service in direct contact to the customers and with significantly less effort than before. The managing directors Carsten Trentau and Falk Tzschichholz aim at further improving the reliable

and trustful customer relations since the Indian market is of major importance for Kjellberg. The subsidiary Kjellberg Cutting and Welding India Pvt. Ltd. will support the Indian customers in all service and sales affairs. Pune as the location for the subsidiary and with its local industries such as automotive engineering offers great potential for Kjellberg’s portfolio of cutting equipment. The new plasma cutting series Smart Focus is ideally suited for the Indian market and has been received positively after the

”Kjellberg strongly believes in further continuous and longterm growth of the market. Therefore we reinforce and expand our local activities to meet rising market expectations.”

Falk Tzschichholz Managing Director, Kjellberg Cutting and Welding India Pvt Ltd

Kjellberg offers products and technologies for the thermal cutting, joining and processing.

sales launch in February. The three compact plasma cutting units are user-friendly and easy to service and achieve best cutting results in the range of 1 to 80 mm with a convincing price performance ratio.

Kjellberg offers plasma and

Users benefit from the patented Contour Cut technology for the fast and precise cutting of mild steel. As the longest established manufacturer of plasma cutting technique in the market

Deore, Country Manager,

laser cutting equipment for a wide range of diverse tasks in automated, mechanised or manual cutting – made in Germany. For more details write to Vishal Kjellberg Cutting and Welding India Pvt. Ltd, R K Plaza, Survey No. 206/3, Plot No. 17, Loahgaon, Viman Nagar, Pune – 411 014 Tel: +91 20 26741042

Pepperl+Fuchs acquires MACTek Corporation Pepperl+ Fuchs, a world leader in process automation and applications, has acquired MACTek Corporation, a leading provider of HART protocol devices. The move is part of Pepperl+Fuch’s strategy to

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further extend its integrated solutions offerings and strengthen its position in the WirelessHART market.

Interface modems. One of

wireless access to HART field

the company’s most recent

devices designed for hazardous

innovations, the BULLET

areas and Bluetooth-enabled

WirelessHART adapter, can

technologies.

Founded in 1993, MACTek specializes in HART modems, including VIATOR HART

be mounted on any device rated for hazardous areas. The HART modem family includes

For more details visit www.pepperl-fuchs.us

October 2015

IFO starts with Sustainable Foundry Development Meet The INDIAN FOUNDRY ORGANISATION is taking birth on the birth day of Dr.A P J Abdul Kalam who has excelled in all positions- President, Scientist, Writer, Teacher and Missile Man of India. There will be one session dedicated to SUSTAINABLE FOUNDRY DEVELOPMENT MEET on October 15, 2015 at Le Meredien Hotel, Bangalore. Presentations and discussions will be made by very senior policy makers from the Government of Karnataka, Central Government and other leading experts in the steel sector and environment sector. The casting manufacturers and the secondary steel and aluminium manufacturers were always under the feeling

October 2015

that they do not have a â&#x20AC;&#x153;It is a long felt need of the Indian separate forum to represent Foundries to have a forum to (i) Discuss their grievances either to the problems being faced by the foundries the State Governments or among the foundry members, (ii) Share the the Central Government. All Technology Development in the area and other associations have their (iii) Take up the problems of the Industry members who belong to many to authorities in the Government-both State diverse categories of service, and Central-to get suitable solutions. suppliers of machineries and Keeping all these points of interest, it was chemicals, and manufacturers. thought of starting an association solely to Hence the focus was getting take care of the interest of foundries.â&#x20AC;? diverted when the interest of one group is taken for Dr H Sundara Murthy consideration which might be CEO, Fenfe Metallurgicals of either not much of interest or oppose the business of manufacturers, secondary steel of this manufacturing sector. interest of the other group. This manufacturers and secondary This group will be a large group usually ended with some sort aluminium metal processors. solely in the manufacturing of understanding or adjustment sector of production of castings, which did not serve the purpose The formation of INDIAN forgings, re-rollings, extruders, of both. Hence it was always felt FOUNDRY ORGANISATION is billet manufacturers both in that there is a need for a forum made with the sole objective ferrous and non ferrous sector. which takes care of casting of taking care of the interest

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February 2015 November October 2014

THE LAST LEAF Dear Readers, Three years ago when India with slowing growth, a deteriorating macro-economic situation, record current account deficit and fiscal deficit had triggered a flight of capital. The situation was so gloomy that some analysts even talked of Indonesia replacing India as the “I” in BRICS. But, as we see today, Brazil has been downgraded to ‘junk’ and China is battling a growth slowdown. Russia has been the worst-affected by the commodities slump and South Africa’s economy is flirting with contradiction. India, on the other hand, is expected to emerge as world’s fastest-growing major economy. (Courtesy: Economic Times) India is the third-largest economy in purchasing power parity after the U.S. and China, it has a large population of engineers and factory workers, its intellectual property is widely respected, and it is easy to find English-speaking managers there. To broad base this fact, here are some success stories of the world super power America’s companies. For example, Chicago-based Abbott, which operates in 150 countries and owns top brands such as Similac infant formula, recently built a manufacturing facility in Jhagadia, Gujarat, in order to compete in India’s large branded generics market. In 2014, its 14,000 employees in India generated $1.09 billion in sales. India was one of the first expansion markets for Abbott, after Canada and the U.K, and today it’s the company’s third largest market globally — all six of the company’s business units have a presence in the country. For a healthcare company, the reasons to be part of this vibrant country are even more compelling — it’s an opportunity to serve the unmet healthcare needs of a 1.2 billion population. Another American company Cummins does manufacture its engines, generators and turbochargers in India, through its 20 plants, for exports across the globe. Cummins India exports grew at 14% annually over the last five years and now constitute 40% of sales, with one-sixth of Cummins’ 54,000 worldwide employees currently working here. Another company planning to boost exports by manufacturing in India is GE. Among the nine factories it has in the country, its new factory in Pune serves as a global supply source for its businesses, from aviation and turbo machinery to wind turbines and diesel locomotives. Former Texas Instruments Engineer Lou Hutter, now CEO of the startup Cricket Semiconductor, is raising $1B dollars (largely from investors of Indian origin) to build India’s first analog chip fabrication (“fab”) facility. Hutter and his partners hope to be located in the middle-sized city of Indore in Madhya Pradesh, where the Chief Minister has offered free land and a stable supply of water and electricity. The state has implemented a single online registration for business licenses to replace the complicated system businesses previously had to go through: 61 different registers operating under 13 separate federal labor laws. Just two decades ago, most Western executives thought of Ireland or Central America as the place to outsource software and business processes; today, we believe that India’s knowledge worker base is a better option than those two destinations combined. Manufacturing is the next frontier in India, and companies such as Abbott, Cummins, and GE have already proven that the countries’ resources hold tremendous potential. While there is no single formulaic answer to manufacturing success in India, patience and a trusted local partner or advisor to guide western executives’ efforts are necessary. And from India’s perspective, manufacturing is probably the only way to lift half a billion more of its population out of poverty. If our Prime Minister Modi is able to inspire those around him to unlock India’s land and labor for manufacturing, domestic and global corporations will accelerate this transformation. (Courtesy: HBR.org) We need your input on any industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our readers about a better tomorrow. Till then, Happy Technology! Manoj Kabre Member, Editorial Advisory Board

October 2015

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1 U0

CIS CISU 01035

MAX GR TAPE NET

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October 2015

Pressure Range

Capacity

Discription

Sr No

M3/Min

CFM

Bar

Lubricated SCREW Compressor

0.23 to 43.70

8 to 1545

8 to 13

Oil Free SCREW Compressor

5.30 to 51.40

187 to 1815

8 to 10

Lubricated PISTON Compressor

.125 to 6.20

4.5 to 219

8 to 40

Oil Free PISTON Compressor

.156 to 1.30

6 to 45

8 to 40

BOGE FLEXPET

1.55 to 17.9

54 to 634

BOGE AIR. THE AIR TO WORK.

BOGE India , No. 216, Third Link Street, Industrial Estate, Nehru Nagar, Kottivakkam, Chennai - 600 096, india@boge.com* www.boge.in Chennai Mr. F C Jayakaran

: +91 9600041656 : fc .jayakaran@boge .com

/ Chennai Mr. Muthu Ganesan : +91 9003172111 : muthu.ganesan@boge.com

Hyderabad Mr.W.Narendra

: +91 9704770930 : w. narendra@boge.com

/ Mumbai Mr. Hasan Hasware : +91 9840956161 : h.hasware@boge.com

Delhi Mr. Deepesh Upadhyay

: +91 9818556732 : d.upadhyay@boge.com

October 2015

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100

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October 2015