THOUGHT LEADERS WEIGH IN RNI NO.: MAHENG/2017/73912
Vo l u m e 3–I ssu e 5 M u mbai
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ADDITIVE MANUFACTURING SPECIAL
Industry leaders illustrate the status and roadmap of 3D Printing (a.k.a Additive Manufacturing) in Indian manufacturing.
‘3D PRINTING HOLDS GREAT PROMISE FOR HUMANITY’S FUTURE’
RAJIV BAJAJ Managing Director - India and SEA, Stratasys
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CONTENTS
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58 56 64
60 Regular Editor’s Note Notes From The Field Imprint / Ad & Company Index
Curtain Raiser LWOP INDIA
Post-Event Report EMO HANNOVER 2019 Dassault Systèmes’ SCHUNK VDMA
06 08 70 10,12 14 56 58 66
Industry News IMTMA Indospace MARPOSS SECO TOOLS SIEMENS
Product Feature PRINTRONIX Blaser Swisslube
Special Feature Renishaw DMG MORI
38 39,64 42 46 47 40 54 44 50
Cover Feature Additive Manufacturing Special 3D PRINTING'S INDIA STORY STRATASYS amace solutions Pvt. Ltd Dassault Systèmes Altem Technologies Renishaw Metrology Systems 3DPERA Field Ready ANCA Software
Tech Primer TRUMPF
18 20 24 26 30 32 33 34 68 60
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Message | EDITOR’S NOTE
3D Printing Can Help Usher In the Maker Movement
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e work hard at making every issue a special, and sometimes our work pays off truly spectacularly, as it has this time. Our special on 3D printing – also referred to as additive manufacturing – started as an effort to explore its current state of development and adoption globally, and the level of awareness and adoption the technology has gained (or not) – in India. What started out as an exploratory endeavor, soon turned into an illuminating journey, as we got incredible opportunities to interact with leaders in this space. To give you an idea of the tremendous scope and depth of the insights that we have been able to bring to you, let me share names of some of the thought leaders who have contributed to this issue. Ms. Renuka Srinivasan, Director- SIMULIA WW, Dassault Systemes; Rajiv Bajaj, Managing Director, Stratasys India and SEA; Dr. Vishwas R Puttige, Business Head, amace solutions Pvt. Ltd; and Prasad Rodagi, Founder Director, Altem Technologies are among the eminent 3d-printing industry thought leaders who not only shared their perspective of the technology, its current state and the future, they really delved deep into the subject to give us fascinating facts, solutions and case studies that could only come from those who are spearheading the 3DP revolution, helping large and small companies gain from the tremendous benefits of the technology. Here are some of the main (not all) insights that we gathered about the current state and the future of additive manufacturing, from the interactions: One, the technology has taken big strides in terms of utility and deployment in manufacturing, particularly in the automotive, aerospace and the healthcare sectors. Two, the technology has the proven ability to turbo-charge manufacturing capabilities, especially for the SMEs, in the ways that it slashes the cost of customization and speeds up prototyping. Three, India’s education sector, particularly the engineering and medical institutes, can leverage this technology and its applications to leapfrog to the forefront of the global technological innovation movement – many institutes, such as NTTF, Bengaluru and GNDEC, Ludhiana have already taken this route. And four, as Dr. Puttige so insightfully and presciently noted in his article, 3D printing promises to usher in the ‘maker movement’ or the ‘maker culture’ in India, which gives craftsmanship its deserved status of the most prized skill in a society, and is therefore an essential requisite for igniting the industrial revolution, which has eluded us in India for long. I urge you to take your time to read our cover feature on 3D printing. It’s truly special. Do take a look. I look forward to your feedback. Stay tuned.
ANAND PANDEY Editor DMI Write to me at editorial@meshmixmedia.com
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Message | NOTES FROM THE FIELD
The China Experience I
had the privilege of attending Dassault Systemes’s two-day Annual Event Manufacturing in the Age of Experience, held in Shanghai, China on September 18 and 19. This year the theme of the event was Sustainable Manufacturing, which covered how global manufacturers are using the virtual world to reinvent their businesses. The event was attended by more than 200 decision makers, influencers and media personnel from the manufacturing sector, a large number of whom came in from different parts of the world. It was a very well organized and a highly focussed event with keynotes and presentations from a number of eminent speakers from companies Like Accenture, ABB, HUAWEI, SATS, among others. Panel sessions were engaging. Conversations highlighted the status and the growth of the global manufacturing industry, the current trends in China’s manufacturing sector and how Dassault Systemes is helping global organizations with its innovative solutions. I also got the opportunity to visit China International Industry Fair (CIIF), a guided tour organized by the Dassault Systemes team. The Electric Vehicle (EV) segment was the highlight of the show. All the leading global car manufacturers had put up there latest EV models for display. A number of Chinese carmakers had also showcased there latest models, which to me was a sign of the big way in which China is playing its role in the global EV revolution. Back in India, the Laser world of Photonics (LWOP) India is scheduled to take place from October 17 – 19 at Bombay Exhibition Center (BEC). I am happy to share that we are collaborating with Messe Muenchen India to publish the show-daily. As a team, we have the experience of working for major shows in India – it is always an exciting experience and a great way to experience the industry. Our current issue is an Additive Manufacturing special. We have the privilege bringing to you views from the biggest players of the AM industry – it is a special in the true sense of the word, in terms of the brilliant insights on how additive manufacturing is shaping up in India and the world, its state of adoption in India, the various case studies and use cases. We have Diwali around the corner. I want to take this opportunity to wish everyone a Very Happy & Prosperous Diwali 2019 in advance. Happy Reading! Sincerely,
DINESH MISHRA Senior VP – Strategy Meshmix Media Write to me at dinesh.mishra@meshmixmedia.com
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Curtain Raiser | LWOP INDIA
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Messe Muenchen India And ARCI Bring CALM This October Messe Muenchen India and ARCI present CALM 2019 – a two-day conference focusing on laser processing and its applications.
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esse Muenchen India (MM India) and India International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), an autonomous research and development centre of the Department of Science and Technology (DST), Government of India have joined forces to bring a two-day conference – CALM 2019, at the upcoming edition of Laser World of Photonics (LWOP) India, taking place from 17th to 19th October 2019 at the Bombay Exhibition Center (BEC) in Mumbai. CALM 2019 – International Conference on the Application of Lasers in Manufacturing – will focus on laser as a vital manufacturing tool and give an outlook on its various applications. Applications of lasers in manufacturing have been consistently growing globally, over the years. The conference will cover both the basic as well as industrial perspectives. With keynote speakers who are experts in the fields of lasers and laser processing as well as laser and laser system manufacturing, the conference will cover important topics such as metal additive manufacturing, laser cladding/laser metal deposition/ repair and refurbishment, laser hardening, laser welding, cutting /drilling, and laser micro/ nano processing. A series of panel discussions and open forums will ensure that the conference is interactive and informative. Bhupinder Singh, CEO, Messe Muenchen India, commented on the collaboration: “The laser industry in India is witnessing an upsurge with the increasing applications of lasers in various industries. We hope that this initiative will bring the topmost experts at a common platform. It is being concurrently organized with LWOP India, which is a great opportunity to gain both theoretical as well as practical knowledge and to prepare one’s business for the future.” CALM 2019 will give in-depth insights on the latest technologies and is ideal for engineers and managers from any industrial sector involved in manufacturing processes, laser-processing professionals looking for new technology developments in micromachining, cladding, hardening, welding, cutting, drilling, repair & refurbishment and metal additive manufacturing; laser system manufacturers and suppliers of
components; and researchers and students from academic and R&D organizations. The laser and optical industry in India is gaining an increasing momentum with every passing year. LASER World of PHOTONICS INDIA provides an optimal platform for the industry professionals to exhibit their technological advancements and solutions and to build a strong network for business alliances. Correspondingly organized CALM 2019 will increase the value quotient of the show by providing conclusive and detailed study on laser processing and its applications. The upcoming edition of LASER World of PHOTONICS INDIA in Mumbai is going to be an extensive three-day event from 17th – 19th October 2019 at the Bombay Exhibition Center (BEC) and a must-visit for the professionals of the laser and optical sector in the country. LWOP India has been held every year since 2012 in different places in India. In 2018 the trade fair attracted 9,974 visitors and 158 exhibitors. The LWOP global network LWOP is an international trade fair network. LWOP held every year in Munich, Germany is deemed as the world's leading trade fair for the laser and photonics industry. The World of Photonics Congress is Europe’s largest photonics congress. LWOP China and India are leading regional trade fairs for laser and optical technologies and are hosted annually. Messe München is one of the leading exhibition organizers worldwide with more than 50 of its own trade shows for capital goods, consumer goods and new technologies. Every year, a total of over 50,000 exhibitors and around three million visitors take part in more than 200 events at the exhibition center in Munich, at the ICM – Internationales Congress Center München and the MOC Veranstaltungscenter München as well as abroad. Together with its subsidiary companies, Messe München organizes trade shows in China, India, Brazil, Russia, Turkey, South Africa, Nigeria, Vietnam and Iran. With a network of associated companies in Europe, Asia, Africa and South America as well as around 70 representations abroad for over 100 countries. www.mm-india.in
Key Highlight: Messe München organizes trade shows in China, India, Brazil, Russia, Turkey, South Africa, Nigeria, Vietnam and Iran. With a network of associated companies in Europe, Asia, Africa and South America as well as around 70 representations abroad for over 100 countries.
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Curtain Raiser | LWOP INDIA
Laser Focused On Growth Laser World of Photonics (LWOP) India aims to bring greater business opportunities for exhibitors and visitors this year
Mr. Bhupinder Singh, CEO, Messe Muenchen India Picture: Messe Muenchen India
L
aser World of Photonics (LWOP) India is the only regional trade fair for laser and optical technologies in India. It has been held every year since 2012 in different cities in India. In 2018 the trade fair attracted 9,974 visitors and 158 exhibitors.
The upcoming LWOP India will take place from October 17 to 19, 2019 at the Bombay Exhibition Centre (BEC), Mumbai. DMI interacted with Mr. Bhupinder Singh, CEO, Messe Muenchen India, who shared the fair's evolutions and main attractions. Edited excerpts.
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Over the years, Laser World of Photonics has grown to become India’s biggest trade fair of the laser and photonics sector in terms of size and industry participation. What are your plans for the upcoming edition? It’s been seven years since Laser World of Photonics’ (LWOP) inception and the growth rate of the trade fair has been exceptional with exhibitors from over 13 countries and the visitorcount reaching about 10,000 in the last edition. For the 2019 edition we plan to bring even bigger global brands to the Indian turf. The laser and optical industry in India is gaining momentum with every passing year and we aim to make LWOP a central platform for industry professionals to exhibit their technological advancements and build a strong network for business alliances. With the 2019 edition, we want to bring laser manufacturing and its applications in the forefront. The conference CALM (International Conference on the Application of Lasers in Manufacturing), jointly organized with India International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI) is particularly designed for this purpose. What are the key attractions for exhibitors and visitors in store at LWOP 2019? Along with providing a lucrative stage for industry players to network and showcase their brands to visitors from various industries, we will also have a pavilion dedicated to displaying laser-based additive manufacturing machines, 3D printers, software, raw material and services to visitors from Aerospace & Defence, Automotive, Electronics, Medical, Machine tool, Jewellery, Tool-making and machining, job-shops, and R&D and other industries. The Machine Vision Pavilion will display machine-vision products and services with visitors from various manufacturing industries like Automotive, Machine Tools, Die Mould, Electrical, Engineering & Electronics, Medical, Packaging, R&D institutes and government bodies. A major attraction is the Buyer-Seller forum which is a vendor development program, providing a platform for buyers to conduct one-to-one meetings with numerous sellers. The conference CALM will focus on laser as a vital manufacturing tool and its various applications. Can you share your experience of hosting the country’s largest trade fair for laser and photonics technologies and product offerings? What insights have you gained from this experience? Organizing India’s number one trade
fair Laser World of Photonics, with Congress for Photonics Components, Systems and Applications, has given us a great number of insights on the laser and photonics sector in India. The market is rapidly growing and swiftly moving from conventional methods to modern technologies. Laser and its applications have tremendously helped in reducing manufacturing cost, increasing productively while delivering unsurpassed quality. In the last couple of years, the laser technology has taken big strides in the production of agriculture equipment, automobiles, aerospace, and fabrication while maintaining a strong foothold in the jewelry sector. How do you see the current economic environment impacting the country’s laser and photonics industry in particular? The Indian market for photonics had been witnessing a healthy growth rate until last year. The past few months, however, have been challenging for the Indian manufacturing industry in terms of growth and investments. To revitalize the industry, the government has recently announced a host of supportive measures, including permitting 100 percent FDI in contract manufacturing and lowering lending rates. These supportive measures initiated by the government will prove highly advantageous to the laser and photonics industry in India in the medium and long term. Can you throw some light on the CALM conference? CALM is an international Conference focused on the application of lasers in manufacturing. CALM 2019 will focus on laser as a vital manufacturing tool and give an insight on its various applications. The various applications of lasers in manufacturing have been consistently growing globally over the years. The conference will cover both the basic as well as industrial perspectives. With keynote speakers who are experts in the fields of lasers and laser processing as well as laser and laser-system manufacturing, the conference will cover important topics such as metal additive manufacturing, laser cladding, laser metal deposition, repair and refurbishment, laser hardening, laser welding, cutting, drilling, laser micro- and nano-processing. A series of panel discussions and open forums will ensure that the conference is going to be interactive and informative. www.mm-india.in
Key Highlight: 3D printers, software, raw material and services to visitors from Aerospace & Defence, Automotive, Electronics, Medical, Machine tool, Jewellery, Tool-making and machining, job-shops, and R&D and other industries.
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Post-Event Report | EMO HANNOVER 2019
EMO Hannover 2019 provides clarity in uncertain times Trade fair builds on successful run
Visitors from Asia, particularly India, China, Japan and Taiwan, made up almost one third of foreign visitors this year.
Key Highlight: The next EMO will be staged in Milan from 4 to 9 October 2021.
E
MO Hannover 2019 closed its doors this year following a six-day run. From 16 to 21 September, round about 117,000 production specialists from 150 countries convened at the world’s leading tradeshow for the metalworking industry. “This EMO Hannover 2019 built on the success of our boom year in 2017,” reported EMO General Commissioner Carl Martin Welcker. He continued: “In the context of subdued economic expectations over the past several months, the moderate decline in attendance has to be viewed as a success. We are particularly delighted at the further increase in the percentage of foreign attendees.” The mood in the halls was positive, with many exhibitors pleasantly surprised at the high volume of visitor traffic at their stands. “EMO Hannover has once again proved solid as a rock, providing clarity for the further development of production technology, even in uncertain times,” Welcker added. Its trademarks included a
strong international character, a high caliber of visitors and exhibitors, and an amazing wealth of innovations and new products, he stressed. As the world’s leading metalworking fair, it was the “place to be”. Mixed mood – investment-readiness bodes well for post-show business Exhibitors with a broad customer base were satisfied with the run of the fair. In the words of Dr. Wolfgang Heuring, CEO of the Erlangen-based Motion Control Business Unit at Siemens: “The level of visitor interest at our stand this year was incredible. We are delighted at the way things have gone.” Other firms with a stronger focus on the passenger car industry seemed to be less upbeat about the situation. “Firms are clearly more reluctant to commit themselves, given the general uncertainty over where the market is heading,” remarked Dr. Christian Lang, CEO of Liebherr-
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Verzahntechnik in Kempten. “But our discussions with customers at our stand have still been substantive and very promising for the future,” he added. While some exhibitors spoke of a historic paradigm shift in the automotive industry, which still needed to be mastered, other exhibitors reported successfully negotiating business deals with automakers during the fair. At the start of EMO Hannover, there was some worry about the news that many customers were cutting their travel budgets. Yet the percentage of company executives among tradeshow attendees was about as high as two years ago, at 58 percent. Around half of these came armed with capital investment plans, and for foreign visitors, this figure was even higher, at more than 62 percent. 25 percent of attendees placed orders during the fair or planned to do so in the near future. A further 20 percent intended to spend money downstream from the fair. “We’ve had a lot of discussions focusing on specific customer requirements. Many users are carefully considering which capital expenditures they need to best position themselves for the future,” said Matthias Funk, CEO of Hedelius Vertriebsgesellschaft in Meppen. The main focus was on expansion and replacement investments in flexible manufacturing, production machines, tools and automation. “First we need to find out what is happening in the industry, then we will make
Carl Martin Welcker, EMO General Commissioner, (r) and Dr. Wilfried Schäfer, CEO of the EMO event organizer VDW (German Machine Tool Builders’ Association), looking back on a successful EMO Hannover 2019.
Key Highlights: The highly international makeup of EMO visitors, particularly from Asia, resulted in a busy and extremely global atmosphere at our stand. - Dr. Stefan Brand
our investment decisions after EMO is over,” says Kiyokazu Sugiyama of Nissan Motor Co. Ltd., Yokohama, after spending three days at the fair taking a close look at all the displays. Gebhard Debor, manufacturing manager at Linde Hydraulics in Aschaffenburg, commented: “If we find what we’re looking for, we’re ready to talk business right now.” Strong Asian presence at EMO Hannover As the flagship fair for its sector of industry, EMO Hannover has a strong international profile. More than half of all attendees came from abroad, split almost evenly between other European countries and overseas. A 20 percent growth in attendance from overseas in comparison with the 2017 event was particularly impressive. This included a high percentage of Asian guests, who accounted for almost one third of visitors from abroad, with China, Japan, Taiwan and India heading the rankings. “The highly international makeup of EMO visitors, particularly from Asia, resulted in a busy and extremely global atmosphere at our stand,” said Dr. Stefan Brand, CEO of Vollmer Werke in Biberach. This trend was clearly related to a higher number of Asian exhibitors at this year’s event, who encouraged their customers to visit them in Hannover. Other countries with strong representation at the event included Italy, Poland, Sweden, Russia and Turkey.
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Post-Event Report | EMO HANNOVER 2019
The EMO motto: “Smart technologies driving tomorrow’s production” accurately anticipated the key themes at EMO Hannover 2019.
From 16 to 21 September, round about 117,000 international production specialists from 150 countries convened at EMO Hannover 2019.
Key Highlight: The EMO motto “Smart technologies driving tomorrow’s production” accurately reflected the key issues facing the industry today.
Digitalization and automation gathering momentum “This year’s EMO once again generated fresh momentum for innovations,” reported Lothar Horn, Managing Director of Paul Horn GmbH in Tübingen. As an innovation platform for production technology, EMO is expected to chart the trends for the years ahead, and once again the mission was successful. The EMO motto “Smart technologies driving tomorrow’s production” accurately reflected the key issues facing the industry today. “Our many discussions with customers at EMO 2019 in Hannover revealed that a focus on the holistic process chain, including digital services, creates the relevant added value for customers,” said Christian Thönes, Chairman of the Executive Board at Bielefeld-based DMG Mori AG.
This feeling was shared across all exhibitor segments. “The positive visitor response to our cloud-based simulation tools and monitoring system as an Industry 4.0 application was striking,” commented Marie-Sophie Maier-Wember, CEO of Haas Schleifmaschinen GmbH in Trossingen. And the buzzwords of IoT platforms, apps, digital twins, artificial intelligence (AI), edge and cloud computing were omnipresent at the fair. This all served to highlight just how much has changed since the most recent event two years ago. Particularly in Hall 9, the domains of research and practice came together. This blend of research and industry attracted large visitor numbers from around the world. “We have made many new contacts, and the ideas garnered from talking to all these people will hopefully feed into future research projects,” commented Prof. Berend Denkena, President of the Academic Association for Production Technology (WGP) and head of the Institute for Production Technology and Machine Tools (IFW).“One clear conclusion from all this is that digitalization and automation will chart our path into the future, you can see that right here at EMO Hannover,” he added.
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industrial internet of things (IIoT), 5G and OPC UA or umati, the new standard interface between machine tools and overarching IT systems. The standout attraction consisted of the big umatishowcase, which included 110 machines from 70 international firms and partners, demonstrating for the first time that the universal interface between machines and IT systems can function across all product types. According to umati project manager Dr. Alexander Broos, “the response to umati among our partners and customers has been huge. This display at EMO has successfully launched us on the market. Our next commission on returning home is to deliver the OPC UA Companion Specification at the earliest possible date.”
This year’s EMO also featured the first AI applications in the Start-up area and at the stands of the relevant trailblazing companies. Along with the strong interest in AI and machine learning, visitors’ appetite for future visions was reflected in the accompanying events and forums, where the topics included not only AI, but also additive processes, the
Key Highlight:
EMO Hannover 2019 opens window to future “Against all expectations, we can wrap up EMO Hannover 2019 on a positive note. The fair is attractive for the entire international production technology community and has confirmed there is still demand for capital investment in the marketplace. Despite all the political turmoil, this trade fair has revealed that industry is actively addressing the challenges of the future and is determined to make its contribution as a problem solver,” concluded EMO general commissioner Carl Martin Welcker. The next EMO will be staged in Milan from 4 to 9 October 2021.
110 machines from 70 international firms and partners, demonstrating for the first time that the universal interface between machines and IT systems can function across all product types.
www.emo-hannover.de
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PRESENTS
Actionable Insights from Industry Leaders on Strategy, Innovation & Growth
A
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Cover Feature | ADDITIVE MANUFACTURING SPECIAL
ADDITIVE MANUFACTURING SPECIAL
Industry leaders illustrate the status and roadmap of 3D Printing (a.k.a Additive Manufacturing) in Indian manufacturing.
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Cover Feature | STRATASYS
3D Printing Holds Great Promise for Humanity's Future Rajiv Bajaj, Managing Director, India & SEA, Stratasys shares fascinating insights on the additive manufacturing a.k.a. 3D printing technology. An engaging conversation replete with unmissable takeaways for both students and practitioners of manufacturing
S Mr Bajaj speaking at a Stratasys India User Forum, about the usage of Stratasys technology for wind-tunnel testing of the Statue of Unity model, among other success stories
tratasys, one of the global leaders and pioneers in additive manufacturing (also known as 3D printing technology), is the manufacturer of FDM (Fused Deposition Modelling) and PolyJet 3D Printers. The company’s technologies are used to create prototypes, manufacturing tools, and production parts for industries, including aerospace, automotive, healthcare, consumer products and education. For 30 years, Stratasys products have helped manufacturers reduce product-development time, cost, and time-to-market, as well as reduce or eliminate tooling costs and improve product quality. The Stratasys 3D printing ecosystem of solutions and expertise includes: 3D printers, materials, software, expert services, and on-demand parts production. The company's India arm has been at the forefront of adoption of 3D
printing in manufacturing in Inda. Rajiv Bajaj, Managing Director, India & SEA, Stratasys spoke to Aanand Pandey, Editor, DMI on a range of areas related to the technology, including its various benefits and breakthroughs in manufacturing, healthcare, and education. Edited excerpts. Additive manufacturing (AM) or 3Dprinting (3DP) is said to be the 4th emerging field of manufacturing after subtractive, forming and casting. In the overall spectrum of manufacturing technologies, were do you see a fit for 3D printing? It’s a pertinent question because a lot of people perceive that one form of manufacturing could possibly limit the other form. For example, there could be a misconception that AM may completely eliminate traditional manufacturing technologies like subtractive, casting or forming.
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But the best use of any technology and that of AM – in terms of the increasing complexity of products and manufacturing – is to utilize it in conjunction with each of these traditional technologies and the scope of their capabilities. So an intelligent organisation would use AM to complement traditional technologies as per utilization and the various possibilities. Could you give me an example of how AM could be used to complement conventional manufacturing technologies and/or processes? Let me give you an example of a Hong Kongbased tool, die, and mould-making company that we worked with. I met their managing director in my early days of joining Stratasys. He recounted that after he deployed additive manufacturing, he started giving samples of parts to customers in the aerospace industry, which the latter found to be a good fit for wind tunnel testing. With the passage of time, customers started to give more orders of such samples. Starting from one, the number of AM-made sample parts increased to 40-50 pieces. The customers would use these sample parts to do wind tunnel analyses as per their parameters, whereupon they would give orders for bulk quantity of the components, to be made through conventional manufacturing process, in numbers running into hundreds to thousands. So this is one way, where you make the first few samples using AM for testing, and then manufacture the parts using the traditional methods. To share another example, automotive companies use CNC machines, which are typically used as part of an automated line. When they automate a process, there is a good amount of customization that they can do, where they can use additive manufacturing along with the subtractive machining to give a complete solution to the customer and reduce overall process cycle times significantly. Let’s say they are setting up a line that uses automated manufacturing robots. There is a component in the robot systems called the End of Arm Tooling which is used to pick, place or hold certain parts during the process of machining. Additive manufacturing can quickly customize the End of Arm Tooling application, making the entire process highly cost and time efficient. The level of awareness of 3D Printing (3DP) in India is low. How do you use your position and legacy to promote and increase the use of this technology in India? Stratasys is a 30-plus year old company and a pioneer in the additive manufacturing
Rajiv Bajaj, MD, India & SEA, Stratasys
Key Highlight:
We recently tied up with NTTF (National Technical Training Foundation), Bangalore to set up India's first and only certified additive manufacturing training program which will equip students with additive manufacturing skills that can be applied to the industry.
industry. We have been present in India for the last 20 years and have invested significantly in a state-of-the-art Experience Centre in Bangalore to showcase our latest technologies to Indian customers. As a domain leader, we collaborate with industry and academia to champion the adoption of 3D printing in India. Working closely with the industry has helped us realise that the industry is looking for trained manpower in 3D Printing – people who could use 3DP from day one for adoption in the organisation. This is one of the areas where our collaboration with the academia helps. We recently tied up with NTTF (National Technical Training Foundation), Bangalore to set up India's first and only certified additive manufacturing training program which will equip students with additive manufacturing skills that can be applied to the industry. Education is a big application area – in addition to the aforesaid academic collaborations, we are in the process of setting up some new Centres of Excellence with leading educational institutes. This is a specialized program – we will qualify these centres to ensure that the quality of AM certification programs is world class, and therefore limit the number of COEs to one per key geography in India.
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Cover Feature | STRATASYS
Key Highlight:
The 3D-printed fixtures were 75-percent lighter [than the original weight], and the manufacturing cost was reduced by 50 - 60 percent!
Process design is a highly important element of additive manufacturing applications – a 3D printer simplifies the complexities [of the manufacturing process], and practically builds any part with any complex feature. To that goal, students trained in additive manufacturing design are able to bring about much larger benefits to the process and the industry at large. To give you an example, we worked with Honda cars in India, which was looking to explore the possibilities of deploying 3DP into its manufacturing process. We completely redesigned their inspection jigs and fixtures for additive manufacturing, from metal parts to consolidated plastics assembly. The 3D-printed fixtures were 75-percent lighter [than the original weight], and the manufacturing cost was reduced by 50 - 60 percent! These are the kinds of paradigm shifts that happen when you bring in the technology and collaborate with customers to expand and explore the possibilities for introducing additive manufacturing to their existing process. And this is our role as well as responsibility as a technology leader – of bringing the knowhow to the industry. Today, most of the leading Indian engineering institutes like the NITs (National Institutes of Technology), the IIT (Indian Institutes of Technology) and other top universities are using our industrial 3D printers to bridge the skill gap by training and enabling the students with advanced technologies used by the industry and making them industry ready. Could you list out the top, say, three industries in India in terms of the current applications and possibilities for the 3DP/AM technology? Aerospace and automotive industries have been fast adopters of additive manufacturing, particularly for components which are low in volume but high in design complexity. Of course, prototyping plays a big role, which can be expanded to make jigs, fixtures, tooling and customized features. Global car companies like Daihatsu and BMW use 3DP to manufacture customized parts, for example. So let’s say if you buy a car in India and you are given the choice of designing some elements of car such as the design of the car’s tail or side lights, then such things can be made with 3DP. India has a lower adoption level compared to the other part of the [industrialized] world, but there are early adopters in India in sectors beyond aerospace and automotive. We have had successes in the shoe-making industry, in the manufacturing of products as diverse as dental aligners and bicycles and with architecture firms. In fact, the Statue of Unity model was
built and analysed for wind-tunnel testing by a company called RWDI using Stratasys technology [The Statue of Unity is a colossal statue of the Iron Man of India, Sardar Vallabhbhai Patel, in Gujarat]. The other big industry for 3DP applications is the medical industry. Surgical planning is a big area where 3DP helps with the simulation of any planned procedure. With new advanced printers which offer a range of materials that mimic tissue matrix, bone, and gel along with millions of colour and transparency options, surgeons are able to create specific morphologies to simulate the surgery on 3D-printed models which are anatomically precise and realistic. These 3D printed models accurately follow a patient's unique anatomy with the help of MRI and CT scans. I want to share an inspiring success story of a miraculous surgery done by Dr. Harinder Singh Bedi, Chief Consultant Cardio Vascular Endovascular & Thoracic Sciences, Shalby Hospital, Mohali, Punjab. In 2018, a 23-year old man consulted Dr. Bedi for treatment of a mysterious condition that was turning his body blue in colour [termed cyanosis in medical parlance] and was causing shortness of breath. A CT scan revealed a large malformation that connected a pulmonary artery and the vein; a rare condition called AVM (Pulmonary Arteriovenous Malformation) in which the blood bypasses the lungs and is therefore bereft of oxygen when it enters the heart [hence the cyanosis]. Since it was a highly complex and mission-critical operation, Dr. Bedi approached the Manufacturing Research Lab (MRL) of Guru Nanak Dev Engineering College (GNDEC), Ludhiana, which specializes in additive manufacturing activities. The MRL used a Stratasys 3D Printer to make an exact replica of the AVM using its 2D dimensions from the CT scan. The 3D model helped Dr. Bedi do the surgery in a record time, reducing the surgery duration from expected 4.5 hours to 1.5 hours, that too with minimal loss of blood. [The case study has been published on CTS Net, a reputed global cardiothoracic surgery network platform, and widely hailed as a breakthrough in 3DP-assisted surgeries. – Editor] So what I gather is that the medical industry is the biggest in terms of the level of adoption and potential, then we have the aerospace and automotive industries... Yes and no. The aerospace and automotive industries have taken big strides in terms of the adoption of 3D printing. The level of reach in terms of the number of manufacturers could be low globally, but the level of adoption in terms of processes is higher than the other industries. The medical industry in India is a promising
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domain for adoption of 3D printing. Since the healthcare industry is more cautious than others is adopting any new technology, it is important that the medical students are trained well in advance for them to adopt the new digital healthcare solutions for practice. The integration of medicine and technology in India is only a matter of time now. The world is progressing towards research on printing through human cells and bio printing. There is a lot of scope for expansion and adoption in terms of saving lives, providing quality healthcare and improving the quality of life. I firmly believe that AM holds great promise for the future of humanity. The adoption of AM in India is very low compared to, say China and Japan. As per one estimate, India accounts for a total 3 percent of the units installed in the APAC region, whereas China makes for 35 percent and Japan 30 percent. What are the reasons responsible for the low level of adoption of AM in India? If you take any other cutting edge technology, you will find adoption levels low in India in terms of the market share and size. For example, any leading manufacturer in Europe would have 50 plus 3D printers installed, a Japanese manufacturer will have nearly 25 3D printers, and a similarly ranked Indian manufacturer will have 1 or maximum two. That to me presents an opportunity of expanding the scope of AM into multiple areas and multiple departments within organizations that we work with. That also puts onus on leading technology organizations like ours to showcase the usage and spread its awareness through the academia among the current generation of manufacturers and technologists. Speaking of awareness, can you cite the major benefits of 3D Printing/Additive Manufacturing which must appeal to the Indian manufacturers, particularly those from the SME sector? Sure, here are the other main benefits: One, when you are launching any new product, there is lot of investment that goes into designing jigs, fixtures and tooling, both in terms of the lead time and money. When you successfully integrate 3D printing into your existing manufacturing process, you can save anywhere between 40 to 60 percent in terms of time and investment, which can really help in making your product line successful. Two, there is also a lot of platform utilization that goes on across a production line. Additive manufacturing plays a defining role in making production lines modularfor assembling different
models of a product, like a car, wherein only a few parts in the assembly line need to be changed. To share an example, we worked with a leading bearings manufacturer to identify areas in its conventional manufacturing process where the company needed to replace a few machining parts to make different bearings sizes. We were able to build those parts in a single day as against 10 to 12 days that it normally takes. Three, rapid prototyping is a great benefit which is already utilized globally. In India, this is a feature that can be used more by manufacturers in industries such as automotive, consumer electronics, mobile phones and even shoes. 3D printing helps cut down the concept-to-production time significantly as you can use 3DP as a bridge to quickly finalise your design and accelerate the production cycle. In addition, there are many other benefits that emerge when we work jointly with the customer since no two shop floors are completely similar. There is perception among the customers that the cost of installation of 3D printers, their parts and maintenance are highly expensive. How do you address that perception? For companies and schools new to 3D printing as well as the established users, Stratasys 3D printers are a game-changing choice, what with the highest levels of plug-and-print reliability and repeatable accuracy they bring to the table. Customers need industrial 3D Printers at an affordable price. When I say industrial 3D printing, it is not about the size of the 3D printer, it’s also the predictability, quality and throughput of the printer which it delivers continuously throughout the process. Stratasys printers are known for quality, reliability, and throughput. Today we have printers like the F120 which are specially made for MSME and SME bringing 3D printers to individuals and small sized teams which support and enhance creativity and innovation. Not only are these 3D printers affordable, they also give the same industry-level output which our bigger printers do. Then we also offer top-of-the-line 3D printers like the Fortus 450 mc or Fortus 900 mc, which most large automotive companies in the country use to streamline manufacturing while maximizing client’s capabilities of making large prototypes as well as low-volume parts with agility and accuracy.
https://www.stratasys.com
Key Highlight:
The MRL used a Stratasys 3D Printer to make an exact replica of the AVM using its 2D dimensions from the CT scan.
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Cover Feature | AMACE SOLUTIONS
3DP Could Help Augment India’s Maker Culture Dr. Vishwas R Puttige, Business Head, amace solutions Pvt. Ltd shares many prescient insights on 3d printing and the promise it holds for India’s manufacturing sector
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engaluru-based amace solutions Pvt. Ltd is the brainchild of two leading machine tool manufacturing companies in India – Ace Designers Ltd. and Ace Manufacturing Systems Ltd (AMS), one of the largest CNC machining center manufacturers in India. They are an integral part of the larger Ace Micromatic Group. Ace Micromatic Group serves almost every sector, from the automotive manufacturing, general engineering, die & mould industry to defence, aerospace, and medical among others. Dr. Vishwas R Puttige, Business Head, amace solutions Pvt. Ltd shared with us highly informative and comprehensive insights on the subject. Edited excerpts of the interaction. Could you please cite instances of applications of additive manufacturing in India in your own production facilities or your customers’ facilities deployed through your services? Since our inception, we at amace solutions have been actively serving the automobile, aerospace and defence industries. We have been using 3D printing for prototypes as well as end-use parts for defence applications. The freedom to design and manufacture complex geometries at a rapid scale has allowed this technology to be used for such a wide range of applications. The migration of the auto industry to BS-VI has made the auto OEM’s to 3D print critical transmission components rapidly that would be tested and validated before it goes for the actual production. ISRO has been extensively using additive manufacturing technology and has printed several parts for its space missions. A lot of 3D-printed parts were used for the recently executed Chandrayaan II mission. The tooling industry has been taking advantage of printing conformal cooling channels for the die inserts. The tooling manufacturers have been benefited through increased productivity from the dies manufactured through the 3D printing process. General engineering components which are required either in small quantities or with complex geometries are being 3D-printed costeffectively. Can you share similar examples of additive-manufacturing applications happening globally that could be adopted in Indian manufacturing? Globally, additive manufacturing is adding value to sectors such as automotive, healthcare, aerospace, defence, education and research. The aerospace industry is an early adopter of additive manufacturing technology with diverse applications that range from concept prototyping to printing structural aero parts.
The automotive industry has adopted additive manufacturing technology for customised parts development. The production of customized features in low-volume vehicles is often too expensive for automakers. Additive manufacturing offers solutions for printing of small batches of automotive parts for low-volume models. The aerospace and automotive industries are increasingly using additive manufacturing technology to manufacture lightweight components in order to improve fuel economy. What are the main benefits of incorporating 3D printing into the manufacturing process? 3D printing can help organisation realise the benefits along its complete value chain. Some of the benefits are:
Dr. Vishwas R Puttige, Business Head, amace solutions Pvt. Ltd
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• Topology optimization. Structural optimization with weight reduction and generative design concepts are possible without deterioration of quality or strength. Light weight and stronger designs provide higher mechanical strength and stiffness. • Freedom to design. Through Additive Manufacturing, parts with intricate and complex geometries can be printed with ease. • Rapid prototyping. Additive manufacturing allows for faster new product development with the flexibility of creating, testing & validating multiple design iterations as per end application or customer’s specifications. • On-demand manufacturing. Additive manufacturing offers the flexibility to print only when it is required. Hence avoiding the unnecessary costs of carrying inventory. This finds applications in spare parts management and can lead to reduced costs on inventory, logistics and spare parts production. • Reduced inventory and aftermarket costs. 3D printing brings high flexibility in delivery of spare parts and reduced costs on inventory, logistics and spare-parts production.
As it appears, the ultimate goal of 3D printing is to move production close to the point of consumption, also called nearshoring. Is this a feasible goal, considering that locating production at manufacturing hubs is far more economical, particularly for mass produced goods? Near-shoring may not be possible everywhere. However, in the near future as mass production reduces and with increased customisation, this will cater to the diverse demands of each customer, hence heavily shrinking the batch sizes of manufacturing. Additive manufacturing is the only way forward for such applications. How do you see the evolution of adoption of additive manufacturing, globally? For example, do you see it evolving from the current stage of creation of highly specialized, low-volume parts, to that of creating customized mass-produced goods? Yes, the transition is happening. Additive manufacturing is already being used for producing high-volume parts such as dental copings,
hearing aids, etc. that are patient specific. This is only going to grow at a rapid rate henceforth once the value is seen by many end users. Can the 3D printing technology be used in the area of education to increase the awareness and interest for engineering and technology among students in India? In India, awareness remains a major issue. There are start-ups that have taken 3D printing to schools. The Government of India in association with NITI Aayog has initiated “Atal Tinkering Labs” as part of the “Atal Innovation Mission” where young minds are provided a handson experience in designing & building solutions. This fosters curiosity, creativity, and imagination in young minds and inculcates skills such as a design mindset, computational thinking, making them become the future thinkers and innovators. A lot of the technological institutes across India are making use of the 3D printing technology for academic research activities. The maker movement [a social movement with an artisan spirit] is quickly gaining strides in India. People want a hands-on experience in making their object. 3D printing augurs very well with these trends, fueling the demand for such initiatives. What are the biggest challenges that you see in the path to a large-scale adoption of 3D printing in manufacturing in India? The current AM market in India is at a very nascent stage as compared to the European and South East Asian markets. According to the 2018 Wohlers Report, India accounted for approximately 3 percent of total installed AM units in the Asia Pacific Region, while China stood at 35 percent and Japan at over 30 percent. Additive manufacturing is making slow but steady inroads into the industry. The scattered AM adoption in India is due to the reason that India is a very cost sensitive& risk averse market. However, some of the auto OEM, defence and aerospace organisations who were among the early adapters of this technology are currently realising the benefits. The rate at which the technology is changing, sooner or later it will become cost competitive for some of the batch production applications too, thereby leading to much more investments and adoption of additive manufacturing technologies. Do you feel that 3D printing has a big role to play in the coming years in the areas of humanitarian aid such as disaster relief? Absolutely! With the evolution of additive manufacturing technology, there is a high probability that this technology could be used in disaster relief applications on a larger scale and be introduced to build infrastructure such as bridges and homes for communities that have been displaced during natural disasters. Additive manufacturing continues to change the face of the medical industry and has been assisting doctors create patient specific implants very soon we would be witnessing 3D bio-printing which has made it possible to print live tissues and organs such as heart and kidneys.
https://am-ace.com
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Cover Feature | DASSAULT SYSTÈMES
3DP Will Change The Way Business Is Done Ms. Renuka Srinivasan, Director- SIMULIA WW, Dassault Systèmes shares with us fascinating and comprehensive insights on 3D printing’s benefits, scope, and the future of the technology.
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assault Systèmes is a leading 3D Design & Engineering Software company globally. The company provides PLM and 3D modeling software, simulation apps and industry solutions. Its solutions foster social innovation, expanding possibilities for the virtual world to improve the real world. The group brings value to over 250,000 customers of all sizes, in all industries, in more than 140 countries. Ms. Renuka Srinivasan, Director – SIMULIA WW, Dassault Systèmes shares with us fascinating and comprehensive insights on 3D printing’s benefits, scope, the future of the technology and her company’s solutions that are being deployed in India and the world. Could you please cite instances of applications of additive manufacturing in India deployed through your services? Additive manufacturing as a manufacturing technology has been evolving rapidly in India and has proved its worth in many fields. Recently, the technique has been more widely popularized as advancements in technology that have brought 3D printing to the desktop and the home, expanding the scope of additive manufacturing beyond rapid prototyping into industrial applications of both tool-product and direct-part production. In India, additive manufacturing has started surfacing in and has potential in commercial segments like aerospace, life sciences, industrial design, architecture, jewellery, automotive, engineering and construction, and many more. It is being used for both prototyping and manufacturing products. Our 3DEXPERIENCE platform covers all aspects of the additive manufacturing process, from conceptual design to manufacturing, and certification to repair. The 3DEXPERIENCE Marketplace allows our customers to collaborate with qualified services providers for on-demand manufacturing. The 3DEXPERIENCE Marketplace has over 50 digital manufacturers featuring over 500 machines, including qualified industrial providers from India. Can you share similar examples of additive-manufacturing applications being deployed globally that could be adopted in Indian manufacturing? As technology progresses and processes get streamlined, additive manufacturing is being adopted across Industries in the manufacturing sector. The scope of the technology has now expanded beyond rapid prototyping into industrial applications of both tool-product and direct-part production. Today, there are 3D printed structural parts certified for flying. Additive manufacturing provides manufacturers freedom from traditional design and manufacturing constraints, allowing them to take their designs to
new heights to meet engineering requirements without sacrificing part strength or performance. Additive manufacturing as a high-tech industry is still evolving rapidly, though it has already gained importance in the manufacturing sector. The ingenious nature of the technology allows for transformation not only in manufacturing but in the business model itself. Globally, 3D printing technology is already being used in a variety of Industries with aerospace, medical and consumer goods leading the charge. Dassault Systemes and Airbus APWorks, a subsidiary of Airbus and specialist in metal 3D printing, have a collaborative partnership for an integrated endto-end approach connecting upstream material design with downstream manufacturing process parameters enabling standardization of parameters and allowing for certification standards.
Ms. Renuka Srinivasan, Director – SIMULIA WW, Dassault Systèmes
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The automotive Industry is not far behind, with most OEMs having a design and manufacturing focus on additive manufacturing. Research firm Gartner Inc. predicts that by 2020, 75 percent of manufacturing operations globally will use printed jigs, fixtures, and other tooling made in-house or through a manufacturing service partner. With a push towards electrification of the automotive sector, additive manufacturing could be a useful technology for the auto manufacturers and startups in India for faster development of products and at a lower operational cost. What are the main benefits of incorporating 3D printing into the manufacturing process? The benefits of 3D printing for faster prototyping, faster tool creation and a faster timeto-market are well documented. 3D printing offers flexibility in manufacturing that is not easy to accomplish with conventional methods. This flexibility frees designers to develop natural shapes with complex interior structures, resulting in lightweight but structurally durable parts. Further, multiple parts of a sub-assembly may be combined and printed as a single complex part reducing the number of assembly operations and the part count. The process of 3D printing by adding layers – rather than a subtractive process like a traditional manufacturing process – results in lower wastage and increased savings. In addition, there is the possibility of printing on-demand (i.e. reduced inventory) as well as printing close to the point-ofuse contribute to a lower carbon footprint. Besides all of these benefits, the single most common factor for choosing 3D printing is the possibility for mass customization within a single batch. These benefits of additive manufacturing are not derived by just 3D printing an existing part – which was designed for traditional manufacturing processes. To gain these benefits, a collaborative process of designing for additive manufacturing across the enterprise, including design, materials, manufacturing and even business functions is necessary. The 3DEXPERIENCE Platform allows for collaboration across the enterprise connecting designers, analysts and manufacturing experts to enable innovation. It gives designers an integrated end-to-end process for additive manufacturing including generative design, coupled with optimization of topology and internal structures, build planning, virtual printing and part durability assessment. This would allow companies to shorten the lead time to production while designing a part that meets the performance, safety and quality requirements.
The ultimate goal of 3D printing is to move production close to the point of consumption. Is this a feasible goal, considering that locating production at manufacturing hubs is far more economical, particularly for mass produced goods? Certainly, one key benefit envisaged with 3D printing is bringing it closer to the point-of-use. Whether that is economically and environmentally viable would be driven by the type of product (e.g. a motorcycle versus a shoe), the type of printing (nature of materials used, type of printing process, emissions from the printing process, amount of electricity required) and the cost of the printer itself. 3D Printing technology – printers, printing processes and materials – is rapidly evolving, and hence, as industrial printers are becoming more affordable and clean, there will be proliferation of printing services bureaus. Printing closer to consumption areas will also reduce the need to transport the products across geographies, and to reduce the inventory for such goods. Thus, while this may be not be viable today, I expect technology advances in the future will make 3Dprinting closer to consumption locations viable for small to medium-scale productions of certain types of customized goods. How do you see the evolution of adoption of additive manufacturing evolving hereon, globally? While 3D printing as a technology has been around for some time, it has become popular only in the past few years with advances in printing technology and materials. It is a disruptive technology in many ways – the constraints of other manufacturing processes are no longer applicable, allowing for a design which is based on functional needs. Thus, you can see organic shapes which could not be created by traditional manufacturing methods. This has an appeal in creative areas like architecture, consumer products, jewellery, fashion and furniture. In addition, 3D printing allows personalization of the product so you could have patient specific implants being printed. This has a huge potential not just in life sciences but even in consumer goods and electronics, other industries as well. Besides 3D printing of implants or of wearable devices, the rapid development in bioprinting has tremendous potential and is worth following. Across most Industries, the use of additive manufacturing for spare parts or to replace out-dated models will continue. Digital information (like a CAD model) could be sent over the Internet and a spare part could be 3D Printed on demand. The 3D printing technology especially related to materials and to postprocessing will continue to evolve rapidly. The move to production of lowto medium volume parts using 3DPrinting will continue. Hybridization of manufacturing is to be expected. Most importantly, 3D printing will not only disrupt the manufacturing assembly line, but even the way business is done – creating new business opportunities but also, challenging and disrupting existing businesses. Can the 3D printing technology be used in the area of education to increase the awareness and interest for engineering and technology among students in India? 3D printing technology is being used actively in the education sector to increase the awareness and interest of the engineering students in India. Several engineering institutions in India have provided access to3Dprintersto students and have organized special courses on 3D printing. To fully leverage this, it is important to teach the best practices in designing the product to account for the additive manufacturing process – optimization for tool path, considering the impact of orientation, for example. Allowing students to design, virtually test and then physically create the parts using a 3D printer provides an experience-based learning environment. In addition
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Cover Feature | DASSAULT SYSTÈMES to the engineering students, even school students should be exposed to this technology to encourage a future generation of “makers”. As the emerging technologies disrupt the traditional manufacturing setups, the need for skilled workforce with know-how in these domains increases. To help develop these “workforces of the future”, Dassault Systemes has competency centres called 3DEXPERIENCE Innovation Centers where Dassault Systems collaborates with a college and a government body to offer specialised training and industry best practices to students in aerospace and automobile engineering. What are the biggest challenges that you see in the path to largescale adoption of 3D printing in manufacturing in India? Today, in India, suppliers and manufacturing companies alike are facing challenges on maturity and feasibility of 3D printing process, their own technical expertise in this area, and the availability and cost effectiveness of the printing materials. However, they realise the potential of additive manufacturing. They are aware of the need to improve 3D manufacturing costs, materials, and quality. There is a need for a skilled workforce in India for companies to expand and adopt 3D Printing technologies at a large-scale. Thus, three main areas of technological improvements in additive manufacturing in order to increase its field of application are: • Materials and Post-processing: Most 3D printed parts still require postprocessing before they can be used. Availability of printing materials (and possible standardization of these materials), along with the overall cost impacts the adoption of 3D Printing. • Improvements in the speed of printing • Quality standards for the materials and the printing process. This would allow for assessing the quality of the printed part, and help in easier acceptance by regulatory bodies, OEMs and even end-users. In addition, the need for technical expertise in additive manufacturing is need for companies to confidently adopt AM. As mentioned earlier, parts need to be designed for additive manufacturing process to fully exploit the benefits of using 3D Printing. Developing a part for 3D printing requires design and analysis abilities, understanding of the printing processes, knowledge of material behaviour and the ability to optimize across all these domains to arrive at a lightweight but effective design. Best practices need to be developed collaboratively and shared across the enterprise. Dassault Systemes is committed to offering a comprehensive digital platform to advance Additive manufacturing technology and to allow for digital continuity across the entire process. The 3DEXPERIENCE Platform allows for collaboration across the enterprise connecting designers, analysts and manufacturing experts to enable innovation. It gives designers an integrated end-to-end process for additive manufacturing including generative design, coupled with optimization of topology and internal structures, build planning, virtual printing and part durability assessment. Do you see 3D printing playing a big role in the coming years in the areas of humanitarian aid such as disaster relief and healthcare? Today, technology allows for 3D printing of parts in remote or hard-to-reach areas, provided there are 3D printers already available and online there. This makes 3D printing a potential source of relief in the aftermath of a disaster. The concept is that essential parts – spare parts for broken equipment, even medicines and implants – could be printed onsite based on digital data transmitted to the printers. There are examples of NGOs using 3D printing to create spares for equipment – even something as simple as fittings for water supply, to more complex medical equipment spares – as this is faster than shipping to the disaster area.
Many in the medical and healthcare industry have been pioneering the use of 3D printing for some time. Examples are available of 3D printing being used for personalized implants and prosthetics that are specific to a patient’s specific needs. Other areas of application include 3D printed models for training of medical students, use of bioprinted skins and soft tissues for medical research and 3D printing of pre-surgical models. There are still many risks associated with medical procedures and surgeries, and for complex surgeries, doctors need to evaluate and decide between different surgical approaches. Here, 3D printing of patientspecific model helps in surgical planning. Life-sciences and healthcare are directly linked to social well-being, and technology plays a major role in increasing treatment impact. In India, healthcare IT was expected to grow three times between 2012 and 2018, marking the criticality of adopting next-gen techniques in life sciences. The 3DEXPERIENCE Platform addresses requirements across the innovator-manufacturer-caregiver-patient matrix in Life Sciences. Through our 3DEXPERIENCE Lab, we have worked with several startups in this area. For example, Lucid Implants was one of the winners at the Startup Pitch organised at the 3DEXPERIENCE Forum 2019 in Bangalore. Lucid Implants founded in 2018 aimed at helping surgeons to predict and to validate a medical device for a specific patient by providing custom polymer and metal hard tissue implants as a bone replacement. Their total solution seamlessly integrates virtual surgical planning, intraoperative patient-specific tools, and personalized implants. Lucid Implants will get a chance to present their innovative idea to the members of the executive committee at Dassault Systèmes at the corporate headquarters in Vélizy, France. Further, they will be accelerated in the 3DEXPERIENCE Lab and mentored by Dassault Systèmes experts based in one of its offices around the world. Through 3DEXPERIENCE Lab we are also working with a French-American startup Biomodex. With the Lab’s support, Biomodex uses advanced software and 3D Printers for developing life-like organs for medical training and surgical planning. The 3DEXPERIENCE Lab was involved throughout the entire process from generating a cloud of points based on CT scans or MRI, to constructing the 3D virtual model, and during simulations to test material resistance and zones where the organ is most fragile. This process of creating the virtual 3D model is automated to reduce human error, and is now being extended to individual patient data. Thus, doctors could have a virtual twin of the exact organ which should help in surgical planning. https://www.3ds.com
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Cover Feature | ALTEM TECHNOLOGIES
AM Saves Time, Labour And Cost Prasad Rodagi, Founder Director, Altem Technologies shares unmissable insights on the key benefits, evolution, the top challenges pertaining to Additive Manufacturing (AM)
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LTEM Technologies (P) Ltd, as a partner to Dassault Systemes for PLM solutions, Stratasys for 3D Printing, Artec 3D for 3D Scanners, MSC Software for CAE solutions and ESTECO for Optimization solutions, presents advanced products and solutions in field of CAD/CAM/CAE/PLM and rapid prototyping machines. The company is headquartered in Bengaluru and operates through offices in Hyderabad, Chennai, Pune, Kolkata, Ahmedabad and New Delhi. Prasad Rodagi, Founder Director, Altem Technologies shares unmissable insights with us about the adoption, evolution and the top challenges pertaining to Additive Manufacturing. Industrial Applications – India Altem Technologies has been in the Additive Manufacturing space for over 9 years. In these years we have seen a lot of interesting projects and applications being executed using this technology, however traditionally these have been in conventional industries like Automotive and Aerospace. The past two years or so have seen a radical shift with respect to the adoption within other sectors such as consumer goods, packaging, education etc. But the most interesting work that we and some of our customers are doing is in the Healthcare space. The key of AM is customization, and what better example of customization than Humans, each of our organs are different and complications and surgeries can get very complicated. Use case in healthcare domain is divided into three segments: Surgical Planning, Dental and Medical Devices – Anatomical Studies and Surgical Planning, where we work to print replicas of actual human anatomy (example a kidney with a tumour or a heart with a congenital abnormality, etc.) following dimensions taken from medical scanning methods like MRI or CT Scan, to help the surgeon to prepare and plan the surgery beforehand. With advanced technologies like Polyjet that we house, we can produce these anatomies in full colour and multi-materials to differentiate different parts of an organ and create a close mimic of the organ not just in form but also in same feel as the real organ would feel when the surgeon is operating on it. The main value proposition of this is that a well-preparedsurgeon can perform the surgeries faster which results in less blood loss and faster recovery. The same is also being used in clinical trials and teaching. Industrial Applications – Global Additive Manufacturing has three prime applications in the world of manufacturing namely: Prototyping, Tooling and End Part production. Globally, the most usage is in the field of prototyping, however the trend is slowly moving from prototyping to tooling to end-use parts. The Indian market, with the exception of aerospace is a little slow in terms of adoption, while globally many companies are adopting tooling and end-use parts making additive a big part of their complete product life cycle. In India that trend is not yet seen. Globally, many companies have dedicated machines to jigs and fixtures, end-use parts, whereas in India, these applications are only a small part of
utilization of the systems installed in R&D for RPT (Rapid Prototyping Techniques). Main Benefits Additive Manufacturing (AM) offers various business benefits to companies, depending upon use case we have seen companies benefiting in terms of time, cost and efforts. Now use of additive may not always enable the user to save all three, but the general belief is that even if 1-2 of the 3 are saved then it’s worth going to additive manufacturing over conventional methods. For example, some of our customers have been able to cut down product development timelines from 2-3 months – and from a process that involves multiple machineries and people – to 1 week or less. In a few cases, additive is more expensive than traditional methods but its worth spending that extra cost due to time compression. Another major benefit of this is the ability to take faster go/no-go decisions, the ability to
Prasad Rodagi, Founder Director, Altem Technologies
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experiment with multiple options and to some extent the luxury to make mistakes. For example, the prototype of a taillight lens with traditional methods (CNC+Joining+Painting and Finishing) will take two weeks or so whereas with AM you could have 5-10 different prototypes at your desk overnight. And most importantly it saves time, labour and cost. 3D printing is a near-lights-out, toolless, labour-less manufacturing process. It’s a 24x7 employee to any organization, while some may argue that it may lead to job losses, It actually makes up for the people that an organization cannot hire or afford. Evolutionary Road Today the maximum potential of production that one can see from 3D Printing is in the tune of 15 to 20 thousand (golf to tennis ball size) objects per year from one machine (Polymer Sintering). With improvements in High Speed Sintering, these numbers could increase but the challenge arises when part-size increases. Sintering systems are typically small and if you take, say, a dashboard cover, you may not be able to produce 2,500 parts per year. The challenge is even higher with metal where metal most of the time only produces net near geometries and must be treated and machined further. You could always add a fleet of hundreds of machines but even then, the challenge of cost-per-printer-part remains high which doesn’t change in AM irrespective of quantity. Today additive materials cost much higher than same materials for moulding, this is primarily because of the form they must be in to be able to always print successfully. Unless costper-part comes to same as mass manufacturing methods and speeds increase by a factor of 2030, it will be challenging to move from traditional to additive for commodity goods. 3D Printing/AM in Education As a Secretary-General of 3D Printing Education & Research Association, my interest is focused on four aspects which work in confluence with the government and industries – Education, Research, Skill Development, and Industry Facilitation. I am sure that the need is to start with schools where a curriculum needs to be instituted at a basic level to impart knowledge on the design and manufacturing process using 3D Printing. Further, in higher education, particularly for disciplines like engineering, architecture, design and medicine, 3D Printing needs to become an essential part of the curriculum.
Top Challenges Today the industry association and sectors will need to first educate the potential adopters about the technology. So awareness is key. 3DPERA (3D Printing Education & Research Association) is consistently working towards creating all the possibilities to address it all through the association. Trinity Group in association with Prittle Prattle is organizing the 5th edition of the 3D Printing World Conference and 3D Printing World Award 2019, on 29th November in Mumbai, which is a platform promoting new innovations in 3D printing, 3D printing technology, latest machines, 3D software, and materials. 3D Printing/AP for Humanitarian Work Education is one of the most important segments for all major AM providers including us, The dynamics of education and the approach of both the institute and the government is changing from a theoretical education to making students industry ready. We often hear large corporations complain that students are not ready for jobs and money must be spent to train them. Institutes are addressing this and are focusing on making students ready for the industry. Large Advanced Technology labs and incubators are being set up for emerging technologies like robotics, IoT, AI, drones etc. Additive manufacturing itself besides being an emerging technology is also a key enabler for other emerging technologies and hence more suited for academia for quicker hands-on training of all these technologies. Top Challenges India is not so much of a high value customization market. Commodity goods don’t really gain so much from the manufacturing benefits of AM, the challenge is that the cost efficiency of AM remains only till a certain quantity, so scaling it to mass manufacturing or even batch manufacturing is not always beneficial. Also labour costs in India are much less than overseas so even the cost benefit of avoiding tooling for small batches is compressed by cheap labour costs in the final cost-per-part equation. There are companies that are doing end-use parts for either getting the most out of the design (for optimization and reducing the weight) and applications that require customization and to some extent even to ease or maintain intermediate level supply chain of rare, outdated or outsourced products. MRO and digital inventory through AM are areas that I anticipate to pick up more as its can be more cost efficient rather than importing from overseas vendors. For Greater Good Medical Industry is the most important beneficiary of AM in India. This industry makes large contribution to the economy of AM in India. A lot of work is already happening in patient-specific medical devices, prosthetics, surgical planning, a few of which we have written blogs about on our website. We only see such applications grow from here.
https://www.altem.com
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Cover Feature | RENISHAW
Education Is Playing A Key Role In AM Growth In India Sanjay Sangam, National Sales Manager, Renishaw Metrology Systems Ltd shares important facts and insights on additive manufacturing, also known as 3D printing and its applications in India and the world
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enishaw is a global company with core skills in measurement, motion control, healthcare, spectroscopy and manufacturing. The company supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing a.k.a. metal 3D printing. Sanjay Sangam, National Sales Manager, Renishaw Metrology Systems Ltd shares engaging insights on his company’s deployment of the technology. Industrial Applications – India Please see below applications which we have deployed in Indian industries. Medical and Dental Implants. Customized Implants – Cranial, Maxillofacial, Mandible Orthopedics Implants. Surgical Guides – Renishaw India has helped a company in Pune set up ISO 13485 and FDA approved facility to manufacture the medical Implants. Aerospace. Light weight parts in Inconel 718 and Titanium. Automotive. Direct part replacement and high value and low volume parts in SS316L and Aluminum. Tooling and Dies Industry. We have supplied conformal cooling parts to tooling industry to reduce their cycle time and scrap rate. It will also results into increase in mold life. Consumer Goods. We are working closely with a tobacco manufacturing company to make their limited edition and customized container. Hydraulic Manifolds. Light weight and topologicallyoptimized hydraulic manifolds to save the time and cost.
Industrial Applications – Global Sharing some of our global success stories: HiETA Technologies. In making a compact and high-temperature sustainable Heat Exchanger Frazor Nash Manufacturing (Aerospace Industry) • Increased speeds of prototyping and printing metal parts • Reduced costs and avoidance of need for special tooling • New possibilities for creation of complex custom metal components • Optimization via parts consolidation and weight reduction Ferrari. For making consolidated lightweight parts. In Formula 1, the research is focused on maximum performance with the lowest possible weight. ‘Factors of safety' are normally designed into a part to make it more durable and reliable, add weight which, in a road-going vehicle, wouldn't be an issue. BLOODHOUND SSC (UK). Renishaw produced a prototype nose tip for the Bloodhound Supersonic car. Bloodhound’s aim is not only to break the sound barrier but also to be the first land vehicle to exceed 1,000 miles per hour (1609 km/hr) - at this speed it will be travelling the length of 4.5 football pitches every second [the car is set to do high-speed tests in October, as per recent reports. – Editor] Titanium alloy, Ti-6Al-4V, is easily processed using additive manufacturing, and complexity can be built in at no additional cost. Main Benefits The main benefits of 3D printing for manufacturing are as follows: • Reduce the Cycle Time, which leads to be faster into the market • Short batch production for high value and low quantity parts
• Parts consolidation to avoid the large number of parts • Lightweight structured components • Reduce the scrap rates in tooling and increase the mould life • Customized parts as per requirements Evolutionary Road In the global market, manufacturers are focusing on redesigning of the parts to make it more compatible to AM. Finished parts are more efficient and effective as compared to conventional manufacturing. Numbers of AM users are increasing year on year. 3D Printing/AM in Education Yes, the education sector is playing a key role in growth of AM industry in India. Students can help to develop the thousand of new materials which are better in mechanical properties. Students also help to design the parts for AM. Top Challenges The cost of the raw material is still challenging factor in AM industry, but it can be overcome by identifying the right application and components. https://www.renishaw.com
Sanjay Sangam, National Sales Manager, Renishaw Metrology Systems Ltd
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Cover Feature | 3DPERA
Awareness Is Key Dr. Shibu John, Secretary General, 3D Printing Education & Research Association shares insights on 3DP’s status and future
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r. Shibu John is Founder, Trinity Media and Secretary-General, Founder, 3D Printing Education & Research Association (3DPERA). The association works towards promoting the adoption of the technology. Trinity Group in association with Prittle Prattle is organizing the 5th edition of the 3D Printing World Conference and 3D Printing World Award 2019, on 29th November in Mumbai. Edited excerpts: Industrial Applications – Global Additive Manufacturing globally is used in industries where customization is the best option. Dental, Orthopaedics, Prosthetics, Tissue Engineering, and other medical applications are increasingly adopting 3DP for patient care and medical solutions. Pre-operative surgery planning with 3D printing is a great solution. We are also seeing a great way to even print anatomical parts like the mandible, maxilla jaw, knee roll and other hard tissues. The other sector is Aerospace where manufacturing is not for mass production but is selective for a few numbers of aeroplanes, engines, nozzles, etc. and also for space mission programs for rockets. Other industries like Oil and Gas and Shipping are also great beneficiaries. Further, Automobile, Tooling, Electronics, Packaging, FMCG, Engineering, Art and Entertainment all need prototypes for manufacturing, depending on the size of parts and the demand. The technology is catching up fast with more awareness and knowledge disseminated through research journals, media, and events. Main Benefits 3D Printing will be a facilitator in each manufacturing sector, big or small. Every manufacturing company today needs to see the proof-of-concept and this is possible with a quick responsive measure through 3D Printing, that allows for a maximum number of iterations to choose from to make the final mold. Therefore, 3D printer is going to become an integral part of the industrial shop floor.
and medicine, 3D Printing needs to become an essential part of the curriculum. Top Challenges Today the industry association and sectors will need to first educate the potential adopters about the technology. So awareness is key. 3DPERA (3D Printing Education & Research Association) is consistently working towards creating all the possibilities to address it all through the association. Trinity Group in association with Prittle Prattle is organizing the 5th edition of the 3D Printing World Conference and 3D Printing World Award 2019, on 29th November in Mumbai, which is a platform promoting new innovations in 3D printing, 3D printing technology, latest machines, 3D software, and materials. 3D Printing/AP for Humanitarian Work Yes, I am sure 3D Printer will be much in prominence for humanitarian work with better and wider material availability for the construction of the affordable homes for rehabilitating people. 3D bio-printing of soft tissues in skin, organs, etc. and for prosthetic limbs can all be used to support the relief and rehabilitation efforts. https://www.3dpera.org
The Big Aim 3D Printing currently is not meant for mass production. It is only meant to facilitate mass production. The other goal is to make customised manufacturing ubiquitous. Evolutionary Road Additive Manufacturing will progressively be an important function supporting manufacturing. With economies of scale the technology will grow with machines becoming more cost-effective. This will mean affordability and more SMEs using the high-end metal machines for production. There is a great opportunity for the technology to benefit the industry at a larger scale. 3D Printing/AM in Education As a Secretary-General of 3D Printing Education & Research Association, my interest is focused on four aspects which work in confluence with the government and industries – Education, Research, Skill Development, and Industry Facilitation. I am sure that the need is to start with schools where a curriculum needs to be instituted at a basic level to impart knowledge on the design and manufacturing process using 3D Printing. Further, in higher education, particularly for disciplines like engineering, architecture, design
Dr. Shibu John, Secretary General, 3D Printing Education & Research Association
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Cover Feature | 3D PRINTING
3D Printing’s Humanitarian Side: A Photo Journal from Nepal How Field Ready, an international NGO, brought the benefits of 3D printing to Nepal’s post-2015 earthquake reconstruction efforts
I Key Highlight:
We, at Field Ready, found practical demonstrations very engaging for local people and helped to demystify the [3D printing] technology, which is really quite simple once explained
n April 2015, Nepal was struck by a severe and devastating earthquake. It killed more than 9,000 people, injured more than 22,000 and displaced hundreds of thousands of people. Rescue and relief agencies from Nepal and all over the world rushed to people’s aid. In the face of substantial challenges posed by aftershocks, incessant rainfall, damaged physical and communications infrastructure, local and international agencies including the Nepalese army, Médecins Sans Frontières and the Red Cross continued their relief and rescue operations. Field Ready (Fieldready.org) an international NGO with partners worldwide, which is focused
on manufacturing humanitarian supplies, joined the relief and reconstruction efforts. Cofounded by Dara Dotz – a pioneer in 3D printing (3DP), and a well-known and a prolific international speaker – Field Ready brings 3D printers to make essential medical supplies, replacement parts, water pipe fittings and more to multiple countries simultaneously training locals. Field Ready determined how they could contribute to medium and long-term recovery, reconstruction and disaster risk reduction efforts. In December of 2015, Field Ready deployed a team in Nepal to meet the ongoing challenges in health, water, shelter and livelihoods.
Water connector made by Field Ready being used in an IDP camp
Clean cookstove installation
Mark Mellors 3D printing powered by a vehicle
Mr. Madhukar KC-- a brilliant Nepalese inventor!
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Madhukar KC, inventor of the improved cookstove air supply disk, warms himself from the heat generated by his invention.
Ram Chandra Thapa making medical parts for a local health post
An iterative design of Madhukar KC’s cookstove air supply disks. 3D printing enabled the successful manufacture of new designs. Photo by Ram Chandra Thapa, Field Ready
Nepal after earthquake
Andrew Lamb, Innovation Advisor on a needs assessment
Ram Chandra Thapa discussing with locals on some of their needs
Key Highlight:
This is a powerful tool for engagement and production alike.
Ben Britton, International Lead – Programs, Field Ready shared with DMI his team’s aim and experience of its work, “‘We, at Field Ready, found practical demonstrations very engaging for local people and helped to demystify the [3D printing] technology, which is really quite simple once explained. The demonstration, once undertaken, is rarely forgotten.” The use of 3D printing for humanitarian work not only helps bring unmatched efficiency to the efforts, it also helps foster a sense of ownership of the technology. “When using 3DP for
creating fixes or spares in health centres etc., the local community is engaged with the process and feels like it is a beneficiary of leading-edge technologies. This is a powerful tool for engagement and production alike,” says Mr. Britton. He shared with us that Field Ready, at that time, was exclusively using the Tiertime UP Mini and Mini2 small 3D printers and the UP Box for larger jobs and was using mainly ABS plastic for material. Presenting some glimpses of Field Ready’s humanitarian work carried out at the time and its use of 3DP technology for the purpose, in the form of a photo feature. https://www.renishaw.com
Photo journal and work description republished with permission from Field Ready. Please visit www.fieldready.org to know more. Field Ready is a non-profit, non-governmental organization. It aims to meet humanitarian need by transforming logistics through technology, innovative design and engaging people in new ways. The organization does this by working with a variety of partners and helping to build people's resilience.
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Industry News | IMTMA
Indradev Babu elected IMTMA President Ravi Raghavan, MD, Bharat Fritz Werner is elected as IMTMA’s new VP
AGM Business Session
From left to right: Ravi Raghavan, Indradev Babu and V Anbu
Key Highlight: The Indian Machine Tool Manufacturers’ Association (IMTMA) held its 73rd Annual General Meeting (AGM) at the Bangalore International Exhibition Centre (BIEC)
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engaluru, 12 September, 2019: The Indian Machine Tool Manufacturers’ Association (IMTMA) held its 73rd Annual General Meeting (AGM) at the Bangalore International Exhibition Centre (BIEC). Mr. Indradev Babu, Managing Director, UCAM Private Limited was elected as the new President of IMTMA. Mr. Indradev Babu will succeed Mr. P. Ramadas, Managing Director, Ace Manufacturing Systems Limited as IMTMA’s President. Mr. Ravi Raghavan, Managing Director, Bharat Fritz Werner Limited was elected as the new Vice President of IMTMA. The new Executive Committee of IMTMA for the year 2019-2020 was also formed. Earlier, in a special session at the AGM, Mr. Kamal Bali, President and Managing Director, Volvo Group India Private Limited, spoke about the current economic downturn as well as the opportunities in store for the auto sector. He said that the slowdown that we see in the auto sector is cyclical and the industry should continue its efforts digitalization, innovation and
providing solutions that are economically and environmentally viable. Elaborating further he said that industry should move from the earlier definition of VUCA (Volatility, Uncertainty, Complexity, and Ambiguity) towards a new definition of VUCA, i.e. (Vision, Understanding, Clarity, and Agility). About IMTMA IMTMA is the apex body and single point of contact for the machine tool industry in India. IMTMA plays a crucial role in the growth and development of the metalworking industry in the country. IMTMA’s initiatives range from policy advocacy, export promotion, trade fairs, mega-events, training, seminars, technology missions, publications, etc. IMTMA formed in 1946 has a membership of over 450 members and represents 90% of the organized machine tool and allied equipment manufacturers in the country. https://www.imtma.in
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Industry News | INDOSPACE
IndoSpace Named Year’s Best Indian Industrial/Warehouse Developer by Euromoney The industrial real-estate developer wins the award for the fifth consecutive year
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he prestigious ‘Euromoney’ magazine has named IndoSpace, India’s leading developer of modern industrial and logistics real estate, the ‘Best Developer of Industrial/Warehouse Real Estate in India’ for 2019 in their 15th annual real estate awards survey. IndoSpace has received this recognition for the fifth year in a row. Euromoney also ranks IndoSpace among the top three overall developers in the country. The Euromoney award is one of the world’s biggest and most respected awards in the real estate industry. The winner is decided by voting, where leading firms involved in real estate worldwide as well as advisors, developers, investment managers, banks, corporate end-users and customers of real estate are invited to vote. This year, Euromoney received 3,274 valid responses that recognized firms that had been the best providers of real estate products and services in their market during the past 12 months. The 2019 survey was conducted from March 7 to April 26, 2019. Rajesh Jaggi, Managing Partner, Real Estate, Everstone Group, said: “We are extremely proud to be selected as the best developer of industrial/ warehouse real estate in India for the fifth year consecutively. This recognition would not have been possible without the amazing work of our employees, as well as the strong and collaborative relationships with our investors, customers and partners. We are thankful to Euromoney for
providing a platform to recognize our efforts to set up best-in-class industrial warehousing facilities, to support the growing logistics and warehousing sector in India.” Clive Horwood, Editor, Euromoney said, "The Euromoney real estate awards are the pinnacle of the industry, as they are voted for by the constituent parts that rely on each other – developers, advisers and banks. We congratulate IndoSpace for all their achievements in winning Best Developer India of Industrial/Warehouse Real Estate, and for clearly earning the respect of their peers and colleagues in the highly competitive global real estate market." In growth mode IndoSpace continues to expand its portfolio across India with an aim to offer its award-winning offerings to an ever-growing number of customers. In 2019, IndoSpace launched parks in Ahmedabad (Bavla), Haryana (Luhari), Punjab (Rajpura) and Tamil Nadu (Mevalurkuppam and Koodapakkam), spanning a total area of around 200 acre. In total, IndoSpace has a portfolio of around 31 million square feet that include developed and under-construction projects comprising 31 industrial and logistics parks in nine cities. The company’s customers include IKEA, Amazon, Nissan, DHL, DB Schenker, Delhivery, Steelcase, Ericsson, Bosch and Aptiv.
Key Highlight: ‘Best Developer of Industrial/Warehouse Real Estate in India’ for 2019 in their 15th annual real estate awards survey. IndoSpace has received this recognition for the fifth year in a row.
https://www.indospace.in
We invite all industry participants in India to register and participate at ORDERFOX.com. We can help them take advantage of the international business opportunities, achieve new contacts locally and globally - and to optimise workflows.
DINESH MISHRA Senior VP – Strategy M: +91 9833076669 E: dinesh.mishra@ meshmixmedia.com
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Product News | PRINTRONIX
Picture: PRINTRONIX
Industrial-Strength Printing Printronix Auto ID introduces high-performance thermal desktop printer with RFID in India
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Key Highlight: The T800 with optional UHF RFID was designed to meet the growing demand for encoding and printing RFID labels at an affordable price.
rintronix Auto ID, Inc., a global player in industrial printing solutions has introduced the T800, a high-performance thermal desktop printer. The T800 offers enterprise-level productivity, dependable performance, and a suite of versatile features such as RFID, and Wi-Fi with advanced security protocols. Strengthening its existing desktop thermal printer range, the T800 offers enterprise-level productivity and advanced features usually found only in industrial printers. A highperformance ARM A7 processor offers fast-time to -first-print and it is easily capable of producing over 1,000 labels per day. Its 300-meter ribbon ensures fewer roll changes and therefore less downtime. One of the key differentiators between traditional desktops and the T800 is its ability to print RFID labels. The T800 with optional UHF RFID was designed to meet the growing demand for encoding and printing RFID labels at an affordable price. Retail, manufacturing, and healthcare are just a few of the industries that use RFID to track products throughout the supply chain, take inventory in real-time, or locate assets
within the enterprise. The T800 makes printer setup for encoding and printing of RFID labels fast and easy. Not only can it support labels down to 625 inches in length, but the antenna can be adjusted for non-standard inlay positions. Further, the RFID label calibration function automatically sets the optimal label encoding position within the printer. “The T800 represents the latest in the aggressive growth strategy that has marked the Printronix product line for the past few years with a special focus on high-end features such as RFID and exclusive technologies such as barcode verification solutions,” said Andy Edwards, Director of Product Management. The T800 is also Printronix’s first desktop printer to incorporate its renowned Printronix System Architecture (PSA) and includes a full suite of labor-saving features and printer management tools for easy day-to-day operations. PSA is an exclusive intelligent design platform that combines advanced features with a common set of building blocks to simplify printer installation, operation, and improve productivity. https://printronixautoid.com
# 1901, 19th Floor, Elecia Tower, Dosti Imperia Building, Ghodbunder Road, Opp R Mall, Manpada, Thane West - 400610, India E: accounts@meshmixmedia.com
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Industry News | MARPOSS
TBD HS, the Tool Breakage Detector A programmable system for non-contact high-speed tool breakage detection other hand, choosing “Low Filter” TBD responds in a faster way, as the filter is less severe. Lastly, it is possible to choose the appropriate range of spindle speed, up to 5000 rpm.
The Tool Breakage Detector (TBD). Can be mounted around the machine area. Picture: MARPOSS
Key Highlight: Selecting “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples.
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ndustrial realities, where productivity represents the priority to achieve, aim to implement tool measurement solutions, which prove to be quick, accurate and reliable. Aware of such need and willing to develop an application that could avoid affecting production efficiency, Marposs presented TBD, the Tool Breakage Detector, a time-saving laser-based solution for broken tool detection on machine. TBD on milling machines and machining centres permits to keep under control the process, thanks to a very short tool checking cycle. Fast and reliable detection achievable by the TBD allows to reduce production time and to avoid expensive work-pieces scrap due to wrong cutting process by damaged or broken tools. All functionality is contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table. It is possible to choose among different working modes, which endow TBD with a great flexibility. Switching the power to the maximum gives TBD the chance to recognize a tool placed at a longer distance (up to 2 meters), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, an user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck on the tool could create variation in the signal received. Setting “Hi Filter” makes the software of the TBD more restrictive in order to give the more reliable response. On the
The new TBD HS Marposs S.p.A. has recently introduced the new TBD HS, High Speed, on its wide range of products for tool checking on milling machines and machining centers. The new TBD HS is a programmable system for non-contact checking hi-speed tools, particularly committed to those applications where there is the need for hi-speed spindles, up to 80.000 rpm. Thanks to its rotary switch selector, the TBD HS is able to recognize the tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. Selecting “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. With a reflective, clean tool an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD. High spindle speeds and small tool dimensions lead to the need for a fine adjustment for positioning the TBD HS in a very precise way: that is the reason why an effective system has been designed to make accurate and easy the searching procedure of the tool verification position. Once TBD installed and tool approximately pointed, now is even more quick and simple to optimize the laser beam and to find the checking position. The tool breakage detection performed by the TBD HS is improved by the presence (upon request) of a blower for cleaning the receiver glass: taking advantage of the usual standard inlet, both in terms of air flow and pressure, it has been developed a solution able to protect the glass from swarf and scraps without increasing the air consumption. Moreover, when the conditions are particularly harsh because of the aggressive presence of shavings, there is the chance to substitute the standard protection glass with one in sapphire crystal: being 9 out of 10 its hardness degree on the Mohs scale, this kind of protection lets the receiver performance always at its maximum, no more damaged by the extreme machine conditions. https://www.marposs.com
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Special Feature | RENISHAW ADDITIVE MANUFACTURING
Speeding Up Bike-Making Atherton Bikes accelerates with Renishaw additive manufacturing
G Key Highlight:
Atherton Bikes to produce additively manufactured titanium lugs for the company’s bike frames.
lobal engineering company Renishaw is working with new mountain bike brand Atherton Bikes to produce additively manufactured titanium lugs for the company’s bike frames. The new brand was launched in January by the Atherton siblings, Gee, Rachel and Dan and co-founded by Piers Linney of Dragons’ Den fame. The Atherton family are World Championship-winning mountain bikers who will now race their own downhill mountain bikes during competitions as well as sell a range of bikes all over the world. The introductory bike range will be manufactured from carbon fibre tubing and lugs produced on a Renishaw multi-laser
Atherton AM parts supplied by Renishaw
high productivity RenAM 500Q metal additive manufacturing (AM) system. Initial production will be at Renishaw’s Additive Manufacturing Solutions Centre located in Staffordshire, UK, followed by a transition towards in-house manufacture by Atherton Bikes. Also partnering in the project is Dave Weagle, the renowned suspension designer, along with Ed Haythornthwaite and other members of the former Robot Bike Company. Renishaw had previously worked with the Robot Bike Company by manufacturing the titanium lugs for its R160 bike frame. The lugs for Atherton Bikes are the first bike componentsto be built on the fourlaser RenAM 500Q system, which enables increased productivity, without compromising on quality.
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“Renishaw is a world-leader in metal additive manufacturing machines,” explained Jono Munday, Additive Manufacturing Applications Manager at Renishaw. “Due to our position as a leading metrology business, we are also perfectly positioned to help customers develop an end-to-endsolution, from AM build, all the way through machining and post-processing, providing an end-use engineered component. “Manufacturing the lugs on the RenAM 500Q enables rapid production time,” added Munday. “This means that the bike frame development can be turned around quicklyand customised to the exact requirements of the rider, whether that is the Atherton Racing team on the World Cup circuit or an individual retail customer. Whereas traditionally a lot of tooling is required, additive manufacturing is an entirely digital process, meaning that the lugs can be modified in CAD and reproduced more efficiently.” During the development of the new Atherton Bikes, Renishaw has been giving
feedback and modifying the lugs so that they can be built accurately and successfully. The AM build process, machining and post processing are managed by Renishaw at its Solutions Centre. UK-based Renishaw offers a global network of Solutions Centres, staffed by AM experts, so businesses can build their knowledge and confidence using additive manufacturing technology. The company supplies products used for applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It has over 4,500 employees located in the 36 countries where it has wholly owned subsidiary operations. For the year ended June 2018 Renishaw recorded sales of £611.5 million of which 95% was due to exports. The company’s largest markets are China, the USA, Germany and Japan.
https://www.renishaw.com
Atherton mountain bike
Atherton siblings Dan, Rachel and Gee
Atherton Bikes - AM parts inspection
Key Highlight:
Atherton Racing team on the World Cup circuit or an individual retail customer.
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Industry News | SECO TOOLS
We Are Partners To Our Customers Seco Tools, one of the world’s largest metal cutting solutions provider, bets big on India’s aerospace industry
E Key Highlight:
On August 23, 2019, we hosted the Aerospace Summit 2019
very year, Seco Tools hosts an aerospace conference in India, which attracts sector experts and Seco’s major customers, helping the company chart out their future course for one of their biggest revenue earners – the aerospace industry. This year, DMI spoke to Ravindra Dixit, Deputy General Manager Aerospace Business (India) and Tamas Molnar, Application Engineer (Hungary), Seco Tools about the yearly conference, their experience of the industry, and the company’s future roadmap.
Please share the key highlights of Seco Tool India’s aerospace conference which you organized recently. Ravindra Dixit (RD): On August 23, 2019, we hosted the Aerospace Summit 2019. This is the fifth year of the conference in India. This year the event focus spanned all the material requirements for the aerospace industry. It is important for our customers to understand the challenges that arise, related to material machining, and the solutions that Seco Tools India offers to address these challenges. To add an important point, among the many challenges that the global aerospace industry faces, the top challenges are two: the weight of the aircraft, and the related factor of fuel efficiency. As a tooling partner, in what ways is Seco working for its aerospace customers? Tamas Molnar (TM): We develop tooling products based on the material that a customer machines. We not only offer machine tools such as cutters or inserts specially developed for each and every type of material like nickel or titaniumbased alloys, we also offer tooling solutions for composite manufacturing. Our objective is to work like partners with our customers, which is why we also offer complete solutions, including the programming and the tooling, to the customers. RD: Composites materials are the ones which are being considered for reducing the weight of the aircraft and improving the fuel efficiency and that is the trend that we are seeing among our customers. Seco already has many solutions for this requirement. In addition there are lot of innovations happening in composites for which we have dedicated solutions. Seco’s major focus has been on research and development of newer and better composites aerospace material and all our teams are working towards developing such tools for the aerospace applications.
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Ravindra Dixit, Manager Business Development-Aerospace Business (India)
Tamas Molnar, Global Aerospace Expert-Seco Tools
Can you tell us a bit about Seco CET, and how it’s helping aerospace component manufacturers in India? RD: CET or Component Engineered Tooling an offering which helps Seco customers improve profitability through minimizing machining time and production costs by involving the Seco team early in the process. Here, our team looks at the entire picture - the component material, the machining methods, the machine tool, the cutting tool, the inventory and puts together the pieces of the puzzle to manufacture the highest quality part in the most cost-effective manner. As Mr Molnar said, it is an important part of our goal to be a tooling partner of our customer and that partnership can only happen when we partner with them on the entire engineering process and not for just a single solution. Our CET team comprises application experts who have a rich experience and are supported by segment expert, for example, aerospace experts in this case.
at the orders from the two main manufactures (Boeing and Airbus), one can see a period of fast growth in aerospace for the coming ten years at least. In terms of challenges, a big one I think is that with such a rate of growth, manufacturers need to produce more parts for which they have to invest in new machines to boost productivity. That is why, in addition to offering our products, we also work very closely with different CAD/CAM suppliers and machine-tool builders not only from the toolmaking perspective, but also for the purpose of applying new manufacturing methods such as Dynamic Milling or Advance Roughing. In fact, we specifically design cutters for new manufacturing methods like the ones I mentioned, as well as for other high-feed solutions which we have in our portfolio. Essentially, these we all developed to help customers to boost their production and increase output.
Tamas as you are working in different markets such as Asia and Europe, how different is the Indian aerospacecomponents manufacturing industry from its international counterparts? And what are the challenges or opportunities you see in the Indian market? TM: Generally I can say that the global aerospace market is growing at a healthy pace. If one looks
As per the recent estimates, India’s aerospace industry makes for about oneand-a-half percent of the global aerospace market. And countries like Mexico and Vietnam have been able to take advantage of the ongoing USA-China trade war to expand their manufacturing base. What are the ways in which the Indian aerospace component manufacturing industry can do better in this scenario? RD: As Mr Molnar mentioned, there is a healthy demand, and the challenge that I see
Key Highlight:
Our CET team comprises application experts who have a rich experience and are supported by segment expert, for example, aerospace experts in this case.
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Industry News | SECO TOOLS for the Indian customers is that they need to maintain the expected delivery timelines and yet produce quality components given the resources that they have. So I think it is important for them is to manage their resources well, produce quality products well in time, for which they can’t make any compromises on the choice of tooling partners, and this is where we will be able to help them achieve these goals. Has the Make in India campaign made any impact on the Indian aerospace component manufacturing industry? RD: I do see quite a big change in the sentiment of investors given that the government is keen on growth. I’ve seen customer like Aequs Aerospace grow leaps and bounce utilizing this opportunity – their fast expansion in the aerospace industry is a positive sign for the prospects of the Make in India initiative . TM: I agree. We see an increasing number of global players that are setting foot in India either via joint venture with local companies or by setting up their own manufacturing plants. Therefore we are definitely seeing the benefits of this push. How do you see the Indian market from an APAC perspective in terms of the marketing challenges and what are the major plans going forward? RD: Currently our focus is to cater to the market requirements, increasingly augment our delivery and research capabilities to be ready for the future requirements. The aerospace segment is one of the biggest revenue earners for us globally. Our R&D teams continue to develop solutions for newer and fastevolving technologies, working with major OEMs, universities and sector experts, helping our
Key Highlight:
Our R&D teams continue to develop solutions for newer and fast-evolving technologies, working with major OEMs, universities and sector experts, helping our customers reduce the cutting time, improving the productivity and product quality.
customers reduce the cutting time, improving the productivity and product quality. The intention is to meet the customer requirement, leveraging on our strength of being a global company . TM: There is not a big difference between other markets of Asia and India in particular. What I can say with certainty that India has one of the highest competency levels in the Asian region, whether it’s the people on the shop floor or the strategy teams. Aerospace has been, and continues to be our main focus for the coming years. We have great solutions, people and the distributor network. We want to be much more than a tool supplier – we want to be a tooling partner. https://www.secotools.com
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Industry News | SIEMENS
Siemens Partners With Hindustan Zinc Siemens to upgrade and modernize Hindustan Zinc Limited’s Power Asset Fleet with state-of-the-art technology
S Key Highlights:
• Six 80 MW steam turbines to be upgraded with new state-of-the-art design and digital technologies • Turbines to be manufactured at Siemens’ Vadodara Factory; designed to improve efficiencies and result in an estimated reduction of 1 million tons of carbon emission
iemens Limited will modernize and commission 80 MW steam turbines to Hindustan Zinc Limited, India’s leading zinc-lead mining company. The modernization of the power asset fleet of Hindustan Zinc Limited includes state-of-the-art design steam turbine components and digital technologies. Siemens will also provide on-site project services on a turnkey basis. V. Jayaraman, Head – Power Plants, Hindustan Zinc Limited, said, “We are pleased to partner with Siemens, a leading global technology provider for modernization of captive power plants. We are aiming at higher efficiencies of power generation from steam turbines along with higher generation. Further, the modular project execution will ensure lower outage. Operations will be more economical and using latest technologies help reduce carbon footprint which is in sync with our groups philosophy.”
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Gerd Deusser, Head, Gas & Power, Siemens Limited, said, “We take great pride in partnering with Hindustan Zinc Limited in the modernization of their power asset fleet. The upgraded 90 MW steam turbines is the best-in-industry solution and ensures high flexibility, reduces emissions and maintains high reliability. By leveraging our experiences and technological leadership, we will continue to work actively to provide highly efficient steam turbines to contribute to customers’ benefits.” The efficient utilization of available energy sources has become essential and many industrial companies are prospecting for opportunities and solutions for improving efficiency. Siemens steam turbinesplay a significant role in many industrial applications, combined cycle and cogeneration plants and thus can be instrumental in meeting targets of improved efficiency in industrial plants. https://siemens.com
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Special Feature | ADDITIVE MANUFACTURING
DMG MORI’s AM Journey As a global full-liner in the additive manufacturing (AM) of metal components, DMG MORI provides the rapidly expanding technology area with innovative developments and a holistic advisory service
Key Highlight:
DMG MORI consistently takes this into consideration in the further development of its LASERTEC 3D hybrid, LASERTEC 3D and LASERTEC SLM model series.
The LASERTEC SLM machines realize internal, near-contour cooling channels which cannot be manufactured using conventional means.
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n 2013, DMG MORI created the new additive manufacturing business area in the field of laser-deposition welding using a powder nozzle with the LASERTEC 65 3D hybrid. Six years later, after extending the product portfolio with powder bed technology, the machine tool manufacturer is regarded as a global full-liner in the additive manufacturing of metal components. DMG MORI provides a comprehensive service and integrated consulting in this pioneering field. Additive manufacturing is becoming increasingly established as a pioneering procedure for industrial use. The demands made of the technology are therefore also changing. DMG MORI consistently takes this into consideration in the further development of its LASERTEC 3D hybrid, LASERTEC 3D and LASERTEC SLM model series. The main topics are the technical availability of the machines, their productivity, the component quality and occupational safety. Innovative process chains have therefore emerged in both additive manufacturing and also the powder bed procedure.
LASERTEC 3D hybrid and LASERTEC 3D With the LASERTEC 3D hybrid and LASERTEC 3D machines, DMG MORI has realized a continuous concept consisting of machine, software solution and applications know-how which is completely process-reliable. The basis of this is a series-produced machine for 5-axis milling machining from the DMG MORI product portfolio which is already well established on the market. With regard to laser deposition welding, the customer can expect build-up speeds of up to 1 kg per hour, and repeat accuracy that he is only used to from CNC machines. This is in interaction with Siemens NX – the most powerful software solution that currently exists on the powder nozzle technology market. It was developed in collaboration between development engineers from DMG MORI and SIEMENS. “We support customers during construction design and process development with the applications know-how of our applications engineering. In this way, we also provide special training and also start-up support“, explains Patrick Diederich, managing director of SAUER GmbH and therefore
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responsible for the LASERTEC 3D and LASERTEC 3D hybrid model series. Laser deposition welding: Cost-effective tech In the past five years, laser deposition welding has emerged as an excellent technology for the repair and coating area in many target industries. “Every other industrial customer purchases the LASERTEC 65 3D hybrid because of the cost-effective repair options,” says Patrick Diederich, quantifying this trend. The hybrid machine has an extensive customer base in the manufacturing of reforming and forging tools, i.e. in warm and cold sheet metal reshaping. “At this point cutting knives should be mentioned, which previously had to run through a manufacturing process lasting for several days, but can now be deployed again within a shift thanks to the powder nozzle technology,” he says. Particularly also in industries where the main focus is not on the construction costs but system availability, users benefit from the strengths of the LASERTEC 65 3D hybrid. These include industries such as oil and gas, and also the chemical and pharmaceutical industries. Patrick Diederich envisages the development of laser deposition welding extending to bigger customer components: “For example, complete die casting tools can be additively manufactured instead of production using moulds. Direct integration of additively manufactured features leads to an increase in tool service life.” DMG MORI is expecting positive developments as far as automated manufacturing and repair are concerned. According to Mr Diederich, the LASERTEC 3D machines must be regarded as “Build and Repair” solutions: “Several repair process steps run sequentially and automatically here, without loss of quality due to handling.” Maximum precision in the powder bed The DMG MORI portfolio in powder bed technology includes the LASERTEC 30 SLM 2nd generation with its large footprint of 300 x 300 x 300 mm and the LASERTEC 12 SLM, which sets new standards in precision thanks to its focal diTopology-optimized wheel carriers for motor sport.
ameter of just 35 µm. In relation to this accuracy class, it has the biggest footprint with 125 x 125 x 200 mm. One thing that all LASERTEC SLM machines have in common is the powder change using the rePLUG powder module. On the one hand, the closed powder circuit provides the occupational safety that was mentioned at the beginning, and on the other hand the powder can be changed in an uncomplicated way within two hours using the rePLUG powder modules. “That is the quickest method on the market”, emphasizes Mathias Wolpiansky, who is responsible for the LASERTEC SLM model series as the managing director of REALIZER GmbH at DMG MORI. Intelligent powder management DMG MORI is also interested in increasing productivity in the powder bed technology area. Mathias Wolpiansky looks to the future: “On the hardware front, multi-laser systems are available which immediately increase the productivity of the machine,” He also thinks that automation systems will be important in the future: “An initial approach is the automation of powder management, where we are already a long way ahead with the rePLUG powder module. Setting up and component handling, including powder removal, can also be automated using new machine concepts or with the aid of external robots.” The OPTOMET software is also said to make an additional contribution to productivity. DMG MORI presented two new functions in this area at the EMO: OPTOMET Max. Power provides optimized lighting strategies and improved utilization of machine performance, which makes build-up rates that are up to 50 percent higher possible. The residual stress in the component can be reduced by means of active control of the construction platform temperature with OPTOMET Temperature Control. This creates constant conditions at process level. A cost-effective powder circuit DMG MORI has underlined the holistic process thinking by also extending the range of DMG MORI Qualified Products to peripheral and accessory components for additive manufacturing. On the one hand, the main focus is on open powder selection, and having a qualified and integrated powder circuit on the other. Powder return and recycling with selected DMQP partners provides an economical way of processing expensive powder materials. A highly competent DMQP partner has been acquired in this area in the form of Hanaubased Heraeus, which ensures that a comprehensive powder portfolio which fulfils the strict quality standards is available to customers. DMG MORI
Key Highlight:
The LASERTEC 3D machines must be regarded as “Build and Repair” solutions: “Several repair process steps run sequentially and automatically here, without loss of quality due to handling.
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Special Feature | ADDITIVE MANUFACTURING
End-to-End AM Process: From Drawing to the Finished Part
Key Highlight:
Our ADDITIVE INTELLIGENCE advice unit supports companies in setting up the required know-how and process chain integration involving our LASERTEC SLMand LASERTEC 3D model series.
Complex lightweight structures can be manufactured using additive manufacturing.
• Unique and continuous process chain from simulation to material cycle and also service and consulting • LASERTEC 3D hybrid/LASERTEC 3D: Continuous and process-reliable concept • Cost-effective repair thanks to laser deposition welding • New: AM Assistant software package for simplifying process development and improving quality control; includes Automatic Process Control, AM Guard, Powder Flow Monitoring and AM Evaluator • LASERTEC SLM: Maximum precision in the powder bed • OPTOMET Software: Exclusive new functions for increased process efficiency and improved component quality • DMQP Powder Cycle: Simple powder procurement via the DMG MORI web shop • ADDITIVE INTELLIGENCE: Holistic advisory solutions for successful technology start-ups • Efficient linking of LASERTEC 30 SLM 2nd generation and CNC machining with a zero point clamping system
has also conclusively validated these standards on a LASERTEC SLM powder bed machine. “The wide range of materials in our web shop ranges from tool steel and stainless steel to aluminium and cobalt chromium to Inconel and titanium, meaning that we can cover almost any requirement in our target industries – worldwide and within just a few working days,” explains Mathias Wolpiansky. All powder is said to be marked with a DMQP seal of quality and ready to use, since it is provided with the relevant parameters.
Building up know-how in a targeted way The continuing growth of additive manufacturing is obvious, and many companies recognize the potential thereof. However, there is often a lack of a consistent procedure. Precisely for this purpose, DMG MORI brings its experts in the Additive Manufacturing Excellence Centers into play. They can pass on their know-how in the local markets at the locations in Bielefeld, Pfronten, Tokyo, Shanghai and Chicago. The DMG MORI Academy provides support in order to fully utilize the potential of additive manufacturing. “Our ADDITIVE INTELLIGENCE advice unit supports companies in setting up the required know-how and process chain integration involving our LASERTEC SLMand LASERTEC 3D model series,” says Mr. Diederich. The scope of the advice includes services along the entire process chain of additive manufacturing, from potential determination and engineering to small series manufacturing. “The AM Quickcheck is the perfect introduction for identifying applications in your own company.” Future-oriented manufacturing Additive manufacturing already deals with tasks which stretch conventional methods to their limit. Using a powder nozzle and in the powder bed, complex structures can be manufactured which are significantly lighter and have intelligent function elements, such as with multi-material components with improved cooling capacity due to the use of bronze. Mr. Diederich is convinced: “Against this background, our LASERTEC 3D and LASERTEC 3D hybrid machines and the LASERTEC SLM model series support new process thinking and are the perfect addition to future-oriented manufacturing.” https://www.renishaw.com
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Product News | BLASER SWISSLUBE
Technology Center of Blaser Swisslube in Switzerland
Tata Motors and Blaser Swisslube: Partners in Progress The Blaser coolant Blasocut 4000 Strong has a sump life of over 20 years. It all began in 1998 when Tata Motors was looking for a high-quality metalworking fluid. Punit Gupta, Managing Director of Blaser Swisslube India, shares the success story
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ata Motors has been a pioneer in India’s commercial vehicles sector. In 1998, the company decided to enter the passenger car market with Indica car. For the car production, the plant in Pune was investing in high-performance technology for aluminum machining and was looking for competent partners. Their main requirement was a high-performance material removal and also using a very good coolant system. After thorough research, it was decided by Tata to start a partnership with Blaser Swisslube. This defined the beginning of Blaser Swisslube India, followed by the founding of a subsidiary, Blaser Swisslube India in 2001. At the beginning of this partnership, Mr. Hans Niederhaueser from Blaser Swisslube Switzerland came to India to personally fill the central system. “I still remember how it all started. I flew to India in May 1998 to fill the central system with 80,000 liters of our Blasocut 4000 Strong. I am very happy to see that the emulsion is still stable and
running smoothly for 20 years now. By avoiding a huge quantity of coolant disposal from the last 20 years, the contribution to the greener planet is priceless,” says Hans. For a greener planet Blasocut 4000 Strong is a coolant of the Blasocut line. The Blasocut products have an excellent human and environmental compatibility. The technology has been able to contribute to the robust process of machining, high productivity, and better machining quality. In today's manufacturing world, it has become a global requirement for all manufacturing industries to contribute toward a green planet. There is a high level of awareness about the ill effects brought in by many factors of industrialization. Sustainable technologies like the Blaser Swisslube Bio-Concept work in perfect harmony with nature. With the Blasocut BioConcept, emulsions need no tank side addition of bactericides. They stay inherently biologically
Blaser Swisslube” Technology Centre, Switzerland In 2011 Blaser Swisslube extended its ultra-modern Technology Centre, which now occupies about 300 sq m of floor space at its Head Office site in Hasle-Rüegsau, Switzerland. This is where the latest metalworking fluids to be developed are tested, and where the versatile machining operations of its customers and partners are recreated in a realistic way. The Technology Centre enables the machining specialists from Blaser to provide customers with cutting and grinding fluids that deliver an effective form of added value.
Punit Gupta in discussion with Blaser India Customer Service Head
Blaser Microbiology Lab
stable. These emulsions have a unique way of maintaining the long-term bio-stability of metalworking fluid emulsions. The Bio-Concept uses an age-old law of nature whereby bacteria normally colonize aqueous media immediately. To keep the emulsions stable, the concept fosters this by creating ideal conditions for harmless primary bacteria. These bacteria, also present in drinking water, build up a naturally stable biotope where undesirable bacteria have no chance of propagating. Customer delight “A happy customer is our main goal. At Tata Motors in Pune, the emulsion Blasocut 4000 Strong is still running great. The Tata Motors' passenger vehicles plant in Pune is one of the most advanced manufacturing facilities in India. The facility has introduced many popular models like Indica, Indigo, Marina, Vista Manza, Zest, Bolt, and Nexon. Our specialists check and monitoring the emulsion on a regular basis to control the vital parameters like pH, emulsion concentration and many more. We offer each customer a tailored monitoring plan for their central systems. Customers like Tata not only want a cutting fluid, but also look for a competent and dependable partner to help organize and optimize their machine processes. With our committed team, we provide this partnership. The partnership with
Blaser Microbiology lab technician at work
Tata for instance, contributed to the robust process of machining, high productivity and better machining quality. The collaboration of 20 years is a result of trust and strong commitment from both sides, to deliver the best to the industry, environment and safety,” says Punit Gupta, Managing Director, Blaser Swisslube India. Mr Gupta adds that the team is always excited to work with customers in exploring the possibility to exploit the full potential of machines and tools in the manufacturing process. “Productivity, economic efficiency, and machining quality are factors that critically depend on the choice and the quality of the metalworking fluid. With us, as a partner you will get the Liquid Tool – the right coolant for your application, correctly used and monitored with on-site support by our specialists,” he says. https://www.blaser.com
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Event Report | DASSAULT SYSTÈMES’
Driving Sustainability By Inspiration Global Thought Leaders Examine Strategies at Dassault Systèmes’ Annual Manufacturing in the Age of Experience Event
D Key Highlight: The annual Manufacturing in the Age of Experience event, which was attended by more than 200 Decision Makers & Influencers in the Manufacturing field from around the world.
assault Systems Organized a 2 day event on September 18th & 19th in Shanghai and This Year Theme of the event was sustainable manufacturing and how global manufacturers are using the virtual world to reinvent their business, at the annual Manufacturing in the Age of Experience event, which was attended by more than 200 Decision Makers & Influencers in the Manufacturing field from around the world. Thought leaders from Accenture, China Center for Information Industry Development, FAW Group Corporation, Huawei, IDCand SATS joined Mr Guillaume Vendroux CEO DELMIA
Dassault Systèmes brand DELMIA on stage to delve into digital trends, value creation strategies and best practices for achieving sustainable growth, innovating and inspiring the future workforce. These are key approaches to create better, customized, more affordable and sustainable customer experiences in the Industry Renaissance. Michael Larsson, group vice president and head of robot systems at ABB, delivered the keynote speech on automotive manufacturing in the age of experience. Through interactive experiences with Dassault Systèmes’ 3DEXPERIENCE platform,
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Key Highlights: • Annual event in Shanghai gathers global decision-makers to discuss digital trends, insights and best practices for sustainable manufacturing in the Industry Renaissance • Speakers include thought leaders from ABB, Accenture, China Center for Information Industry Development, FAW Group Corporation, Huawei, IDC, SATS • Interactive workshops featuring the 3DEXPERIENCE platform highlight the transformative role of virtual worlds on the creation of new customer experiences
technological workshops, consulting sessions, networking opportunities and a “hackathon” challenge, industrial businessescan explore how to transform the way they invent, learn, produce and trade by using digital platforms, artificial intelligence, digital twins, robotics and more to optimize global operations, orchestrate value networks, and leverage existing skills. Manufacturing in the Age of Experience has dedicated one day of its agenda to reveal the latest manufacturing trends and strategies in China.
Attendees in all industrial sectors got insights from tailored speaker presentations&interviews,. Each year, Dassault Systèmes’ Manufacturing in the Age of Experience engages global decision-makers in a learning expedition that delivers new perspectives on the evolution of manufacturing in an economy where a product’s value comes from its usage.
https://www.3ds.com
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Show Report | EMO 2019
Under the motto "Empowering Machines & Operators" SCHUNK presented highly effective gripping systems and clamping devices for modern production. Picture: SCHUNK
Smart clamping and gripping SCHUNK’s iTENDO awarded at EMO 2019
U Key Highlights: SCHUNK presented the smart future of gripping systems and clamping devices in modern production at EMO 2019.
nder the motto "Empowering Machines & Operators," SCHUNK presented the smart future of gripping systems and clamping devices in modern production at EMO 2019. One thing is certain: The purely mechanical solutions of today will be smart tomorrow. Among the pioneers is the sensory toolholder iTENDO, the world's first precision toolholder for real-time process monitoring and control for machine tools, which was honored with the MM award at the EMO. It can be used to detect vibrations, chatter marks, and tool failure, and adapt processes immediately and fully automatically. The sensory toolholder allows seamless documentation of process stability, real-time compatible control of RPM and feed rate, and unmanned limit value monitoring and tool breakage detection. SCHUNK demonstrated how this can be successful using practice-based pilot applications that provided some idea of the wide range of fields, in which
the smart hydraulic expansion toolholder can be used. Applications range from classical milling applications and micro-cutting to deburring with brushes. Particularly in case of processes with severe fluctuations due to material or ambient conditions, in production of premium parts and processes with a high degree of tool wear, the iTENDO really comes into its own. Built-in intelligence Further highlights were the sensory quickchange pallet module VERO-S NSE-S3, the smart long-stroke gripper EGL, presented for the first time with a plug-&-work-compatible interface for lightweight robots by Universal Robots, and automatable run-out and conical run-out compensation for high-precision workpiece clamping with tolerances of a few micrometers. In addition, SCHUNK presented a wide range of solutions for flexible, automated machine loading: Lean automation solutions, palletizing
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A global first: The automatically adjustable run-out and conical run-out compensation based on hydraulic expansion technology is enabling a leap forward in terms of quality for high-precision workpiece clamping with tolerances of just a few micrometers. Picture: SCHUNK
Henrik A. Schunk, Chief Executive Officer, SCHUNK GmbH & Co. KG, Lauffen/Neckar, Germany Picture: SCHUNK Versatile: The quick-change module VERO-S NSE-A3 138 has been specially developed for automated applications. Picture: SCHUNK
Well matched: The gripping system portfolio for lightweight robots from Universal Robots enables particularly simple and cost-effective machine loading. Picture: SCHUNK
systems for the smallest batch sizes, but also highperformance Co-act solutions for human-robot collaboration. Chief Executive Officer Henrik A. Schunk is convinced that automated solutions in particular, will be of increasing importance in the years to come: "The boom in lightweight robotics, the growing demand in the area of human-robot collaboration, and the wave of automation among medium-sized businesses show that users are now focusing on automation of machine tools. At the
same time, there is a clear demand for simplification. Gripping systems and clamping devices need to be commissioned rapidly and intuitively; and adapted simply and quickly to various part scopes." With its extensive, highly compatible modular programs, SCHUNK is making an important contribution to ensuring that this becomes a success, adds the entrepreneur. schunk.com https://www.schunk.com
Key Highlights: SCHUNK presented a wide range of solutions for flexible, automated machine loading: Lean automation solutions, palletizing systems for the smallest batch sizes, but also high-performance Co-act solutions for human-robot collaboration.
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Tech Primer | TRUMPF
TRUMPF uses 3D printing to improve satellites and aircraft TRUMPF showcases new applications for additive manufacturing in the aerospace sector at the International Paris Air Show
Communications satellite TRUMPF has printed a mounting structure for the microwave filter in a German communications satellite, reducing its weight by 55 percent in the process. (Picture: TRUMPF, GettyImages, TurboSquid)
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he high-tech company is continuing to expand its market share in the industry. TRUMPF offers expertise in both the key methods required by aerospace companies: laser metal fusion and laser metal deposition.
Thomas Fehn Thomas Fehn is general manager sales, marketing & finance at TRUMPF Additive Manufacturing. (Picture: TRUMPF)
This year, TRUMPF participated in the world’s largest aerospace industry exhibition, the Paris Air Show, where it is demonstrated how additive manufacturing can improve satellites and aircraft. Satellites are subject to a whole array of ever more stringent requirements. On the one hand, they need to be as light as possible, because every kilogram that a launch vehicle carries into space costs the client several hundred thousand euros. At the same time, however, satellites must be robust enough to withstand the tremendous forces experienced during launch. “With a market share of over 20 percent, the aerospace sector is one of the world’s most important industrial users of additive manufacturing. We are steadily expanding our market share and helping to establish the process as a key technology,” says Thomas Fehn, TRUMPF general manager additive manufacturing (AM) with responsibility for sales. Weight reduction is equally important for aircraft because it leads to a significant drop in fuel consumption. This reduces both their environmental impact and costs. Additive technologies are the perfect match for the aerospace industry because they enable engineers to create parts that are
Laser metal deposition The LMD process shown here on a TRUMPF system is suitable for repairing large parts and developing prototypes in the aerospace sector. (Picture: TRUMPF / Claus Morgenstern)
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Tech Primer | TRUMPF
both lightweight and robust. These methods only add material where it is needed, while conventional methods such as milling and casting often struggle to eliminate superfluous material. 3D printers are also adept at handling light metals such as aluminum and titanium, and AM engineers enjoy much more freedom in the design process because they are not confined by the limitations of traditional production methods. The importance of 3D printing in the aerospace industry TRUMPF offers expertise in both the key methods required by the aerospace industry: laser metal fusion (LMF) and laser metal deposition (LMD). LMF is carried out entirely
TruPrint 1000 TRUMPF used the TruPrint 1000 3D printer to optimize a device known as a “rake”, which is used in aircraft engine development. Their work led to a 74 percent reduction in overall costs. (Picture: TRUMPF)
within the confines of the 3D printer, with a laser building up the part layer by layer from a powder bed. LMF technology is particularly suitable for creating complex parts for engines, combustion chambers, specialist aerospace components and similar applications. In contrast, LMD, or laser metal deposition, uses a laser beam to build up layers on the surface of a part, with the metal powder being injected through a nozzle. LMD can also be used to rapidly generate very large parts. Typical applications include prototype development and repairs to large parts such as gas turbines and compressor blades. “Thanks to our LMD and LMF capabilities, we are perfectly placed to offer our aerospace customers 3D printing solutions that match their needs,” says Fehn.
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Three examples of how 3D printing is improving the aerospace industry: 1. Weight of satellite mounting structure reduced by 55 percent TRUMPF took this opportunity at the Paris Air Show to showcase real-life applications of additive manufacturing in the aerospace industry. The high-tech company has been commissioned by the space company TesatSpaceroom GmbH& Co.KG to produce a 3D-printed mounting structure for Germany’s Heinrich Hertz communications satellite, which will be used to test the space-worthiness of new communication technologies. The mounting structure includes strap-on motors that are used to modulate microwave filters. In collaboration with the company AMendate, engineers succeeded in optimizing the topology of the mounting structure and reducing its weight by 55 percent. The mount now weighs just 75 grams instead of 164 grams. “This is just one example of how we can use additive processes in satellite construction to reduce weight and increase payload capacity”, says Matthias Müller, industry manager additive manufacturing for aerospace and energy at TRUMPF. The team of experts printed the redesigned part on TRUMPF’s TruPrint 3000 3D printer. The new geometry cannot be produced using conventional methods. As well as being lighter, the optimized mounting structure is also more robust. During the launch of the satellite the new mounting structure will withstand the same high forces and will hold its shape better. The Heinrich Hertz satellite mission is carried out by DLR Space Administration on behalf of the Federal Ministry of Economics and Energy and with the participation of the Federal Ministry of Defense. 2. Cost of engine parts reduced by three quarters TRUMPF also showcasedan AM use case for the aviation sector at the Paris Air Show. In collaboration with Spanish supplier Ramem, the TRUMPF experts have employed 3D printing to optimize a part known as a “rake.” Manufacturers use this part during engine development to measure the pressure and temperature of the engine. These kinds of measurements are an important part of testing aircraft performance. Mounted directly in the engine’s air flow, rakes are exposed to extreme temperatures and high pressure. To deliver accurate measurements, they must conform to precise dimensional requirements. Producing rakes by conventional means is an expensive and time-consuming process. Workers produce the base structure on
a milling machine before inserting six delicate tubes, welding them into place and sealing the body of the rake with a cover plate. If just one of these tubes is out of place, the rake must be scrapped. TRUMPF produced an optimized rake geometry on the TruPrint 1000 3D printer. Redesigning the part in this way makes it quicker for the manufacturer to produce and reduces the amount of material used by around 80 percent, ultimately slashing the overall cost by 74 percent. “This result shows that 3D printing can save a significant amount of time, material and money in the aircraft industry,” says project manager Julia Moll from TRUMPF Additive Manufacturing. 3. Making engine blades easier to repair TRUMPF also presentedsome sample applications of LMD technology at the Paris Air Show. These included the LMD repair of a high-pressure compressor blade – also known as a 3D aeroblade – used in aircraft engines. These components have to withstand extreme changes in temperature during flight. They are also in constant contact with dust and water, and they typically show signs of wear on the edges and tips. Aviation engineers must periodically repair the blades to maintain engine efficiency. The LMD method is perfect for this job. In some sections of the blades, the material is just 0.2 millimeters thick. Conventional methods quickly reach their limits in these kinds of applications. With LMD technology, however, the laser can be positioned with an accuracy of approximately one hundredth of a millimeter before it applies a precisely calculated dose of energy. At the same time, the system feeds in material of exactly the same composition as the part itself. Depending on the application, this process typically takes just a few minutes. It makes it easy to repair the blades multiple times, significantly reducing the cost per part in each engine overhaul. “Laser metal deposition delivers a low dose of energy – and that makes it perfect for aerospace applications. We can use it not only to repair and coat parts, but also to build up three-dimensional structures. That’s simply not possible with conventional welding methods,” says Oliver Müllerschön, head of industry management laser production technologies at TRUMPF.
https://www.trumpf.com
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Industry News | INDOSPACE
IndoSpace Launches Parks in Tamil Nadu, Punjab and Haryana IndoSpace, a major industrial and logistics parks developer, recently launched parks in three states. The parks span a total area of over 150 acres
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ndoSpace, India’s leading developer of Grade A industrial and logistics parks, announced in mid-July the launch of parks in Mevalurkuppam and Koodapakkam near Chennai, Tamil Nadu. These new parks will strengthen IndoSpace’s foothold in the South and help it move toward its goal of building a portfolio of 120 million square feet (11.1 million square meter) of modern infrastructure across the country. Spread across an area of over 15 acres, IndoSpace Industrial Park Meva is located in Mevalurkuppam village of Kancheepuram district. The park is situated near national highway NH-48, which connects Delhi to Chennai, providing easy access to nearby industrial hubs.
IndoSpace Sugal Industrial Park, Koodapakkam is spread across 26 acres and is located in the Tiruvallur district in the state of Tamil Nadu. It is situated on State Highway 50, and is closer to NH-332 which runs across Tamil Nadu and Puducherry providing excellent road connectivity within the state. Both the parks come under Irungattukottai micro-market area which has a large concentration of medium and small-scale enterprises that support the large-scale auto and auto-ancillary units based in SriperumbudurOragadam. Also, both parks are in proximity to the seaports of Ennore and Chennai, which gives them a superior logistical advantage. IndoSpace has a significant presence in Tamil Nadu with
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existing parks located in Coimbatore, Polivakkam, Oragadam, Puduvoyal and Vallam. “Chennai is one of the most sought after investment and development destinations in India, and is easily accessible through air, land and sea. The momentous increase in the number of Grade A industrial parks shows that Chennai has become the nodal point for supply chain and logistics in South India. This investment is in synergy with IndoSpace’s goal to build a significant portfolio of modern logistics infrastructure across the country,” said Rajesh Jaggi, Managing Partner - Real Estate, Everstone Group. Recent launches in the North In May 2019, IndoSpace launched two new parks in Rajpura, Punjab and Luhari, Haryana. IndoSpace Logistics Park Rajpura I, the region’s only Grade A park, is spread across 47 acres and is located at the junction of NH 44 and NH 7. Rajpura has emerged as a warehousing and logistics hub due to its proximity to three prominent cities (Chandigarh-Mohali-Panchkula). The area is well-connected with rail and road links to the rest of Punjab, Himachal Pradesh, Delhi-NCR and Rajasthan. IndoSpace Logistics Park Luhari III, close to the Delhi-Jaipur highway – situated in the heart of the warehousing hub in Gurugram (NCR)–
is spread across 67 acres. The site is in close proximity to several large industrial clusters, such as IMT Manesar, Dharuhera and Bhiwadi. IndoSpace currently has two operational parks in Luhari (Luhari I and Luhari II) spread across a combined area of 66 acres. The parks cater to the key markets in North India. With the new addition, IndoSpace has doubled its acreage in Luhari. “This significant expansion showcases IndoSpace's commitment to building Grade A logistics infrastructure to support the growth and modernization of the nation's supply chain. IndoSpace will continue to expand across existing as well as new markets in the future” said Rajesh Jaggi, Managing Partner- Real Estate, Everstone Group. Earlier this year, IndoSpace announced its foray into Gujarat with the launch of a park near Bavla, Ahmedabad. IndoSpace has a portfolio of around 31 million square feet (2.9 million square meter) across developed and under-construction projects comprising 31 industrial and logistics parks in 9 cities. All parks are located in key manufacturing hubs - from the National Capital Region in the north to Chennai in the south making IndoSpace the only national network in India. www.indospace.in
Key Highlight:
Chennai is one of the most sought after investment and development destinations in India, and is easily accessible through air, land and sea.
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Event Report | VDMA
The VDMA Mechanical Engineering Summit Industry experts present their views on India’s role in the global manufacturing scenario
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he 8th VDMA Mechanical Engineering Summit was held on 6th September 2019 at Hotel Sheraton, Bangalore and was attended by around 250 people. The summit commenced with a welcome speech from Mr. Rajesh Nath, Managing Director, VDMA India. He spoke about the year 2019, which was eventful in many ways starting from the domestic side where Narendra Modi government was re-elected with a thumping majority leading to beginning of Modi 2.0 era and on the global side the escalating trade war between the U.S. and China rippling through the global economy, hurting confidence among U.S. small businesses, crippling trade among industrial giants in Asia and hitting export-oriented factories. The glooming uncertainty of Brexit followed by the slump in the automotive sector in India in the first two quarters of 2019 has already raised a lot of pertinent questions including where the Indian economy is heading for. But this is the ideal time to consolidate and to have an optimistic view. The monsoon revival followed by a lot of positive steps taken by the Government of India to boost investment and growth will eventually help India to come out of the current situation. This was followed by a special address by the guest of honour, Mr. Vinay Kumar Katyal, Director, Bangalore Complex, Bharat Electronics Ltd. In his speech, Mr. Katyal mentioned that there is a wrong perception that most public sector undertakings in India were not performing well and incurring losses. Contrary to this perception, Mr. Rajesh Nath inaugurating the event Picture: VDMA
Bharat Electronics Ltd. had a turnover of 11,000 crores in 2018. The fundamental reason for this success is the transition from a manufacturing organization to a technological solution provider. Mrs. Margit Hellwig-Böette, Consul General, Consulate General of the Federal Republic of Germany, Bangalore gave a special address on Innovation, Digital Workplace and Startups. She mentioned that the speed of innovation is slowing down globally because of the trade war between the U.S and China and there is a lookout for a motivated young workforce. In this regard, India is in a comfortable position. Mr. Ulrich Ackermann, Managing Director of Foreign trade division, VDMA Frankfurt, presented the challenges of global trade. Global trade and investment or broadly, globalization, is a common market condition for all countries of the world now. However, it is not free from challenges. There are seven major challenges to global trade and investment the world is facing now starting with economic warfare. The world is experiencing increased conflicts, major economic powers are seizing influence, financial sanctions are being used as a weapon, and the Internet is breaking into pieces. Therefore, the international flow of money, information, products and services may slow down. On occasion of the Summit, a knowledge paper on “Automotive Industry-Impact due to Electro Mobility” was released by BDB India Pvt Ltd. The study came out with very interesting inputs about Electric Mobility. The prices of battery have almost come down by 70%, rent sharing has started getting preferences, and the subsidy announced by the Government on EV buying would have a
Guests of honour Picture: VDMA
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positive impact. According to this report the public transport, two-wheeler and three-wheeler segment are expected to be quicker in adapting to EV in India. The technical session I commenced with a presentation on Macroeconomics Trade and Digitization by Mr. Suvir Davda, Global Market Corporate Sales, HSBC, India. He mentioned the need to watch out for US-China trade tension, RMB move, domestic slowing down of the economy and resultant impact on capital flows. On the positives, lower oil prices and a possible movement of global supply chains to India could give a push to exports. The next presentation on Foreign Trade benefits and GST update given by Mr. Prashanth Bhat, Partner Indirect Tax, Deloitte. Some important points that were mentioned during the presentation were the WTO Agreement on Subsidies and Countervailing Measures permits the host country to provide export linked subsidies when the gross national income per capita is less than USD 1,000. The last presentation before the lunch was from Mr. Debabrata Sinha, Chief Financial officer & V.P, Rittal India. He shared his experience on anti-profiteering in the engineering industry and mentioned that the anti-profiteering framework under the goods and services tax (GST) has been extended by another two years. The post-lunch technical session began with the release of the report “Industry 4.0 and its impact on the people practices- within the HR domain” prepared by the HR Strategy Partner Maier+Vidorno. The report tried to elucidate the key strategies and roadmaps required by HR to successfully restructure the various departments within the company and to pursue the establishment of end to end Industry 4.0 technologies. By quoting that “Industry 4.0 is not a destination, but it is a journey”, it was emphasized that there is a need for continuous organization-wide change coupled with a clear vision on the end goal. The theme of Technical Session II was Industrial Automation to Industrial Autonomy. It began with the presentation on the Future on Automation by Mr. M R Subramanya, Vice President, Siemens Technology and Services Private Limited. He stated that today’s automation systems have excelled in efficiency as well as in quality and reach the market within months of product development.
Panel Discussion group Picture: VDMA
However, the classical automation systems of today are largely data-driven as well as operated under crystal clear instructions from a human being and hence, lack the flexibility that is required to categorize them as “Autonomous”. For an automation system to become self-learning, the existing data-based decision making must evolve into a more flexible inference-based system, where the human interaction is confined to a bare minimum. Next presentation was by Mr. Shankar G Rao, GM & HEAD and Mrs. Anuradha Preet, Strategic Consultant – Robert Bosch Engineering Private Limited. They gave an overview of the salient role played by the employees and their effective reskilling in the successful realization of industry 4.0 throughout the organization. With the RBEI NxT 2025 initiative, Robert Bosch aims at training over 20,000 associates per year through tailored Artificial Intelligence and Data Science courses that are focused on making them competent for a digital future. The presentation concluded with Mrs. Anuradha sharing Robert Bosch’s vision for the future and quoting the following: “By 2025, all our products will either feature AI, or AI will have been used in their lifecycle of manufacturing”. The final leg of this session was the presentation on Future Business and its challenges in the Manufacturing sector by Dr. Eric Maiser, Head of VDMA Competence Centre Future Business. The primary focus was on the technologies trending in the year 2030 and the key activities being carried out by the VDMA Start-up Machine in coaching start-ups that build their businesses with futuristic technologies at the core. The final session of the summit was devoted to “India Marching Towards a 5 Trillion Dollar Economy – Role of Manufacturing”. This Panel discussion was moderated by Mr. Rajesh Nath, Managing Director, VDMA India. The participants in the discussion were Mr. Vivek Bhatia, Managing Director & CEO Thyssenkrupp Industries India Private Limited, Mr. Rashmikant Joshi, Managing Director, Festo India Private Limited, Mr. Guruprasad Mudlapur, Managing Director, Bosch Automotive Electronics India Private Limited, Mr. Norbert Koenig, Vice President- Asia Pacific & Managing Director India, Seco Tools India (P) Ltd and Mr. Satish Sadasivan, Managing Director, Schunk Intec India Private Limited. The panel members explained the readiness of Indian SMEs in adopting Industry 4.0, followed by the impact of GST in reforming the business game and the importance of re-skilling as well as the industry-academia interaction. The discussion ended with a rapid-fire round comprised of witty questions and was well appreciated by the audience. https://www.vdma.org
Key Highlight: “By 2025, all our products will either feature AI, or AI will have been used in their lifecycle of manufacturing”
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Cover Feature | ANCA SOFTWARE
NCA Launches The Latest Generation of ToolRoom RN34 Leading cutting tool manufacture Fraisa reduced set up from hours to five minutes through the new tool balancing feature in ANCA’s new ToolRoom RN34
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oolRoom RN34 is the latest generation of ANCA’s successful software package that has been specially designed for the aerospace, die mould, general machining and power generation industries. Thomson Mathew, ANCA Software Product Manager says: “ToolRoom RN34 is aimed to be the differentiator among many suppliers of endmill manufactures in the industry by allowing customers to design complex geometries through software to achieve increased tool life, productivity, cutting volume and increased quality and precision of the workpiece.” “The constant helix ballnose option, for example, is replaced by a graphical drag-and-drop designer. This ballnose type of tool, with optimised irregular helix curves to reduce vibration, and with near-instant visualisation easily achieved by switching from the 2D projection of the cutting edge to the 3D.” The new software promises benefits of: • Improved productivity through the intuitive creation of complex endmill geometries. • Tool balancing to increase tool life, cutting volume, quality and precision of the workpieces. • Minimising chatter through the simple design of high performance, complex tools. Douglas Franke, Fraisa Production Manager said: “with ANCA’s balancing software we have a tool balanced generally within five minutes. Some of our more complex tooling can take a little longer – up to 20 minutes. This drastically decreased
our time in setup on the machine which could take several hours. Our biggest success story has been an aerospace customer who is running our 1” aluminium roughing tool at 25k rpm.” ANCA's ToolRoom software provides industry renowned tool design flexibility, from the simplest to the most challenging tasks. With the benefit of over 40 years of grinding knowledge, ToolRoom supports both manufacturing or regrinding applications. Flexibility is further enhanced by the fact that ANCA develops all aspects of the machine in house - from the CNC control system and application software to the machine and its accessories. New Ballnose Cycles The new ballnose cycles allow end users to manufacture a range of ballnose tools suitable for finishing and roughing. The new designer edge can accommodate high helix on ball cutting edge for better fracture resistance and reduced vibration due to the irregular curve. • Ballnose with designer cutting edge. • New chisel edge grinding method. • Curvature gash – curved gash surface. • Flute gash – curved ball gash and fluting in single move. • Facet gash with periphery of 1A1 or 1V1 wheels. • Bullet and Bullnose style tools. • 11V5 wheel grinding methods for improved wheel life. • Square to ballnose blank roughing cycles. • Various other methods of OD grinding with 11M2 wheels. New Tooltype – Double Corner Radius The double corner radius allows the design of barrel shape or lens shaped tools with larger to smaller or smaller to larger radius from the end of tool. Vibration and deflection are reduced with this style of geometry and the thinner chips that are formed provide longer tool life and enhanced performance. • Barrel shape – large radius to small towards the end of tool. • Lens shape – small to larger radius towards the endface. • Curved endface design. • Roughing operation for corner radius tools.
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Tool Balancing Tool balancing is done on variable helix and pitch or single flute tools to minimise the eccentric weight distribution when using high speed machining. The benefits include reduced noise and vibrations, improved machine bearing life, and better surface finish. The different methods of balance are: • Flute length extension • Shank notch New flute from solid and flute polish cycles The new fluting cycles are catered for manufacturing variable helix and pitch tools to eliminate the harmonics caused during high speed machining by varying the time intervals between the flute contact with the workpiece. • Support for the following option combinations: - Variable helix with NAS hook - NAS hook with radial land - Variable helix and pitch with radial land • Per–Flute programming options to control flute length, flute depth, core taper etc. individually. • Support for single flute tools to have depth equal or greater than tool radius. New Tooltype – Lollipop Cutter A new ToolType is available from the endmill wizard to manufacture lollipop cutters. These cutters are widely used in the aerospace and die mould industries. • High helix angles for better surface finish and chip removal. • Shear lollipop for deburring applications. • Chip breakers for light work and the medical industry. • Use of iView and LaserPlus for measurement and compensation. Endmills – Reverse Infeed In Square Endmills Support for reverse infeed when using large dish angles on square endmills where we can manage wheel wear with number of passes. • The ability to choose between forward and reverse infeeds. Endmills – OD Chip Breakers New operation in Endmill cycles to add OD chip breakers. • Automatic or manual modes. • Applicable to all straight OD profile to complement corner radius, ballnose, side and face cutters and endface operations. A library of all the ANCA supplied collet adaptors and collets are available for the user. Embedded Tom Files This adds additional functionality in allowing one TOM file to be embedded into another TOM file. • Example: Corner radius with multi drill gash. • Like the iPunch operation in iGrind and KHP. • Some limitations exist, such as use of tool segments.
Helical Fir Tree Cutters Support for a wide range of constant helix, constant lead and shear cutters widely used in the aerospace and power generation industries. All the above are supported for unmanned production with the support of the inbuilt LaserPlus which is fully automated. • Support for constant helix fir tree cutters. • Helical fluting with hook generating a flat flute surface. • Support for iView and LaserPlus. New Tooltype – Countersink Tool A new wizard style ToolType has been added for countersink tools to support standard flute and fan gash flute style. The new countersink flute operation can define special flute shapes required for this application. • Support for RR, LL, RL, LR combinations. • Relief grinding using step editor sections. • Supports non-zero shear and upto 6 flutes. • Automatic CIM3D blank form. Drills – Double Margin Fixed Or Float A new feature is added to OD backoff/raised land fluting operation for drills, to be able to produce second margin towards trailing edge of the tool. • Double margin can be produced in both the backoff types OD and raised. • The second margin can also float at an offset angle from cutting edge of the tool. • This feature is made available to drills and step tools. New Operation – Threadmill Manufacturing of a variety of threadmills is now possible with the addition of two new operations to the operations list. Threadmill grinding and cresting operations are supported with formed and standard fluting operations. • Support for drill threadmill, straight OD, tapered OD and all the combinations. • Possible to grind insert style or single rib threadmills. • LaserPlus support for large volume production. New Operation – Pocket Grinding Pocket grinding software allows the user to quickly and easily define PCD pocket geometry. This is required for PCD tools used mainly in the woodworking and aerospace industries for composite and non-ferrous materials. • Ability to specify pocket geometry as common or for individual flutes. • Position of pockets can be fixed or alternated based on number of flutes. • Supported with spindle speed increaser hardware on all platforms for mounted point wheels. www.anca.com
Key Highlight: ANCA's ToolRoom software provides industry renowned tool design flexibility, from the simplest to the most challenging tasks.
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Vo l u m e 3 – I s s u e 5 S e p t / O c t 2 0 1 9
COMPANY INDEX
IMPRINT
3D Printing Education & Research Association
33
Aerospace Business (India)
44
Altem Technologies
30
amace solutions Pvt. Ltd
24
ANCA SOFTWARE
68
Atherton Bikes
44
Blaser Swisslube Dassault Systèmes DMG MORI EMO Hannover
54 26, 56 50 14, 58
Fieldready.org
34
IMTMA
38
INDOSPACE
39, 64
Laser World of Photonics India
10,12
MARPOSS
42
Messe Muenchen India
10
PRINTRONIX
40
RENISHAW ADDITIVE MANUFACTURING
44
Renishaw Metrology Systems Ltd
32
SCHUNK GmbH
58
Seco Tools
46
SIEMENS
49
Stratasys
20
TRUMPF
60
VDMA
66
ADVERTISERS INDEX AMF
53
DMI presents – MANUFACTURING LEADERSHIP HANDBOOK 2019 17 DMI – SUBSCRIPTION FORM
29
DYNAMIC MANUFACTURING INDIA
39
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MITSUBISHI CNC
5
ORDERFOX.COM
4,35
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3
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2
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9
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