Industrial Machinery Digest - February 2024 by Industrial Machinery Digest

IndustrialMachineryDigest.com | February 2024

North America’s Manufacturing Resource for Industry Professionals Since 1986

The Next Step in Welding Safety: How FumeVac is Redefining Fume Extraction With Jim Logan — Sales Director, FumeVac 7 Real-Life Manufacturing Challenges Resolved with MRP Software Tips for Creating a VpCI®-422 Rust Removal Station Flexxbotics Revolutionizing Manufacturing with Advanced Robotics The Essential Role of Fixture Design in Laser-Based Welding Applications Revolutionizing Workforce Development in Manufacturing: Insights from Jai Shah, CEO of Kahuna EMAG Develops Integrated Solutions Custom-fit robot solutions ensure fast parts flow in production

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Table of Contents

February 2024 8 10 16

EDITORIAL DIRECTION INDUSTRY NEWS BUSINESS 4.0 7 Real-Life Manufacturing Challenges Resolved with MRP Software By Madis Kuuse

TALKING SHOP The Next Step in Welding Safety: How FumeVac is Redefining Fume Extraction With Jim Logan — Sales Director, FumeVac

SAFETY & MAINTENANCE

MANUFACTURING SHOWCASE

Tips for Creating a VpCI®-422 Rust Removal Station Flexxbotics Revolutionizing Manufacturing with Advanced Robotics

INDUSTRIAL AUTOMATION The Essential Role of Fixture Design in Laser-Based Welding Applications By Todd E. Lizotte, Orest Ohar, and Joseph Dagher of Bold Laser Automation, Inc. Bedford, NH

WORKFORCE DEVELOPMENT

NEW TECHNOLOGY

PROCESS

Revolutionizing Workforce Development in Manufacturing: Insights from Jai Shah, CEO of Kahuna Revolutionizing Rapid Prototyping: The UltiMaker S-series Transforming Industrial Manufacturing EMAG Develops Integrated Solutions

Custom-fit robot solutions ensure fast parts flow in production

INDUSTRY INSIGHT Forging Ahead: Speedy Delivery of High Quality, Seamless and Contoured Rolled Rings By Del Williams

42 47 49 50

PRODUCT SHOWCASE SURPLUS BUYING & SELLING CLASSIFIEDS ADVERTISER INDEX

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Brian Self, Associate Editor brian@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Shane Bell, Creative Director sbell@indmacdig.com

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Editorial Direction In our February issue of Industrial Machinery Digest, themed "Man + Machine = a Perfect Collaboration", we explore the synergistic relationship between human ingenuity and technological advancements in the industrial realm. Our focus encompasses a spectrum of processes including CAD/CAM, CIM & Robotics, Cutting, Sawing, Finishing, Joining & Metalworking, Precision Machining, and Safety & Maintenance. In "Business 4.0", Madis Kuuse offers solutions to common manufacturing hurdles in "7 Real-Life Manufacturing Challenges Resolved with MRP Software", highlighting the crucial role of modern software in enhancing productivity. "Talking Shop" features insights from Jim Logan, Sales Director of FumeVac. His piece, "The Next Step in Welding Safety: How FumeVac is Redefining Fume Extraction", underscores the evolution of safety measures in welding. Our "Safety & Maintenance" section provides practical advice on "Tips for Creating a VpCI®-422 Rust Removal Station", ensuring effective maintenance practices in industrial settings. "Manufacturing Showcase" shines a spotlight on Flexxbotics. "Revolutionizing Manufacturing with Advanced Robotics" captures the transformative impact of robotics in the manufacturing industry. In "Industrial Automation", we present "The Essential Role of Fixture Design in Laser-Based Welding Applications" by Todd E. Lizotte, Orest Ohar, and Joseph Dagher of Bold Laser Automation, Inc. This article emphasizes the critical role of precision in laser welding. "Workforce Development" features Jai Shah, CEO of Kahuna, in "Revolutionizing Workforce Development in Manufacturing", offering a fresh perspective on nurturing skills in the manufacturing workforce. "New Technology" introduces "Revolutionizing Rapid Prototyping: The UltiMaker S-series Transforming Industrial Manufacturing", showcasing the breakthroughs in prototyping technologies. In "Process", we discuss EMAG's integrated solutions in "Custom-fit robot solutions ensure fast parts flow in production", emphasizing efficiency in manufacturing processes. Finally, "Industry Insight" by Del Williams, "Forging Ahead: Speedy Delivery of High Quality, Seamless and Contoured Rolled Rings", explores the craftsmanship and efficiency in custom ring manufacturing. Sincerely,

William Strickland William Strickland Publisher, IMD

8 | IMD February 2024

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

Predictions for Additive Manufacturing in 2024 by 3D Systems' CEO Dr. Jeffrey Graves, CEO of 3D Systems, forecasts significant advancements in Dr. Jeffrey Graves additive manufacturing (AM) across various sectors in 2024. The technology has already shown transformative effects in industries like healthcare and industrial manufacturing. For 2024, key areas of impact include semiconductors, consumer goods, aerospace, defense, medical devices, and dental sectors. Graves anticipates AM's integration in production applications to mitigate supply chain disruptions, allowing manufacturers to localize production, thereby reducing costs and environmental impact. In healthcare, AM is expected to gain momentum in on-site production of medical devices at healthcare facilities. This will empower surgeons and medical providers to produce personalized devices, enhancing patient care. The dental industry will likely see AM shift from indirect production methods to direct production of patient-specific devices. This trend will enable mass customization in dental solutions like surgical guides, implants, and orthodontic appliances. In the semiconductor industry, plagued by chip shortages, AM is predicted to play a growing role. It offers the ability to produce complex parts with high accuracy, potentially reducing production times for critical semiconductor components. Graves also expects AM to accelerate innovation in consumer goods, particularly electronics, by enabling faster product development and the creation of advanced products. Overall, AM's role in driving industry-wide innovation and customization is set to expand significantly in 2024.

www.IndustrialMachineryDigest.com 10 | IMD February 2024

ABB's Acquisition of Real Tech to Enhance Smart Water Management ABB has announced its acquisition of Canadian company Real Tech, a leader in real-time water quality monitoring technology. This acquisition aims to strengthen ABB's presence in the water sector and enhance its portfolio with Real Tech's optical sensor technology, crucial for smart water management. Real Tech, with over 10,000 installations worldwide, specializes in real-time water quality monitoring in various sectors, including municipal water and wastewater. Their technology, which uses spectrophotometry and fluorescence measuring techniques, enables on-site, real-time water testing, a significant advancement over traditional methods. Real Tech's solutions include optical sensors, controllers, and AI software, Liquid AI®, which provides an efficient way to analyze water quality data. This acquisition allows ABB to capitalize on growing global demand for sustainable water management solutions. Jacques Mulbert, Division President of ABB Measurement & Analytics, emphasizes the strategic importance of this acquisition in expanding ABB’s environmental technology portfolio. Real Tech's co-founder, Jodi Glover, looks forward to integrating their advanced water monitoring technology with ABB's global network to address critical water management challenges. The acquisition highlights the increasing need for advanced water management solutions amidst global water scarcity and the push for sustainable practices. It is part of a broader trend of significant investments in water infrastructure and quality monitoring technologies worldwide.

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Automated Precision, Inc.'s Decade of Wireless Metrology Innovation Automated Precision, Inc. (API) celebrates its 10th anniversary of leading wireless metrology innovation, notably with its Laser Tracker and probe combo. API has been a pioneer in metrology since its inception, continually pushing the boundaries of technology in this field. API's commitment to innovation is evident in its products, like the groundbreaking laser interferometer for 6DoF Machine Tool Calibration and Dynamic 9D LADAR for high-speed non-contact scanning. Their products have evolved to meet customer needs, leading to the development of faster, more portable trackers, intelligent probes, and efficient handheld scanners. In 2013, API introduced the industry's first wireless tracker and probe combo, the OmniTrac and vProbe, revolutionizing metrology with greater mobility and versatility. They have consistently improved this technology, enhancing aspects like battery life, measuring speed, and probe tip recognition. Kam Lau, CEO of API, emphasizes their dedication to innovation and customer satisfaction, which has positioned their wireless tracker and probe combination as a game-changer in various industries. As they mark a decade of excellence, API continues to offer advanced metrology solutions and has reintroduced popular product bundles like the Radian Plus and vProbe.

Cetec ERP Showcasing at Design 2 Part Show in Texas Cetec ERP announces its participation in the Design 2 Part Show in Irving, Texas, showcasing its software solutions tailored for machine shops and metal fabrication businesses. Cetec ERP's software suite includes features like intelligent scheduling, advanced inventory management, and robust job costing tools, all designed to enhance operational efficiency. The software's integration with barcode scanning improves data accuracy and streamlines shop floor operations. It also provides real-time data access for efficient work order management and a quality management module to maintain high standards in product delivery and customer satisfaction.

EXAIR Application Engineer Achieves CAGI Certification EXAIR Application Engineer John Ball has achieved the Certified Compressed Air System Specialist (CCASS) certification from the Compressed Air and Gas Institute (CAGI). This

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certification represents expertise in compressed air systems and involves rigorous training and testing. Ball's accomplishment reinforces his ability to provide valuable insights into compressed air applications for EXAIR's customers. EXAIR's Application Engineers assist in optimizing performance, energy efficiency, and maintenance of compressed air systems. The company offers resources like 3D models, CADs, calculators, and an application database to support manufacturing processes.

KYZEN to Spotlight Cleaning Solvents at MD&M West KYZEN, a leader in eco-friendly cleaning chemistries, will participate in MD&M West 2024 in Anaheim, CA. They will discuss METALNOX M6093 and M6386, their products designed for cleaning medical devices. METALNOX products are formulated for vacuum and vapor degreasing processes, providing reliable and easy cleaning solutions. They serve as environmentally friendly alternatives to traditional solvents. M6093 is a citric acid-based cleaner effective in various applications, including removing industrial soils from metals and providing safe passivation for stainless steel. M6386, a modified alcohol-based solvent, is ideal for automated vacuum degreasing cleaning machines, effectively removing a range of oils and coolants from different metals.

Laserline Showcases Laser Solutions at Photonics West 2024 Laserline, Inc., a specialist in high-power diode lasers, will be presenting its advanced laser solutions at SPIE Photonics West 2024 in San Francisco, CA. The focus will be on blue diode lasers for copper and semiconductor processing, and laser-based processes for battery drying. Key highlights include the LDFblue 4000, the first blue diode laser with 4 kW CW output power, showcasing Laserline's leadership in the field. These blue diode lasers are more energy-efficient and maintenance-free compared to traditional high-power lasers, offering a wide range of applications such as semiconductor material modification and copper welding. Also on display will be Laser Assisted Bonding (LAB) solutions, advantageous over traditional bonding methods for semiconductor packaging. LAB reduces thermal stress and is ideal for thin substrates, offering improvements in fab costs and throughput. Laserline will also demonstrate diode laser-based drying processes for battery foils, an innovative alternative to conventional drying machines. This method significantly reduces space requirements and energy consumption in battery cell production, offering substantial operational and capital expenditure savings.

L&L Special Furnace Company Celebrates Successful 2023 L&L Special Furnace Company concluded an impressive 2023 with two major orders for large front-loading box

furnaces, destined for a Midwest R&D facility. These furnaces, slated for ceramic and composite product development, will be delivered in the second quarter of 2024. Designed for 2,000°F operation, they feature a 48” square work zone, PLC control, temperature recording, and a universal loader. The year saw robust sales, particularly in aerospace and composites, driven by rising demand for new composites and processes. L&L aims to continue supporting diverse thermal requirements in 2024, from small in-house heat-treating to larger custom projects. L&L's diverse offerings span various sectors, including aerospace, high-tech ceramics, and automotive, with a strong focus on meeting specific thermal needs. The company offers customized furnaces with options like pyrometry packages complying with ASM2750 and various control configurations. Their all-inclusive startup service extends across North America, with international service available on request.

MicroCare Appoints Lu Anne Green as Chief Operating Officer MicroCare has announced Lu Anne Green as its new Chief Operating Officer. With a rich background in operational leadership across various industries, Green's expertise includes Lu Anne Green LEAN, Six Sigma, and supply chain optimization. She holds a Bachelor's degree in Mechanical Engineering and an MBA in Business Administration. As COO, Green will oversee manufacturing operations at MicroCare’s Connecticut locations. Her role involves optimizing operational performance, strengthening customer and vendor relationships, and mitigating risks. Her experience is expected to enhance MicroCare’s manufacturing excellence and operational efficiency. Tom Tattersall, MicroCare CEO, commended Green's appointment, highlighting her diverse industry experience and implementation of LEAN and Six Sigma principles. Her leadership is anticipated to strengthen MicroCare's manufacturing solutions and support the company's growth and operational success.

Norwalt Continues Investment in Collegiate Automation Program Norwalt is expanding its Collegiate Automation Program (CAP), designed to prepare students for careers in machine design and manufacturing. Collaborating with the University of Delaware and other institutions, Norwalt provides real-life experiences complementing academic learning. Through this program, Norwalt assists in engineering curriculums, funds hands-on projects, and offers

internships and recruitment seminars. The company also supports community colleges with machinery donations, enhancing student instruction. Norwalt, based in New Jersey and Florida, specializes in custom-built automation machinery for diverse sectors, including medical devices and personal care. Mike Seitel, President at Norwalt, emphasized the company's commitment to nurturing future industry professionals, highlighting the importance of practical experience in education.

Olympic Steel Promotes Zachary J. Siegal to President of Manufactured Metal Products Olympic Steel Inc. has promoted Zachary J. Siegal to President of Manufactured Metal Products. Joining in 2007, Siegal has held various roles, Zachary J. Siegal contributing significantly to the company's strategic growth through acquisitions. Siegal will lead the new Manufactured Metal Products business group, encompassing McCullough Industries, MetalFab, Shaw Stainless & Alloy, and EZ-Dumper® operations. He reports to Andrew S. Greiff, President and COO, and will continue involvement in mergers and acquisitions. CEO Richard T. Marabito and Greiff acknowledged Siegal's role in the company's diversification and growth into the manufactured metals market. His expertise is expected to accelerate growth in this sector, leveraging core competencies to reduce cyclicality in traditional distribution. Siegal, a finance graduate from Miami University and a Deming Scholars Program graduate at Fordham University, also completed the MSCI Strategic Metals Management Program. He is involved with the Cleveland Clinic Children’s Hospital Leadership Council and Olympic Steel’s ESG Steering Committee.

Pemamek Appoints Juhani Tuomola as Application Manager of Wind Energy Segment Finland-based Pemamek Ltd. has named Juhani Tuomola as Application Manager for its Wind Energy segment. With previous experience as an Application Engineer and Simulation Specialist in the same segment, Juhani Tuomola Tuomola brings extensive knowledge of automated welding solutions to his new role. Tuomola is tasked with leading technical sales efforts in the wind tower and foundations industries, developing solutions for OEMs in the wind energy market. His expertise in Pemamek's technologies, developed over 50 years, will be instrumental in supporting the industry's growth and innovation. Pemamek’s robust apprenticeship and internship programs contribute to nurturing future welding INDUSTRIAL MACHINERY DIGEST.COM

IMD | 13

automation experts. Tuomola's appointment reflects the company's commitment to providing advanced, turnkey solutions to meet the evolving demands of the wind energy sector.

RDAbbott Celebrates 75 Years with 75 Acts of Kindness Campaign RDAbbott is celebrating its 75th anniversary by launching "75 Acts of Kindness," a campaign to give back to communities, industries, and employees. Founded in 1948 by Robert David Abbott, RDAbbott has transitioned from a regional distributor to a multi-faceted supplier in distribution, materials science, process engineering, and product customization, emphasizing people over profit. Abbott, who retired from The C.P. Hall Company, contributed significantly to rubber technology education, collaborating with The Los Angeles Rubber Group, Inc. (TLARGI) to develop a rubber technology curriculum at USC. Although the curriculum was discontinued in the 1980s, TLARGI adapted it into a "Basic Rubber Technology" course, which RDAbbott hosted and taught for over twenty years. After Abbott's death, six leaders, including Carl Hoglund and Johnny Arensmeyer, transformed RDAbbott. Hoglund was instrumental in commercializing Chemlok® adhesive technology. Under Jerry Wicker's leadership, the company expanded its product lines to include dispersions, additives, modifiers, colors, and fillers. Current CEO Keith Thomas continued this expansion across North America. In 2017, RDAbbott purchased Novation Solutions, LLC (NovationSi), specializing in modifiers, additives, and colors for silicone. The company's headquarters moved several times within California, with additional facilities in Mexico, Canada, and other locations. Investments in IT infrastructure, technical services, and warehouses have been significant. RDAbbott remains a leading North American rubber industry distributor, focusing on education and rubber technology advancement. Innovations include electrically conductive silicone compounds and sustainable product design. Collaborations have led to advancements in tire tread extrusion, LSR characterizations, lightweight silicone elastomers, and sealing compounds for hydrogen fuel cells. RDAbbott's 75 Acts of Kindness will support local non-profits, community needs, and educational institutions. The company has a history of community involvement, including hosting blood drives and aiding natural disaster victims. CEO Keith Thomas emphasizes the company's commitment to propelling business and equipping future leaders, maintaining a focus on people.

wheel.me Adopts Siemens Xcelerator for Autonomous Factory Robotics Norwegian startup wheel.me has selected Siemens Xcelerator as a Service for developing Genius 2, an

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autonomous mobile robot for factory logistics automation. Siemens Xcelerator offers a flexible, scalable, and secure product engineering solution. Genius 2, engineered at wheel.me's Oslo headquarters, is designed to work alongside humans, enhancing productivity by handling repetitive tasks. It comprises autonomous wheels with advanced sensors for obstacle detection and dynamic path planning. The software allows for customizable process flows and centralized control. In 2023, wheel.me transitioned from a multi-vendor toolset to Siemens' integrated platform, encompassing mechanical design and robust lifecycle management. The platform includes Siemens' NX™ software, Solid Edge® software, and Teamcenter® software for product engineering and PLM. Casper Rødsrud, Head of Mechanical Engineering at wheel.me, highlights the flexibility and benefits of accessing both NX and Solid Edge. The solution enables quick concept designs and in-depth design simulations. Siemens Xcelerator's scalability is crucial for wheel.me's growth, particularly in Europe and the US. Mats Friberg of Siemens Digital Industries Software notes the significance of startups in industry innovation and praises wheel.me's exploration of autonomous robotics in manufacturing. Siemens Xcelerator supports companies of all sizes in their design and engineering ventures.

Siemens and Voltaiq Collaborate to Optimize Battery Manufacturing Siemens Digital Industries Software and Voltaiq have announced a collaborative effort to enhance and optimize battery manufacturing. This partnership aims to integrate Siemens' Insights Hub™ and Voltaiq's Enterprise Battery Intelligence™ (EBI) to provide comprehensive solutions for battery manufacturing companies. This collaboration is in line with Siemens' mission to deliver value in Industrial IoT and assist in the digital transformation of organizations, thereby ushering in a new era in battery manufacturing. The collaboration addresses the growing global dependency on battery-powered products, from electric vehicles to small personal devices. Experts predict a significant increase in battery demand and production, particularly for electric vehicles, which presents numerous manufacturing challenges such as quality control, production efficiency, waste reduction, and cost minimization. The Siemens-Voltaiq collaboration focuses on improving quality control and consistency in battery manufacturing. Maintaining high performance and safety standards for each battery is critical, especially considering the variations in manufacturing conditions that can affect battery quality. The partnership also aims to increase production to meet rising demands without compromising quality or efficiency. This includes managing large automated facilities and understanding the impact of complex machinery on battery cell characteristics.

Furthermore, the collaboration seeks to enhance process efficiency and reduce waste in battery manufacturing, which involves intricate chemical processes. By optimizing these processes, manufacturers can address both cost and environmental concerns. High costs in raw material, manufacturing processes, and technology development are also key challenges that the collaboration aims to tackle. Combining Siemens' industrial IoT solutions with Voltaiq's suite of battery-specific monitoring, visualization, and advanced analytics capabilities, the joint solution helps manage and optimize battery cell manufacturing, particularly in the critical finishing stage. This stage significantly influences production costs and time, and the collaboration aims to minimize risks associated with late-stage production issues, thus enhancing yield and profitability.

Upwing Energy Integrates Additive Manufacturing for SCS Compressor Module Upwing Energy, a gas tech innovator, has successfully integrated metal additive manufacturing (AM) into its manufacturing process using Laser Power Bed Fusion (LPBF). This innovation, developed in collaboration with Velo3D, enhances the manufacturing of its Subsurface Compressor System’s (SCS) compressor module, crucial for natural gas production from wells. The SCS compressor module, made from Inconel 718, features a complex rotor design, challenging to manufacture due to intricate surface geometries. Metal AM allows Upwing to produce these components in just 10 weeks, enhancing part performance and lifecycle. Extensive testing verified that AM Inconel 718 meets ASTM F3055 requirements and downhole compressor application standards. Upwing's move to AM enhances scalability and precision in part production. Tests compared the mechanical properties of AM components to those produced from machined billet. The AM parts endured standard and overspeed conditions, demonstrating their robustness for the SCS’s gas compression process. Robert McKeirnan, Vice President of Supply Chain and External Manufacturing at Upwing Energy, highlighted the company's commitment to continuous improvement and the benefits of AM in creating durable and intricately designed parts.

documentary highlights the unique skills and potential of veterans in boosting the industry’s competitiveness. Bill Leahy, inspired by a phrase from a Navy SEAL, created a program with the University of TennesseeKnoxville to train veterans for manufacturing careers. The film underscores the challenges and opportunities in the sector and the potential of veterans to drive innovation and growth. Tractian's sponsorship reflects its commitment to the 'MADE IN AMERICA' promise and the integration of veterans into manufacturing. The film aims to inspire and positively impact veterans, manufacturers, and the broader community.

Stratasys Wins 3D Printing Industry Award for Medical, Dental, and Healthcare Applications Stratasys Ltd., a leader in polymer 3D printing solutions, has won the 3D Printing Industry Award in the Medical, Dental or Healthcare Application category. Its PolyJetbased J5 DentaJet™, J5 MediJet™, and J850 Digital Anatomy™ 3D Printers were recognized for their market growth, beating nine competitors. Stratasys also received honorable mentions in the Company of the Year (Enterprise) and Enterprise 3D Printer of the Year (Polymers) categories. The awards ceremony took place in London. Rani Hagag, Chief Health Care and Consumer Business Officer at Stratasys, expressed excitement about the achievement, highlighting the impact of their 3D printing solutions in the dental and medical sectors. The technology enables the precise 3D printing of dental parts, biomechanically accurate anatomical models, and full-color multi-material training models. Stratasys' portfolio includes the DentaJet series for dental applications and the J5 MediJet for medical applications, offering multi-material, multi-color capabilities for anatomical models and biocompatible guides. The J850 Digital Anatomy 3D printer further enhances realism in models of human anatomy. Hagag acknowledged the collaborative efforts with partners that contribute to healthcare advancements through their technology.

Tractian Sponsors Documentary Film 'Unturning Steel' Featuring Veterans in Manufacturing Tractian, a leader in manufacturing solutions, announces its Title Sponsorship of "Unturning Steel," a documentary focusing on military veterans in American manufacturing. The film, releasing in Spring, follows Bill Leahy’s initiative to integrate veterans into the manufacturing sector. "Unturning Steel" explores the role of veterans in revitalizing American manufacturing amidst competition from China and the need for skilled labor. The INDUSTRIAL MACHINERY DIGEST.COM

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7 Business 4.0

Real-Life Manufacturing Challenges Resolved with MRP Software

By Madis Kuuse

anaging the processes of a small manufacturing company is an enormous task rife with challenges to overcome. Here are seven real-life manufacturing challenges that MRP software helps you resolve.

Intro Manufacturing is hard work. And managing it is even harder. This is especially true for small manufacturers that need to wear multiple hats every single day, making sure that production schedules are accurate and adhered to, that materials reach the shop floor at the right time, that orders are put in and processed in due time, that product quality is up to standard, that costs are kept in check, and so forth.

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It’s tough. And it’s made tougher by increasingly heavy regulations, constant supply chain disruptions, and labor capacity fluctuations endemic to our age. But when the going gets tough, the tough get smarter. A growing number of small manufacturers are turning to software to alleviate their various day-to-day pains. Here are seven real-life manufacturing challenges that genuine companies from various industries have overcome with the help of MRP software.

STOCKOUTS AND OVERSTOCKING One of the biggest issues that MRP software tackles is material planning. The need to find a balance between too little and too much stock is very acute in small manufacturing companies as each unit represents

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

tied-up cash that could be put to good use elsewhere. MRP software is made to accurately determine material requirements, ensure timely stock replenishments, and facilitate demand planning, allowing companies to optimize their inventory. Paul Long, Website Manager at health and beauty product manufacturer Myddfai Trading Company says: “MRPeasy tells us what our requirements are, and when we create the manufacturing orders, we don’t have to go and tell the manufacturing staff anything, they can simply pull the information from MRPeasy. At the same time, we’re getting flags for stock statuses and can replenish purchases.”

DATA GETTING LOST Data is key to making good business decisions. But managing business information in spreadsheets (or even worse, physical archives) is unsustainable in the long run as finding the correct piece of data becomes increasingly difficult as the company grows. Within an MRP system, however, your data is organized in a way that enables easy navigation and quick search. “We now have all the information in one place – we can see the part, when it’s due, what the costs are, everything. All you need to find is just one click away, which saves us a huge amount of time, and we have eliminated the horrendous paper trail we previously had,” details Lee Brien, Director of Operations at UK precision engineering company A Wrate Engineering.

HIGH ADMINISTRATIVE OVERHEAD Although necessary, it seems counterproductive to hire additional administrative staff if you could put the same resources into growing the manufacturing side of the business. The level of automation MRP software creates, however, allows companies to significantly reduce administrative tasks, especially those involving data entry and analysis. Javed Bashir, Production Director at international textile manufacturing company B&A Quilting confirms this: “We are about eight times the size we were in 2017 but have barely doubled the administrative side of things. MRPeasy really has helped us immensely.”

TRACEABILITY REGULATIONS Being able to track the flow of goods throughout the value chain brings substantial benefits to any company, but especially to those working in heavily regulated industries. Achieving regulatory compliance can be a daunting challenge but it is made effortless by MRP software. “I had a target to install MRPeasy and become ISO 9001 approved within 6 months. After 6 months of using the system, SGS (an industry-leading certification company) came in to undertake the certification audit and we passed without a single non-conformance. On the report, SGS also commented on how good MRPeasy

was with traceability,” states Paul Watson, founder of MPW Precision.

MANAGING COMPLEX BOMS Although the bill of materials functionality is the core of every proper production planning software, many MRP systems do not support complex, multi-level BOMs or BOMs with parameters. Therefore, if you need to manage the manufacturing of intricate products with lots of subassemblies, make sure to find a solution that accommodates that. Ralph Jones, Director at Britannia 2000 Holdings, knows a thing or two about complex products: “MRPeasy is brilliant, it’s enabled us to build up BOMs for all our products. We have BOMs for each individually printed circuit board and for each sub- and final assembly. It works a treat. One of our mission computers has a BOM of 15-20 pages.”

REMOTE COLLABORATION For businesses operating from a single facility, the COVID-19 pandemic illustrated the need to be able to work and collaborate remotely. For many companies, however, interregional or international collaboration is an everyday reality regardless of natural disasters or public health crises. In manufacturing companies, this is enabled by using cloud-based MRP software. “We had staff in two locations in the US, plus the procurement department in Taiwan, therefore we needed a system that could be accessed from anywhere,” says Dennis Lan, Supply Chain Director at lighting systems manufacturer Anthem One. “Before implementing MRPeasy, it was hard to tell which part was where. Now, we know exactly.”

SCALING UP Although growth is generally a positive thing, scaling up operations can be very tough for managers. While spreadsheets cannot accommodate a growing business for too long, even some MRP systems can become an impediment if their functionality is not up to par with what serious manufacturers need. That is why considering your future requirements is as important as considering current ones when choosing a software. Paola Dyboski, founder of Dr Zigs bubble toy company, feels confident about further growth: “There is definitely more functionality to roll out and I am sure we will implement [the MRP system] further as the need arises and our use case and abilities grow. Because MRPeasy grows with you, you can decide as you go, how much you want to implement and then do it in stages.” MRPeasy is a manufacturing resource planning software for small manufacturers with up to 200 employees. Integrating sales, production, inventory, purchasing, and finances, the software provides you with an accurate real-time overview of your manufacturing operation. For more information and a free trial, visit https://www.mrpeasy.com/ INDUSTRIAL MACHINERY DIGEST.COM

IMD | 17

Talking Shop

Welder safety is a paramount concern for us, especially regarding exposure to elements like manganese and hexavalent chromium. FEATURING:

TALKING SHOP WITH: Jim Logan — Sales Director, FumeVac

The Next Step in Welding Safety: How FumeVac is Redefining Fume Extraction In a compelling exchange at the Wisconsin Manufacturing & Technology Show, we sat down with Jim Logan, Sales Director of FumeVac—a product line owned by Hastings Air Energy Control Company. Jim brings over 35 years of experience in the welding industry, transitioning from creating smoke to mastering its efficient extraction. Our conversation delved into the nuances of the FumeVac system, including its components like the ErgoMax MIG Gun, the ErgoBoom, and the innovative FV-190SC high vacuum unit for welding fume extraction. Jim's insights into this state-of-the-art system, coupled with his knowledge of robotic applications and welder safety concerns, offer a detailed perspective on modern welding technology and workplace health.

Could you start by telling us about the primary focus of the FumeVac system? Certainly! The FumeVac system, a specialty of Hastings Air Energy Control, Inc., is designed primarily for extracting welding fumes. It's very effective for many different applications, including semi-automatic, automatic, and robotic welding. Thanks to my extensive background in welding, the design and implementation of this system draw upon my 35 years of industry experience, focusing now on cleaning up the process and efficiently extracting welding smoke.

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Can you explain the features of the ErgoMax MIG Gun and how it manages to extract fumes without affecting the shielding gas? The ErgoMax MIG Gun is an integral part of our system, designed to handle up to 500 amps. One unique feature is the extraction port location, situated at an optimized distance from the end of the gas nozzle, minimizing potential interference with the gas during operation. Despite potential concerns,

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the negative pressure generated around the torch neck effectively redirects smoke into the extraction ports without significantly affecting the shielding gas. Moreover, to address certain challenges like working in tight corners, the gun includes a port to modify airflow and reduce extraction at the nozzle, ensuring the shielding gas isn't pulled away inadvertently. Impressively, this design and its high airflow rates also cools the gun's internal components, allowing for lighter weight design components without compromising on amperage capacity.

Tell us more about the ErgoBoom and how it contributes to both efficiency and safety in welding operations. The ErgoBoom is a novel addition to our product line. It's a custom-designed, six-foot boom that enhances mobility and safety. By running the gun down the boom's length, we utilize overhead space, freeing the floor from clutter and potential tripping hazards. This arrangement also protects the gun from physical damage and weld spatter exposure, leading to increased durability and reduced maintenance costs. The 15-foot gun reach ensures excellent mobility within the welding cell, while the overall design of the ErgoBoom significantly eases the physical strain on operators who no longer need to maneuver a heavy gun cable around their workspace.

What makes the FumeVac High Vacuum Unit stand out, particularly in its capability to handle fumes from high amperage welding applications? The FumeVac High Vacuum FV-190SC Unit is our latest innovation, showcasing exceptional performance in fume extraction. Available in single and dual gun models, it offers from 90 to 115 CFM of airflow at around 90 inches of vacuum pressure – substantially higher than typical systems. Its effectiveness lies in its capacity to provide exceptional levels of airflow, crucial for capturing fumes in high amperage situations (up to 400 amps). The unit also incorporates a 158 square foot high-efficiency filter, push-button vibratory filter cleaning, and a durable 460 volt, 3-phase brushless motor design. These features, particularly the brushless motors, contribute to the unit's longevity and reliability in industrial settings, where frequent maintenance and motor failures can be costly.

Welder Safety Concerns Welding, a critical process in manufacturing and construction, exposes workers to various hazards. Understanding and addressing these hazards is paramount for maintaining a safe and healthy workplace.

Fumes and Gases » Risks: Welding fumes contain a mix of metals like manganese, aluminum, and compounds like ozone and nitrogen oxides. Long-term exposure can lead to lung, larynx, and urinary tract problems, among others. » Mitigation: Use of effective fume extraction systems like FumeVac, adequate ventilation, and personal protective equipment (PPE) can significantly reduce the risk.

Radiation and Heat Exposure » Risks: Ultraviolet and infrared radiation from welding arcs can cause skin burns and eye injuries (like "welder's flash"). » Mitigation: Proper shielding, using helmets with correct shade lenses, and protective clothing (like leather gloves and aprons) safeguard against burns and radiation.

Electrical Hazards » Risks: Electric shock, a primary hazard for welders, can lead to severe injuries or death. » Mitigation: Ensuring equipment is properly grounded, using insulated gloves, and keeping the work area dry are essential preventive measures.

Physical Strain » Risks: Continuous physical strain and repetitive motions can lead to musculoskeletal disorders. » Mitigation: Ergonomic equipment (like the ErgoMax MIG Gun and ErgoBoom), frequent breaks, and proper technique can help minimize these risks.

Noise » Risks: Long-term exposure to high noise levels can cause hearing loss. » Mitigation: Use of earplugs or earmuffs in high-noise areas is a simple, yet effective way to protect hearing.

Hazardous Materials » Risks: Handling metals coated with or containing hazardous substances (like hexavalent chromium in stainless steel) requires caution. » Mitigation: Awareness, proper training, and use of PPE can significantly mitigate these risks.

Ensuring Safety To ensure welder safety and wellbeing, it's crucial to use the right tools, technologies such as the FumeVac system, and personal protective equipment, along with providing continuous safety training and regular health and air quality checks. These steps help employers adhere to safety regulations and promote a culture of safety, essential for the industry’s long-term health and worker welfare. INDUSTRIAL MACHINERY DIGEST.COM

IMD | 19

ErgoBoom Scan QR Code for Video

ErgoMax Gun Scan QR Code for Video

Automation Scan QR Code for Video

Filtration Scan QR Code for Video

Can you describe how the FumeVac system is adapted for robotic welding applications and its advantages over traditional methods? For robotic welding, the FumeVac system offers a significant high-tech advancement. By encasing the existing robotic torch in a custom-designed,

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3D-printed housing, the process doesn’t require costly equipment modifications. The system targets an extraction rate of about 150 CFM, successfully capturing fumes even at 350-400 amp levels. This approach not only improves the welding environment by reducing the need for hoods and large-scale

air movement but also contributes to keeping the robot and workspace cleaner. The reduced need for enclosing the welding area under a hood enhances visibility and lighting, offering a more pleasant and efficient working environment. Furthermore, it addresses the growing need for effective, economical solutions in

maintaining cleaner, brighter, and healthier workshops, particularly in new facilities where companies are increasingly conscious of workplace aesthetics and safety.

How does the FumeVac system address critical safety concerns, particularly regarding the exposure to harmful elements like manganese and hexavalent chromium during welding? Welder safety is a paramount concern for us, especially regarding exposure to elements like manganese and hexavalent chromium. While the OSHA permissible exposure limit (PEL) for manganese is still abnormally high, the ACGIH (American Conference of Governmental Industrial Hygienists) recommended threshold limit value (TLV) for manganese is set at a very low level, and even at this level it still poses a significant challenge in welding environments due to its higher percentage in weld fumes. FumeVac's high extraction rate and efficient filtering system significantly reduce

David Bohrer - President David Bohrer is Hastings Air Energy Control’s Chief Executive Officer and Chairman of the Board. Under David’s leadership, the company has grown 2400% and has developed award-winning and patented products that have revolutionized the air filtration industry. In addition to David’s executive duties, he remains one of the company’s top business development engineers. His client list includes numerous Fortune 500 and Fortune Global 500 companies who have chosen Hastings to design air filtration systems for their global facilities. David’s expertise is solving indoor air pollution with a specialty in on-demand general ventilation systems.

manganese concentration in the air, promoting a safer workspace. Similarly, hexavalent chromium, known for its carcinogenic properties, although present in lower concentrations, demands equally stringent control measures. Our system's design and filtration capabilities aim to maintain air quality well within the acceptable ACGIH TLV and OSHA PEL for these substances, ensuring not just regulatory compliance but, more importantly, the health and safety of the welding workforce.

Jim Logan's expertise and insights shed light on the innovative aspects of the FumeVac system, revealing its critical role in enhancing both efficiency and safety in modern welding operations. From the ergonomic design of the ErgoMax MIG Gun to the practicality of the ErgoBoom and the powerful extraction capabilities of the new FV-190SC High Vacuum Unit, FumeVac stands as a testament to advanced engineering in combating workplace hazards.

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Safety & Maintenance

Tips for Creating a VpCI®-422 Rust Removal Station

t is fairly safe to say that every industrial facility has at least a few rusty parts—whether they be a handful of nuts and bolts that have corroded over time or an entire warehouse inventory of valves, gears, and other spares that have never been properly preserved. Rather than letting these parts go to scrap, a powerful—yet simple—solution is to restore parts by setting up a rust removal station with Cortec® VpCI®-422, a USDA Certified Biobased Product. Cortec® shares tips on why and how that can be done.

Reasons for Rust Removal There are two types of companies that will typically benefit most from setting up a VpCI®-422 rust removal station: » Those that provide services to heavy industry (entire companies can be based on rust removal). » Those that want to make better use of maintenance budgets by in-house chemical rust removal instead of more labor-intensive options.

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Purposes for rust removal include everything from touching up the occasional rusty part that maintenance teams encounter around the plant, to reclaiming millions of dollars’ worth of inventory that has been sitting in poor storage conditions at an oil and gas facility. In each case, the underlying goal is to preserve the value of the component and extend its service life by restoring it to usable condition.

Choosing Rust Removal Equipment and Location Rust removal setups range from simple to complex depending on the size of the components and the length of the job. For example, a one-time job to clean up a handful of rusty parts around the facility may only mean that maintenance needs three dishpans and a mesh steamer basket to dip and remove very small items such as nuts and bolts. Another option for sporadic rust removal is to place the rust removal solutions in portable self-contained units that can be moved from one part of the plant to another

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without spilling concerns. If rust removal is a recurring activity, workers may want to install permanent tubs in a designated area. In some cases, tubs will need to be large enough to hold a giant gear or valve, and cranes may be needed to raise and lower the part. If desired, bubblers and heaters can be added to speed up the rust removal action of VpCI®-422.

Identifying the Stages of Rust Removal Before setting up a VpCI®-422 rust removal station, workers should identify how many stages of the process are needed. At minimum, there should be three: VpCI®-422, rinsewater, and an alkaline cleaning fluid (e.g., VpCI®-41x Series). However, workers should first ask if the parts are dirty or greasy, in which case a precleaning stage is needed to degrease and rinse the parts before dipping them in VpCI®-422 (which removes rust but not dirt or grease). Following rust removal, a preservation step is often critical to preserve what was restored.

How to Remove Rust Once the stations are set up, rust removal proceeds as follows: » Clean and degrease the part if needed. » Immerse the part in VpCI®-422 for one hour to 24 hours depending on the severity of the rust. Workers may check the components periodically to see how rust removal is proceeding. » Dip the parts in plain water to rinse away any residual VpCI®-422 and corrosion products so as not to contaminate the final neutralizing bath. At this stage, the worker can proceed to the final rinse or perform another round of rust removal. » Dip satisfactory parts in an alkaline cleaner such as VpCI®-414, which neutralizes the acid and inhibits flash rust. » Dry the parts and preserve them against further

rusting in storage or transit. This step can take a variety of forms, including dipping the part into a bath of VpCI®-377 or BioCorr® water-based rust preventatives or simply enclosing the dry part in VpCI® Film and Bags or other VpCI® packaging materials.

Ready, Set, Remove Rust! Rust removal with VpCI®-422 can make a major difference in a firm’s inventory value. By understanding the steps and equipment involved, companies can save asset value with a very simple process. Contact Cortec® to learn more about setting up a rust removal station at your facility! INDUSTRIAL MACHINERY DIGEST.COM

IMD | 23

Manufacturing Showcase

Flexxbotics Revolutionizing Manufacturing with Advanced Robotics

lexxbotics, a pioneering force in industrial automation, stands at the forefront of revolutionizing the manufacturing landscape. With an unwavering commitment to innovation and excellence, Flexxbotics has positioned itself as a key player in the transition towards smart factory operations, where the synergy of advanced robotics and operational efficiency is redefining what's possible in manufacturing. At the heart of Flexxbotics’ transformative solutions is its groundbreaking FlexxCORE technology. This patent-pending innovation represents a significant leap in robotic manufacturing, enabling secure and flexible connectivity between robots and CNC machines. FlexxCORE's compatibility with an extensive range of machinery, including the sophisticated series of HURCO CNC machines, marks a new era in machine-robot communication. By integrating seamlessly with HURCO’s MAX®5 CNC control system, FlexxCORE technology enhances the operation of various machining centers, driving increased productivity, higher yields, and greater profitability. Flexxbotics' technological prowess extends beyond HURCO machinery, showcasing its versatility and

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commitment to addressing the dynamic needs of modern manufacturing. The collaboration with Makino machine tools is a testament to this, where Flexxbotics has successfully extended its reach to various machine tools, setting new standards in operational efficiency. The integration with Makino’s advanced Pro6™ CNC Control and Hyper-i™ control system, facilitated by FlexxCORE technology, empowers manufacturers to achieve higher throughput and increased profit margins. Moreover, Flexxbotics has demonstrated its adaptability and technical excellence through its integration with Nakamura-Tome machinery, further broadening its impact across diverse manufacturing requirements. This integration ensures smooth operation and enhanced efficiency for various machine types, solidifying Flexxbotics' role in the evolution of smart manufacturing solutions. Flexxbotics’ solutions are not just limited to machine integration. The company's unique SaaS/hybrid architecture ensures uninterrupted production with or without internet connectivity, compatible with a wide range of business systems like CAD/CAM, SCADA/HMI, IIoT, MES, ERP, and PLM. This architecture forms the backbone of the smart factory, enabling comprehensive control over

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connected machinery through advanced bidirectional communication capabilities. As industries globally embrace the concept of the smart factory, Flexxbotics is leading the charge with its innovative solutions. Through its relentless pursuit of innovation and adaptability, Flexxbotics is not just keeping pace with the evolving manufacturing landscape but actively shaping the future of the industry. With a vision firmly rooted in enhancing efficiency, productivity, and sustainability, Flexxbotics is redefining industrial excellence and paving the way for a new era in manufacturing.

Revolutionizing HURCO® CNC Machines Flexxbotics has achieved a significant technological breakthrough with its integration with HURCO CNC machines. This strategic partnership extends across a comprehensive range of machinery, from complex 5-axis machining centers to versatile turning centers. At the heart of this integration is Flexxbotics’ pioneering FlexxCORE technology, enabling secure, flexible, and efficient robot-machine communication. This technological synergy not only boosts productivity but also drives higher yields, propelling manufacturing units towards unprecedented profitability. The FlexxCORE technology’s compatibility with HURCO’s MAX®5 CNC control system is a testament to its versatility, enhancing the operation of HURCO machines including the TM/X Series and VM/X Series. This integration

represents a significant step forward in manufacturing, making environments more connected, streamlined, and productive.

Advancements with Makino Machine Technology The collaboration with Makino machine tools further illustrates Flexxbotics’ commitment to technological versatility and innovation. Extending its advanced solutions to various Makino tools, Flexxbotics is broadening its impact across different manufacturing domains while setting new benchmarks in operational efficiency. The FlexxCORE technology underpinning this partnership enables robust robot connectivity, aligning with the dynamic demands of modern manufacturing. Flexxbotics' compatibility with Makino’s Pro6™ CNC Control and Hyper-i™ control system demonstrates a comprehensive approach to enhancing machine performance. This integration enables manufacturers to achieve higher yields, greater throughput, and increased profitability, crucial steps in realizing the full potential of modern manufacturing.

Integration with Nakamura-Tome Machine Tools Flexxbotics’ adaptability and technological prowess are further showcased in its integration with Nakamura-Tome machinery. This compatibility highlights Flexxbotics’ ability to cater to diverse manufacturing needs, ensuring seamless operation and enhanced efficiency for various machine

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IMD | 25

types. The inclusion of Nakamura-Tome’s machinery in Flexxbotics’ portfolio represents a comprehensive approach to smart manufacturing solutions, compatible with over 1000 different models of CNC machines.

SpiTrex Orthopedics Case Study: Achieving Remarkable Efficiency with Flexxbotics

Connect your cobot and machine to the FlexxCNC™ middleware

The implementation of Flexxbotics solutions at SpiTrex Orthopedics exemplifies a transformative impact in manufacturing efficiency and productivity. SpiTrex faced significant challenges in enhancing productivity in their FOBA laser marking machine workcells. The integration of Flexxbotics' advanced robotic solutions led to outstanding improvements, fundamentally altering their manufacturing process. Results: » 83% Reduction in Changeover Time Previously, setting up a new job required over an hour of engineering time. With Flexxbotics' solutions, this process has been streamlined remarkably, now taking less than 10 minutes. This drastic reduction in changeover time represents a leap in operational efficiency, enabling quicker transitions and minimizing downtime. » 20% Reduction in Lead Time The autonomous changeover process, combined with closed-loop feedback functionality, has been a game-changer for SpiTrex. This integration allows for the production of extremely high-tolerance parts through continuous flow, reducing overall lead time by 20%. This enhancement is crucial for maintaining competitiveness in the fast-paced manufacturing sector, particularly in the medical devices domain where precision is paramount. » 10:1 Machine to Man Ratio Implementing Flexxbotics across SpiTrex's FOBA laser marking workcells achieved a 10:1 machine-to-man ratio. This significant improvement in operational leverage enables continuous operations, even amidst labor shortages. Consequently, SpiTrex has been able to ship more high-quality parts, addressing both efficiency and output quality. » Horizontal and Vertical Integration The Flexxbotics solution provides comprehensive integration, both vertically from one FOBA machine to another and horizontally across prior workcells and IT systems. This integration exemplifies the seamless and interconnected nature of Flexxbotics' solutions, enhancing the overall workflow and data coherence in SpiTrex's manufacturing operations.

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This case study demonstrates how Flexxbotics' cutting-edge technology not only optimizes specific processes but also brings a holistic improvement to manufacturing operations, setting a new standard for efficiency and productivity in the industry.

Flexxbotics: Powering the Smart Factory Revolution and Showcasing Future Potential Flexxbotics stands at the forefront of the smart factory revolution, fueled by its unique SaaS/hybrid architecture. This cutting-edge system is compatible with a broad spectrum of business systems, including CAD/CAM, SCADA/HMI, IIoT, MES, ERP, and PLM. It ensures uninterrupted production capabilities, regardless of internet connectivity, epitomizing the resilience and adaptability required in modern manufacturing environments. The advanced bidirectional communication features of Flexxbotics provide comprehensive control over connected machinery, establishing it as a cornerstone in the realm of contemporary manufacturing. The impact of Flexxbotics extends beyond its core technology into the realm of industry exhibitions and showcases. The company is gearing up to demonstrate its technological prowess at the upcoming ATX West 2024. This event represents a significant opportunity for Flexxbotics to exhibit its capabilities and innovations to a wide array of advanced manufacturing companies and industry stakeholders. It's an ideal platform to reinforce its position as a leader in industrial automation and smart manufacturing solutions. In the arena of manufacturing efficiency, Flexxbotics' influence is profound. The company's solutions have been instrumental in reducing the need for manual intervention and significantly shortening setup times across various production processes. These advancements in yields, throughput, and profitability herald a new era in manufacturing productivity, marking a shift towards more efficient and streamlined operations. Furthermore, Flexxbotics’ technology is meticulously designed to tackle the prevalent challenges in CNC automation. By enhancing the interaction between robots and machines, Flexxbotics ensures minimal downtime and maximizes efficiency gains. This strategic approach

to problem-solving in automation establishes Flexxbotics as a visionary entity in the sector, adept at addressing and overcoming the complex challenges faced in modern manufacturing processes.

Preparing for the Future: Flexxbotics and Emerging Industry 4.0 Technologies As we look to the future, Flexxbotics is not just poised to adapt to emerging Industry 4.0 technologies; it is positioned to be a catalyst for innovation and transformation in the manufacturing sector. The integration and evolution of Flexxbotics with upcoming technological advancements will further solidify its role as a leader in the smart manufacturing revolution.

Sustainable Manufacturing Practices Eco-Friendly Solutions: As sustainability becomes a priority, Flexxbotics is expected to focus on developing solutions that support eco-friendly manufacturing practices. This could include optimizing energy consumption, reducing waste, and implementing recycling processes within manufacturing operations.

Customization and Flexibility Tailored Solutions for Diverse Industries: Acknowledging the diverse needs of different manufacturing sectors, Flexxbotics plans to offer more customized solutions. This approach will cater to the specific requirements of industries such as automotive, aerospace, and consumer electronics, providing flexibility and adaptability in manufacturing processes.

Integration with Advanced Data Analytics and AI Predictive Maintenance and Process Optimization: Flexxbotics is expected to integrate advanced data analytics and AI to enhance predictive maintenance capabilities. By analyzing data patterns, Flexxbotics could predict machine failures or maintenance needs, thereby reducing downtime and increasing productivity. AI algorithms can also be employed to optimize manufacturing processes in real-time, ensuring maximum efficiency.

IoT and Enhanced Connectivity Real-Time Data Management: With the Internet of Things (IoT) becoming increasingly prevalent in manufacturing, Flexxbotics plans to enhance its connectivity features. The integration with IoT devices will allow for real-time data collection and management, providing a holistic view of the manufacturing process and enabling immediate adjustments to improve performance.

Augmented Reality (AR) and Virtual Reality (VR) AR for Training and Maintenance: Flexxbotics is exploring the use of Augmented Reality (AR) for training purposes and remote maintenance assistance. AR can provide interactive, 3D visualizations of machinery and processes, making it easier for technicians to understand complex systems and perform maintenance tasks efficiently. VR for Process Simulation: Virtual Reality (VR) integration could enable Flexxbotics to offer virtual simulations of manufacturing processes. This feature would allow manufacturers to test and refine processes in a virtual environment before actual implementation, reducing the risk of costly errors.

Collaborative Robotics and HumanMachine Interaction Enhanced Collaboration with Cobots: Flexxbotics is likely to expand its portfolio to include more collaborative robots (cobots) designed to work alongside human workers. These cobots will be equipped with advanced safety features and intuitive interfaces, making them more accessible to the workforce and enhancing humanmachine collaboration.

Paving the Way in Advanced Manufacturing As we peer into the future of manufacturing, Flexxbotics stands distinct, not just as a participant in the Industry 4.0 landscape, but as a pioneering force charting new courses. This company is more than an entity adapting to change; it's an innovator defining the very essence of modern manufacturing. Flexxbotics' strategic embrace of cutting-edge technologies positions it to revolutionize standard manufacturing practices, steering the sector toward uncharted territories of efficiency and innovation. Flexxbotics' relentless commitment to innovation and adaptability uniquely equips it to significantly influence and sculpt the smart manufacturing landscape. By leveraging emerging technological frontiers, Flexxbotics is on a mission to elevate manufacturing processes to levels of efficiency and sustainability that were once thought unattainable. The company is tuned to the evolving needs of a diverse array of industries, ensuring its solutions are not only relevant but revolutionary. The journey ahead for Flexxbotics is more than a path of adaptation to new technologies; it represents a bold stride towards reimagining and reshaping the future of industrial operations.

Leading the Charge in Manufacturing Evolution In an era marked by rapid technological evolution, Flexxbotics distinguishes itself as an influential leader in the manufacturing domain. The company's innovative strategies and advanced solutions are actively directing the industry towards more streamlined, productive, and profitable practices. Flexxbotics is not just following the trends of smart factory development; it is at the forefront, molding these concepts into a tangible global reality. Flexxbotics’ role in manufacturing automation goes beyond mere participation; it is marked by a relentless pursuit of innovation and adaptability. This forward-thinking approach is catapulting the company towards a new era of industrial excellence. With Flexxbotics at the helm, the future of manufacturing is not just about interconnected and efficient processes; it's about embracing sustainability and forward-thinking practices that will define the new standards of industrial excellence. INDUSTRIAL MACHINERY DIGEST.COM

IMD | 27

Industrial Automation

The Essential Role of Fixture Design in Laser-Based Welding Applications By Todd E. Lizotte, Orest Ohar, and Joseph Dagher of Bold Laser Automation, Inc. Bedford, NH

aser-based welding has revolutionized the manufacturing landscape, enabling the precise and efficient joining of intricate assemblies across diverse sectors, including medical devices, automotive, aerospace, and the growing battery and electric vehicle (EV) industries. While lasers are undeniably crucial for achieving top-tier welds, the significance of fixture design cannot be over-emphasized. A well-crafted fixture is the backbone of the welding process, ensuring stability, repeatability, and, ultimately, the operation's success. Five essential functions must be meticulously addressed in fixture design to unlock the full potential of laser-based welding in these industries: ease of loading/ unloading, ensuring intimate contact between parts being welded, maintaining consistent component tolerances and fixture registration, and providing a clear line of sight for laser welding and alignment verification through cameras. Neglecting these functions can lead to subpar weld quality, early failures, and significant production setbacks. Figure 1 shows how gaps can impede proper and satisfactory welds.

Streamlined Loading/Unloading Efficiency is paramount in the fast-paced world of manufacturing. A well-designed fixture must facilitate the smooth loading and unloading of components to be welded. This is especially crucial in industries like medical devices, automotive, aerospace, and EVs, where precision and speed are imperative. A fixture that hampers the easy placement and removal of parts can impede production throughput. This is further highlighted in cases where fixtures act as pallets, preloading components within the fixture before transferring them to the laser system, as shown in Figure 2. Consider a medical device manufacturing scenario where tiny, intricate components must be laser-welded. An inadequately designed fixture can make it difficult for operators to position these delicate parts accurately. In many cases, fixture selection might involve robotic handling to bring the components together one assembly at a time. In another case, this prolongs the

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Figure 1 – Shows inadequate clamping, leaving a gap under the part to be welded.

assembly process and increases the risk of damaging the components. In contrast, a fixture that enables quick and precise loading/unloading (manually or automatically) ensures that the welding process remains efficient, minimizes operator errors, and maximizes productivity.

Ensuring Optimal Part Contact Achieving high-quality welds demands optimal contact between the parts to be joined. Gaps or misalignment between components can result in subpar weld quality, compromising the structural integrity and reliability of the final product. This requirement is particularly vital in aerospace and EVs, where safety and performance are paramount. Imagine an aerospace component with a slight gap between two critical parts due to inadequate fixture design; Figure 1 shows such a case. These gaps can lead to stress concentrations when exposed to rigorous flight conditions, causing premature component failure. In the EV sector, where battery packs are assembled using laser welding, any gaps or misalignment in the components can affect the overall performance and longevity of the battery, potentially leading to costly recalls. These gaps also lead to a failure mode where the weld acts as a hinge flexure, subjecting it to stress and ultimately causing weld failure over time. Furthermore, such gaps can serve as collectors of oxides and contaminants, leading to further oxidation of the weld from its backside.

Consistent Registration and Tolerances Maintaining consistent registration and tight tolerances between components is another crucial function of a

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well-designed fixture. In precision-critical industries such as medical devices and automotive, even minor variations in alignment can result in unacceptable product deviations and increased reject rates. Fixtures must ensure that parts are securely held in their intended positions throughout welding. Tolerance plays a vital role in both the fixture and the components. Unacceptable component tolerance stack-ups can lead to mispositioned components, part gaps, over- or underclamping of the element within the fixture, and overall yield issues in the laser welding process. It should be noted that various clamps may be needed, and the setup of these clamps becomes critical; you don’t want heavy clamping, just a slight preload to keep the parts in a fixed position and the overall fixture in place. Figure 3 shows the typical clamping of a palletized fixture.

Unobstructed Line of Sight and Camera Alignment Verification In laser-based welding applications, maintaining an unobstructed path for the laser beam is evident and crucial for achieving precision.

Figure 2 shows a palletized fixture being placed into the laser welding tool.

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With a variety of off-the-shelf welding optical heads, manufacturing engineers need to be aware of the characteristics of the laser beam output of the lens within that focusing head. The collimated beam diameter received at the focus lens, the cone angle output, the working distance of the focusing lens, and the spot size on the target all play a vital role in the laser material interaction during welding. Once the welding parameters are established, initial testing parameters can be brought to the laser machine tool. The design of the fixture must take into consideration several factors for proper laser welding, including nozzle gas pressure, nozzle end size, the reflectivity of the material being processed, the angle at which the laser focus head is angled to eliminate back reflections, and the observed visual alignment verification to ensure the accuracy of the welding process. Fixtures must provide clear access for the laser beam to reach the welding zone and enable operators to verify component alignment through cameras or other machine vision optical systems. These openings must also ensure that the welding spatter can eject and that those openings can be cleaned easily. Figure 4 shows an image of a typical window and how it might get contaminated over time, requiring maintenance and cleaning. In the automotive industry, for example, welding intricate components within the confined spaces of a

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Figure 3 shows a typical lever clamp to fix the pallet fixture in place, where the pallet fixture was pre-loaded with components and assembled externally.

vehicle chassis requires fixtures that allow the laser beam to reach every weld joint without obstruction. Additionally, using cameras or vision systems is essential to verify the alignment of components and ensure that the welding process is on track. Narrow weld zones or obstructions caused by weld angles and positioning could result in partial laser beam blockage, leading to poor welding performance and potentially no weld due to such shadowing.

Consequences of Neglected Laser Welding Fixture Design Neglecting any of these crucial functions in fixture design can have significant consequences. Mismatched part tolerances, gaps between parts due to poor clamping, loose component registration, inadequate vision illumination, or laser beam obstruction can all lead to subpar welding quality and product failures. These failures not only necessitate costly rework and potential recalls, but they also have safety and financial implications for the manufacturer.

Conclusion Fixture design is integral in laser-based welding applications across industries such as medical devices, automotive, aerospace, and EVs. To achieve the stability and repeatability required for precision welding, fixtures must excel in essential functions: ease of loading/ unloading, ensuring optimal part contact, maintaining consistent fixture registration and component tolerances, and providing an unobstructed path for laser welding and alignment verification. Neglecting these functions can lead to subpar weld quality and costly production setbacks. As these industries continue to push the boundaries of innovation, the role of fixture design in laser-based welding will remain indispensable. Manufacturers must recognize the importance of well-designed fixtures

Figure 4 shows an image of a window and the resulting ejected materials. This view is from the laser side.

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Workforce Development

Revolutionizing Workforce Development in Manufacturing: Insights from Jai Shah, CEO of Kahuna Scan to watch the Industry Insights Podcast with Jai Shah, CEO of Kahuna

n an enlightening session with Jai Shah, CEO of Kahuna, on IMD industry insights, we explore the evolving challenges and strategies in manufacturing workforce development. Shah, with his extensive experience in HR technology transformations, shares invaluable insights into tackling the pressing issues of labor and skills shortages in the industry.

"People are not afraid of work if they're valued for the work that they do," Shah remarks, highlighting the importance of acknowledging and compensating employees' skills. A formal skills program can help in identifying key skilled workers, tracking their engagement, and providing them with clear career progression paths. This approach not only mitigates burnout but also fosters a culture of appreciation and growth within the organization.

The Core Challenges in Manufacturing Labor Shah highlights the challenge in the manufacturing industry as the mismatch between available skills and rapidly changing industry demands. He explains, "The biggest challenge comes down to the availability of the right skills to do the work required in an ever-changing environment." The initial labor shortages observed during COVID have transitioned into a more complex issue of skill shortages. A survey by Deloitte and The Manufacturing Institute reports that the industry is expected to face a shortfall of 2.1 million skilled jobs by 2030. Manufacturers now grapple with not only finding sufficient workers but ensuring they possess the necessary skills for modern manufacturing processes.

The Holistic Impact of Skills Management Shah brings to light the comprehensive impact of skills management on a company. "It's really a shot in the dark as to whether a workforce is going to be prepared to meet that future goal," Shah comments, emphasizing the importance of aligning workforce capabilities with strategic goals, such as net-zero emissions. A skills management platform, he explains, allows for the systematic development of necessary skills like carbon sequestration and offset, ensuring that the workforce can meet future organizational goals. This proactive approach helps companies navigate the evolving industrial landscape with a more prepared and adaptable workforce.

The Evolution of Skills Management Emphasizing the critical role of skills management in bridging the labor gap, Shah explains, "We started to notice a particular challenge for certain technologies to surface that data, collect that data, manage it, and give it back to operations in a way that they could make use of it." A report by McKinsey & Company highlights that 87% of businesses are either currently facing or anticipating a shortage of skilled workers due to automation and digitization. Today's workforce comes with a set of inherent skills, often overlooked, that are crucial in the digital manufacturing era. Effective skills management involves identifying these inherent skills, addressing skill gaps through personalized training, and rapidly aligning workforce capabilities with operational needs.

Combating Employee Burnout To address employee burnout, Shah suggests a proactive approach to recognizing and valuing employees' skills.

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Integration of Apprenticeship Programs In discussing the integration of apprenticeship programs, Jai Shah highlights Kahuna's crucial role in bolstering these initiatives. He notes, "The craft worker skilling journey often requires a mentorship or apprenticeship kind of relationship. Kahuna's approach involves strategically identifying the most effective mentors within the workforce and pairing them with apprentices. This method not only streamlines the learning process but also ensures a more personalized and impactful training experience. Shah further elaborates on the value of this mentorship, explaining how Kahuna's platform is designed to gather and utilize data throughout the apprenticeship. This data collection is key to optimizing the training process and ensuring that apprentices are workforce-ready upon completion of the program. As an illustrative example, Shah cites Stanley Black &

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Decker, which has successfully implemented workforce development strategies that align with this approach. Their experience underscores the effectiveness of integrating structured mentorship and data-driven insights in apprenticeship programs, setting a standard for others in the industry.

Engaging with Kahuna for Skills Management For manufacturers eager to collaborate with Kahuna, Shah lays out a practical and incremental approach. "You don't have to be perfect to get started on this journey," Shah advises, recommending starting with identifying the most critical skills needed in specific operations and then

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systematically exposing these to the workforce. He stresses that the journey towards a skills-based workforce does not require perfection from the outset but rather a commitment to continuous improvement and adaptation. Shah cites the example of Stanley Black & Decker to demonstrate Kahuna’s ability to adapt and implement skills management across various industries, including manufacturing and healthcare.

Navigating the Future: Embracing Workforce Transformation in Manufacturing As we reflect on the insightful discourse with Jai Shah, CEO of Kahuna, it becomes evident that the manufacturing sector is at a critical crossroads. The inevitable transition from a job-based economy to one that is skills-based is not just imminent; it is imperative. The array of challenges brought to the forefront – from acute labor shortages, a byproduct of the COVID-19 pandemic, to the dynamic shifts in technological advancements – calls for a decisive and robust approach centered around strategic workforce development and adept skills management. In the era of intelligent manufacturing, the demand is for a workforce that is not just competent but also versatile, skilled, and prepared to tackle novel challenges head-on. Shah's visionary leadership and the strategic direction provided by Kahuna emerge as a guiding light in this journey. By leveraging the profound potential of skills management and enriching apprenticeship programs, manufacturing entities are empowered not merely to satisfy immediate demands but to strategically prepare for upcoming challenges and opportunities. Shah rightly points out that the path to cultivating a skilled and efficient workforce is an ongoing and dynamic process. It is marked by a steadfast commitment to innovation and adaptability. For the manufacturing sector,

this represents a pivotal opportunity to reassess and revamp their workforce development strategies, investing in their most valuable asset – their people – thereby laying a robust foundation for sustained growth and long-term success.

Reflecting on the Future Looking ahead, the manufacturing industry stands to gain immensely from embracing these changes. A skilled workforce is not just an asset; it's the backbone of innovation and productivity. The integration of skills management and technology in workforce development is not just a trend; it's the future. As we move towards more automated, technologically driven manufacturing processes, the value of a skilled, adaptable workforce cannot be overstated.

Seizing the Moment: A Call to Revolutionize Workforce Dynamics in Manufacturing For leaders in the industry, human resources professionals and decision-makers shaping policy, the imperative is unmistakable: the moment for transformative action is now. Adopting a skills-based approach to workforce development transcends mere benefit; it is a critical strategy for maintaining a competitive edge in an ever-evolving global marketplace. We urge our readers to ponder deeply upon these insights, to critically assess and recalibrate their current workforce development strategies, and to consider how innovative solutions like those offered by Kahuna can be effectively integrated into their operational frameworks. In an era characterized by relentless change, investing in your workforce transcends a mere strategic decision – it signifies a commitment to the future. This is a call to action, an opportunity to adapt and lead in fostering a landscape marked by growth, innovation, and enduring success. INDUSTRIAL MACHINERY DIGEST.COM

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New Technology

Revolutionizing Rapid Prototyping: The UltiMaker S-series Transforming Industrial Manufacturing

n the dynamic world of industrial manufacturing, the advent of sophisticated 3D printing technologies marks a significant paradigm shift. Leading this revolution is the UltiMaker S-series, a line of 3D printers that are redefining rapid prototyping. Historically, prototyping has been an essential but time-intensive phase in product development, often causing delays in innovation. The rise of 3D printing, particularly since the 1980s alongside computer-aided design (CAD), has revolutionized this process, introducing unparalleled efficiency and creativity.

Advantages of UltiMaker's 3D Printing in Prototyping The UltiMaker S-series has significantly improved the prototyping process with several advantages: » Speed: The S-series printers dramatically reduce the time required to develop prototypes. Unlike traditional methods, which necessitate extensive preparation for creating molds or setups, UltiMaker’s 3D printing technology enables rapid production, often overnight. » Flexibility: UltiMaker’s technology facilitates swift iteration of designs. Modifications can be digitally made and immediately applied, fostering a dynamic and responsive prototyping approach. » Cost-Effectiveness: Compared to traditional manufacturing techniques like injection molding, UltiMaker’s 3D printing is a more economical option, particularly for small batches or unique prototypes.

UltiMaker S-series: Technical Innovations and User Experience The S-series stands out for its technical capabilities and user experience. It offers: » Technical Innovations: Over 280 material choices, dual-extrusion printing, and advanced precision capabilities. » User Experience: Features like secure cloud printing, easy-to-use interface, and community support make the S-series accessible to both professionals and enthusiasts.

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» Environmental Impact: UltiMaker is committed to sustainability, with eco-friendly materials and energyefficient processes, making it an attractive option for environmentally conscious businesses.

Impact on the Manufacturing Process The UltiMaker S-series reshapes the entire manufacturing process. Notable examples include: » Quad Lock: Used the S-series for rapid prototyping of smartphone mounts, speeding up design refinement and market entry. » Trivium: Employed UltiMaker’s 3D printers for metal packaging prototypes, shortening their time-to-market and improving customer service. » NoiseAware: Utilized UltiMaker for prototyping noise monitoring devices, leading to streamlined processes, cost savings, and improved product quality. These cases demonstrate UltiMaker’s role in various prototyping stages, accelerating manufacturing timelines and enhancing product quality.

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Industry Implications and Future Outlook The UltiMaker S-series signals the future of manufacturing. Its role in rapid prototyping enables more agile manufacturing processes, crucial in an era where speed and customization are key. As 3D printing becomes more integrated into production lines, expect a more streamlined, efficient, and adaptable manufacturing landscape.

The Broader Impact of UltiMaker in Various Industries » Healthcare: In the healthcare industry, UltiMaker’s precision and material versatility enable the production of medical models and custom prosthetics, revolutionizing patient care and medical training. » Education: In educational settings, UltiMaker is fostering a new generation of designers and engineers by providing hands-on experience with advanced manufacturing technologies. » Aerospace and Automotive: In aerospace and automotive industries, UltiMaker’s ability to produce lightweight, strong components is leading to more innovative designs and efficient production methods.

Embracing the Future with UltiMaker

manufacturing. Embracing innovations like UltiMaker’s 3D printing is crucial for staying competitive in the evolving industrial landscape. The UltiMaker S-series exemplifies the evolution and promising future of rapid prototyping, where adaptability, speed, and efficiency are increasingly vital.

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Process

EMAG Develops Integrated Solutions Custom-fit robot solutions ensure fast parts flow in production

roduction solutions with robotic automation are on the rise: With their help, a fast and low-manpower flow of parts can be established within a site – thus reducing unit production costs and increasing production reliability and quality. In this example, EMAG links pick-up machine technology with highly individual robot solutions designed within the requirements of the workpiece and the production process. What are important details? According to the "World Robotics 2022" report of the International Federation of Robotics (IFR), there are now around 3.5 million robots in use in industrial production worldwide. Europe is the second largest robot market in the world. Current examples from EMAG show why this is so: The specialists combine their high-performance machines with completely different robot cells - and thus not only ensure highly efficient processes for loading and unloading the machines, but also integrate additional stations for quality assurance, labeling, cleaning and much more. What is the overarching objective at EMAG when robots are used? "The focus is always on the requirements of the workpiece and the associated production process," explains Jürgen Maier, Head of the Business Unit Turning at EMAG. "Decisive questions here are, for example, what batch sizes are to be produced in a given period of time and how autonomously the solution should operate. In any case, we are very flexible and adapt in many ways to the existing production environment or space conditions."

With conveyors, palletizers or drawers A look at the details shows just how different EMAG's robotic solutions are: Parts can be fed, for example, using infeed and outfeed belts, palletizers, drawers or bin picking. With the help of these systems, the robot "operates" itself when it picks up or finishes placing new components. Each solution has different strengths and basic conditions. For example, belt or hinge conveyors are an ideal option when the flow of parts needs to be smooth from an upstream production solution to the EMAG machine. The robot can then simply pick up the components from the belt

38 | IMD February 2024

and deposit them again later, with the belts arranged in different ways – depending on the space situation or the desired flow of parts. Pneumatic stoppers ensure that the components are separated. It is also possible to detect the workpiece alignment on the belt using a camera. A highly flexible alternative to this are so-called bin picking systems ("reach into the box"). Here, the workpieces are in a chaotic position, with the robot arm not only picking the components with the aid of a 3D sensor system, but also correctly recognizing and aligning them and feeding them to the next processing step. The system can be used flexibly and configured for many applications. In contrast, the use of palletizers presupposes an "orderly" start. In this case, the system is loaded and unloaded via a blister cart, for example. It contains boxes stacked on top of each other with corresponding mold nests containing the components - i.e. a relatively large quantity per cart, which an operator simply pushes into a defined position from which the robot can access. The cart with finished parts is in a different position. "One of the things that matters in this kind of solution is that you relate the cycle time of the EMAG machine and the desired man-hours at the machine. So if the machining cycle within the machine is only a few seconds and at the same time you are aiming for minimum operator effort at the machine, this solution may not be suitable because the carriages would then have to be replaced too frequently. But these are precisely the calculations that we carry

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out for every robot solution and advise the customer accordingly," explains Maier. A drawer system is a conceivable third variant. The workpieces are located in pneumatically movable drawers, which are quickly loaded by blister systems. In this case, three of these drawers are arranged one above the other in a cabinet, allowing a larger number of pieces to be stacked and processed (without intermediate operator intervention) in a small (possible) footprint. Incidentally, loading and unloading of the drawers takes place without interrupting the process – the robot simply continues to work on a compartmentalized drawer.

Number of robot solutions from EMAG increases The following applies to all these solutions: The equipment options for the individual robotic cell are extensive. For example, it is conceivable to integrate a statistical process control (SPC) including a measuring station. Here, individual components are regularly ejected, measured and reintroduced for quality assurance. It is also possible to place optical control systems with cameras, a gripper station for processing a wide range of workpieces, small washing and cleaning stations, deburring systems or laser or engraving stations within the robot cell. The respective solution is then also controlled by the robot. The result is a continuous flow of parts across different technologies. For sustainable success with all customers, EMAG relies on computer-based simulations when planning automation cells. Our experts thus check many factors such as cycle time, accessibility of the robot, material flow in large production lines and much more. Virtual commissioning - that is, testing planning data on a virtual machine - is similarly important. In this way, unforeseen errors can be detected and eliminated at an early stage of development. What's more, "real" commissioning is much faster later on. "Overall, it is safe to say that more and more robotic solutions are being used on our machines, although this is also obvious," summarizes Jürgen Maier. "After

all, we have a large number of machines that already have internal automation based on pick-up technology. Consequently, we can integrate these solutions via robots into integrated production systems relatively easily and establish a smooth flow of parts at a single location. The components therefore get from A to B with little effort. This is our approach, which is winning over more and more customers."

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IMD | 39

Industry Insight

Forging Ahead: Speedy Delivery of High Quality, Seamless and Contoured Rolled Rings Specialty forgers can manufacture custom, high-quality, seamless rolled rings in a variety of materials and finishes in as little as eight weeks. By Del Williams

wide range of industries such as aerospace, automotive, mining, oil and gas, machinery manufacturing, and power generation rely on seamless rolled rings, which are critical components used for gears, turbines, bearings, clutches, couplings, drives, flanges, valves, machines, robotics, and other forged shapes. Seamless rolled rings have a greater lifespan than other products due to their strength and durability, and are less prone to cracking or warping, making the option ideal for critical components requiring high tensile strength. Seamless rolled rings resist wear, fatigue, and stress, enabling better performance. Depending on the metal and alloy, the rings are also resistant to thermal and chemical damage, which further extends longevity while reducing the need for maintenance, repair, and replacement. Obtaining large seamless rolled rings in a timely manner

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remains a significant challenge, however. Currently, it may take many months to receive the forged components after placing an order. This delay can have a severe impact on the production and maintenance schedules of industrial firms that depend on replacement parts. Rings are typically provided with a rough surface finish, which necessitates the use of CNC machining to achieve the required level of smoothness. This poses a challenge for machine shops with a high workload, as allocating machine time for finishing inevitably leads to a decrease in production speed and an increase in costs, ultimately impacting the end-use cost or profitability. Fortunately, manufacturers can rely on industry-leading forging specialists capable of producing large, custom, seamless rolled rings, and contoured seamless rolled rings with the required surface finish in under two months. One example, All Metals & Forge Group, an ISO 9001:2015 and

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AS9100D manufacturer of custom and standard open die forged parts and seamless rolled rings can cost-effectively deliver these components with the required finish within 8-10 weeks. The range of forged products includes rings, discs, hubs, blocks, shafts (including step shafts or with flanges), sleeves, gear blanks, cylinders, flats, hexes, rounds, plates, and custom shapes. Carbon steel, alloy steel, stainless steel, nickel, titanium, and aluminum are among the materials used for forging. These forgings meet rigorous industry specifications such as ASTM, AMS, AISI, ASME, Boeing, SAE, GE, DIN, ASME B 16.5, ASME B16.47, and API 6A. Numerous industries can reap the advantages of an accelerated process for obtaining flawless rolled rings. This includes sectors like aerospace, aircraft, automotive, chemical, construction, defense, energy, engine and turbine, food processing, hydro, metalworking, mining, oil and gas, petroleum, power generation, pulp and paper, and shipbuilding.

The Benefits of Open Die Forging One of the chief advantages of open die forging is the customization it offers in the seamless rolled ring manufacturing process. According to Lewis Weiss, President of All Metals & Forge Group, open die forging is ideal for providing large, custom parts. “We can produce seamless rolled rings or contoured rolled rings up to 200 inches in outside diameter, and custom forgings up to 40 feet long or 80,000 lbs.,” says Weiss. All Metals & Forge Group has been manufacturing and selling open die forgings and seamless rolled rings for more than 50 years. While open die forging is typically associated with larger, simpler-shaped parts like bars or blanks, the process enables the creation of “custom-designed” metal components. According to Weiss, open-die forging facilitates the production of seamless rolled rings to exact specifications with optimized mechanical properties and structural integrity. He notes that the rings can be produced in a variety of alloys, sizes, and shapes specific to the requirements. The forging of the rings is also cost-effective since the process reduces material waste and manufacturing costs. Since the rings are constructed from a single metal piece using a specialized ring rolling machine, there is no need for welding or assembly, saving time and labor. The seamless rolled rings are also more structurally sound because they create a circular grain flow in the material, following the shape of the ring, which increases strength and integrity, creating a refined grain structure. This can enhance the material's fatigue resistance and overall performance, resulting in a stronger, more durable final product compared to other methods of ring making, such as cutting from plate.

Near Net Shape Parts with Finer Surface Finish Typically, when seamless rolled rings are forged, they

are often left in an unprocessed state with a rough surface measured at approximately 500 RMS. As a result, significant CNC machining time is required to achieve a smoother surface for the finished machined part. This poses a challenge for machine shops as the allocation of machine time for finishing these rough parts directly affects production efficiency and delivery time to the client. To optimize efficiency and reduce costs, All Metals & Forge Group frequently provides near-net-shaped forged parts with more refined surface finishes. “Typically, we provide a 250 RMS surface finish. We can even provide 125 RMS. We can also drill holes and do contour forgings as needed,” says Weiss. “Some forge shops only offer a raw unmachined part. We produce a rough machine part, saving machine shop time and equipment wear and tear since we have already taken off the first rough cuts off the ring or forged parts,” he adds. In addition, the company conducts ultrasonic testing at zero expense to the customer to guarantee the absence of internal cracks, pits, or voids. This instills the utmost confidence in the quality of the parts, according to Tim Grady, Management Consultant for All Metals & Forge Group. “In many cases, All Metals & Forge Group can offer ultrasonically tested parts that are more affordable than raw forged rings,” says Grady.

Streamlining Delivery In today’s market, the procurement of forged seamless rolled rings usually takes a considerable amount of time, from 20 weeks to as much as a year, as there are long lead times in receiving the necessary steel from mills. “When replacement parts are required, a delay of a year or more is not acceptable,” says Grady. “Even 20+ weeks is a serious issue.” To expedite the process for customers, All Metals & Forge Group has established strategic partnerships within the industry, enabling the company to deliver many custom forgings in a timeframe of eight to 10 weeks. Furthermore, to minimize any potential production downtime for machine shops, the company strives to provide accurate quotes within 48 hours.

Positioning for the Future The need to acquire seamless rolled rings will only increase in industries that require high-quality custom-forged components that can safely withstand extreme forces with minimal repair or replacement. In these cases, working with an expert forger who can expedite the process will convey a significant advantage. For more information: Contact All Metals & Forge, LLC at 75 Lane Road, NJ 07004; (973) 276-5000; Canada 416-363-2244, toll-free (800) 600-9290; fax (973) 276-5050 or visit http://www.steelforge.com. INDUSTRIAL MACHINERY DIGEST.COM

IMD | 41

Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers. WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

ANCA’s TX7 - A Solution for Long Drill Production ANCA introduces the TX7, a CNC grinding machine with complete vertical integration in its manufacturing process, ideal for long drill production. The TX7 features a powerful 37kW spindle, a spacious working envelope, and a 6th axis with traveling steady support, accommodating tool lengths up to 480mm. This design minimizes deflection and vibrations during grinding, effectively addressing runout issues. The TX7's ability to complete drills in a single setup enhances production flexibility, enabling the manufacture of both high-volume and customized tools. The machine’s robust design, including a polymer concrete base and bi-symmetrical gantry, ensures high precision and stability. Additional features like LinX linear motors, optional headstock, secondary dresser, and various measurement options, including probing and LaserUltra, further enhance its capabilities. With unique solutions through TXcell automation, ANCA ensures the TX7 is a versatile and efficient choice for long drill production.

CoreTechnologie’s Advanced 4D_Additive Software for Customized 3D Printing CoreTechnologie upgrades its 4D_Additive software to version 1.5, featuring a newly revised lattice structure module for creating customized lightweight components in 3D printing. This software enables rapid and easy generation of complex geometries for additive manufacturing, tailoring products like shoes and bicycle saddles to individual customer requirements. Enhanced geometry generation allows for adaptive cell size and grid thickness,

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improving component properties like damping and heat exchange. The software's interface with Nastran facilitates seamless data transfer for geometry validation. Offering 22 different grid types, the software enables the replacement of component areas with lightweight structures for optimized design. Additionally, new Boolean functions aid in creating perforation patterns, applicable in various industries like thermoforming mold production. CoreTechnologie's 4D_Additive software represents a significant leap in customized production capabilities in additive manufacturing.

E-Z Lok Launches Online CAD Library for Threaded Inserts

E-Z Lok, a premier manufacturer of threaded inserts, has launched an online CAD library, built by CADENAS PARTsolutions, to enhance accessibility to its product range. This digital catalog at https://www.ezlok.com/ cad-downloads offers engineers, MROs, and OEMs on-demand access to threaded insert CAD models, streamlining the design and specification process. Previously reliant on customer-shared CAD files, E-Z Lok now provides robust product information and 3D models for better visualization. The website enables customers to download CAD files in various formats and view PDF datasheets for quick product reference. This online resource marks a significant step in E-Z Lok's effort to provide comprehensive, easily accessible product information and technical specifications, supporting efficient product selection and design integration.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

EXAIR’s New Varistat Benchtop Ionizer for Static Elimination

static decay, reducing 1000V to 100V in 0.8 seconds. It features replaceable ion emitter points, foam filters, and LED functionality indicators. With customizable options like voltage, fan speed, and polarity, the Varistat provides comprehensive static and particulate elimination.

HEMCO Emergency Safety Shower Decontamination Booth

EXAIR introduces the Varistat Benchtop Ionizer, a novel solution for neutralizing static on charged surfaces in industrial environments. The Varistat stands out as EXAIR's first fan-driven static eliminator, requiring no compressed air and offering a hands-free operation. Ideal for various applications, including part assembly and printing, the Varistat boasts rapid

HEMCO introduces its new Laboratory Applications Emergency Shower Booths, designed to meet OSHA and ANSI requirements for immediate decontamination after exposure to hazardous chemicals. These fully assembled booths feature a chemical-resistant fiberglass shower with pull rod activation and an eye/ face wash facility. Equipped with frosted front strip curtains, interior grab bars, raised deck grating, and drain outlets, the booths ensure efficient and safe decontamination. The design of HEMCO's Emergency Shower Booths emphasizes rapid

response to chemical exposure, critical in minimizing injury risks. These booths are an essential safety addition to laboratories and industrial environments handling hazardous substances.

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Hyster’s New Integrated Lithium-Ion Forklifts Hyster Company expands its integrated lithium-ion forklift lineup with the J32-40UTTL and J30-70UTL models, designed for diverse industrial applications. These forklifts, equipped with factory-installed lithium-ion batteries, cater to applications in chemicals, logistics, and trucking, offering a sustainable and efficient electrification solution. Available in 3,200-to-4,000 and 3,000-to-7,000-pound capacities, these trucks enable operations to meet sustainability targets and productivity goals. With zero emissions, fast charging, consistent power delivery, and no battery maintenance, they complement existing UT series models and offer cost-effective electrification options. James Nielson, Senior Business Product Manager at Hyster, highlights the market shift towards electric forklifts and lithium-ion's role in this transition. Hyster ensures maximum uptime and customer satisfaction with comprehensive service and warranties for the truck, battery, and charger. The trucks feature ergonomic designs and a variety of native formats for CAD downloads, enhancing operator comfort and versatility.

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for calibrating torque wrenches according to DIN EN ISO 6789. Designed for user-friendliness and flexibility, caliTEST-B caters to medium-sized companies or those with fewer tools, providing an alternative to sending wrenches to specialized labs. The device supports reliable calibrations ranging from 2.5 to 500 N·m, extendable to 0.2 to 1,000 N·m, with less than 0.5 percent display deviation. It accommodates torque wrenches up to 1,320 mm in length and can perform tool-related machine capability testing. Featuring interchangeable sensors for different torque ranges, caliTEST-B maintains flexibility without sacrificing precision. Additional features include a holder for screwdriver-shaped torque wrenches, barcode reader, and label printer. Kistler's CEUS software facilitates the calibration process with customizable settings, step-by-step guidance, and automatic test report saving, ensuring standard-compliant and efficient calibration.

ITS’ Innovative Self-Cleaning Retrofit for Conveyor Belt Ovens International Thermal Systems (ITS) introduces a Self-Cleaning Retrofit for existing conveyor belt ovens, addressing the challenge of Lead Oxide buildup that hinders oven performance. This retrofit, designed for conveyor belt and Flashdrying Ovens, reduces the need for high temperatures and physical cleaning, enhancing efficiency and safety. Key benefits include a reduction in oven temperatures by up to 60°F, lower energy and maintenance costs, improved production quality, reduced energy consumption, and enhanced employee safety. The retrofit also offers a reduction in airborne lead oxide particles, with an optional vacuum connection, and retains existing system architecture and operation. ITS' Self-Cleaning Retrofit exemplifies an innovative approach to oven maintenance, offering a cost-effective solution for improved performance and safety in industrial settings.

Kistler Introduces caliTEST-B for Torque Wrench Calibration Kistler presents caliTEST-B, a new calibration device offering a more compact and cost-effective solution

44 | IMD February 2024

Kistler Introduces caliTEST-B for Torque Wrench Calibration

Norton RazorStar™ Abrasives for Superior Grinding Performance Saint-Gobain Abrasives introduces Norton RazorStar™ Fiber Discs, Quick-Change Discs, and Belts, featuring innovative engineered shaped ceramic grain technology. This breakthrough enhances grinding performance in tough applications on materials like carbon steel and stainless steel. RazorStar™ products, with

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their razor-sharp grains and supersized grinding aid, reduce heat generation and extend tool life. The consistent shape of the engineered grains ensures sharp cutting points and durability, maintaining their edge as new points emerge upon fracturing. These products boast a high grain concentration, ready for sharp, aggressive cutting. Jeremy Spencer and John Benkoczy from Norton | Saint-Gobain Abrasives highlight the up to 50% improvement in cutting performance over other ceramic discs and the efficiency in medium to high-pressure metal removal. RazorStar™ Fiber Discs, Quick-Change Discs, and Belts, available in 36-grit, serve key markets like metal fabrication, welding, and energy, promising a new level of efficiency in grinding productivity.

Palmgren® 6 x 48-inch Belt Disc Floor Finishing Machine Palmgren introduces the 6 x 48-inch Belt 12-inch Disc Floor Finishing Machine, a versatile and economical tool designed based on end-user input. Distinguished from competitors, this 2 in 1 machine is adept at handling various jobs like contour part finishing, flat stock finishing, grinding, polishing, and deburring. The finishing machine comes with a sturdy steel floor stand, reflecting Palmgren's more than 100-year legacy in delivering reliable workshop tools. As a C.H. Hanson® brand, Palmgren ensures its finishing machine maximizes performance and safety for users. This machine is an essential addition to any workshop, capable of effectively managing a multitude of finishing operations.

Scotchman Industries’ Redesigned Hydraulic PressPro Models Scotchman Industries revamps its PressPro Series of hydraulic presses with enhanced features for industrialgrade fabrication. The updated 5-model range, including

66-ton, 110-ton, and 176-ton presses, now features an improved hydraulic configuration, a more robust base, and forklift accommodations. Mike Albrecht, National Sales Manager, emphasizes the redesign's focus on robustness and mobility. Ideal for various operations like bending, assembly, and quality control, these presses combine strength, precision, and versatility. Features include a movable ram cylinder, pressure regulator, 3 ram speeds, joystick operation, and standard V-blocks. The adjustable H-frame bed height and extra-wide working width add to the versatility, catering to both large and small jobs. Built to last, these presses come with a 3-year warranty, demonstrating Scotchman's commitment to quality and customer satisfaction.

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SprutCAM X Robot Integrates JAKA Cobots SprutCAM Tech expands its CAD/CAM/OLP system, SprutCAM X Robot, by integrating digital twins of JAKA cobots into its online Robot Components Library. The update includes models Zu 3, Zu 5, Zu 7, Zu 12, Zu 18, Pro 16, and MiniCobo, used in industries like machining and automotive. JAKA cobots are known for their compactness and precision, with payloads ranging from 3kg to 18kg. SprutCAM X Robot's MachineMaker application allows users to create digital twins of these cobots for programming. A free 30-day license is available for new users. SprutCAM plans to support the full range of JAKA Robotics models and continue expanding its online Library with 3D models of industrial robots and components.

Suburban Tool’s Master-Edge Hybrid Aluminum Cast Iron Straight Edge Suburban Tool, Inc. introduces the Master-Edge Hybrid™, an Aluminum Cast Iron Hybrid Straight Edge, to its precision tool range. This new hybrid model combines the precision of Suburban's Cast Iron Straight Edge with the lightweight benefits of aluminum, offering about 50% weight reduction. Ideal for applications where cast iron's weight is a limitation, these Aluminum Straight Edges feature a 319 Cast Aluminum body with durable G2 Gray Cast Iron wear strips. Precision ground to Suburban’s standards, they are available in various lengths, catering to diverse industrial needs. The Master-Edge Hybrid™ emerges as an innovative solution in the toolmaking industry, blending lightweight design with high durability and precision.

TAB Industries' Semi-Automatic Upgrade Bundle for Orbital Wrappers TAB Industries, LLC introduces a Semi-Automatic Upgrade Bundle for its TAB Wrapper Tornado Smart Controls orbital wrapping machines. This new option combines popular upgrades into one package, offering automation features

46 | IMD February 2024

at a discounted rate. The bundle includes an automated cut-and-wrap device, a wireless remote transmitter and control system, and steel bumper guards. The upgrade allows a single worker to operate the pallet wrapping machine from a forklift, improving efficiency and safety. Suitable for standard wrapping ring sizes, the patented TAB Wrapper Tornado machines provide secure, unitized loads quickly and without additional packaging materials. The bundle, offering a 25% saving compared to individual purchases, comes pre-installed and ready for operation, complete with a full warranty.

TRUMPF’s Enhanced TruPrint 2000 for Additive Manufacturing TRUMPF introduces the upgraded TruPrint 2000 3D printer, optimized for mass production in the dental and medical technology industries. The TruPrint 2000 now features a square build plate and an optional 500-watt integrated fiber laser, increasing productivity by up to 36% for partial dentures compared to round build plates. With its two lasers, the printer can simultaneously process the entire build plate, enhancing throughput. The TruPrint 2000 is precise, producing high-quality parts for medical applications like titanium skull plates and knee joints. Its motorized beam expander adjusts the laser's spot diameter for varied tasks, with standardization across the TruPrint portfolio allowing easy transfer of printing parameters between machines. This standardization and flexibility make the TruPrint 2000 a productive choice for various industries.

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