Product Design

3D printed titanium structure shows supernatural strength

A 3D printed ‘metamaterial’ boasting levels of strength for weight not normally seen in nature or manufacturing could change how we make everything from medical implants to aircraft or rocket parts. RMIT University researchers created the new metamaterial – a term used to describe an artificial material with unique properties not observed in nature – from common titanium alloy. But it’s the material’s unique lattice structure design, recently revealed in the journal Advanced Materials, that makes it anything but common: tests show it’s 50% stronger than the next strongest alloy of similar density used in aerospace applications. Improving on nature’s own design Lattice structures made of hollow struts were originally inspired by nature: strong hollow-stemmed plants like the Victoria water lily or the hardy organ pipe coral (Tubipora musica) showed us the way in combining lightness and strength. However, as RMIT’s Distinguished Professor Ma Qian explains, decades of trying to replicate these hollow ‘cellular structures’ in metals has been frustrated by the common issues of manufacturability and load stress concentrating on the inside areas of the hollow struts, leading to premature failures. “Ideally, the stress in all complex cellular materials should be evenly spread,” Qian explained. “However, for most topologies, it is common for less than half of the material to mainly bear the compressive load, while the larger volume of material is structurally insignificant.” Metal 3D printing provides unprecedented innovative solutions to these issues. By pushing 3D printing design to its limits, the RMIT team optimized a new type of lattice structure to distribute the stress more evenly, enhancing its strength or structural efficiency. “We designed a hollow tubular lattice structure that has a thin band running inside it. These two elements together show strength and lightness never before seen together in nature,” said Qian. “By effectively merging two […]

Electronics manufacturers adopt generative AI and Omniverse to digitalise state-of-the-art factories

Electronics manufacturers worldwide are advancing their industrial digitalisation efforts using a new, comprehensive reference workflow that combines Nvidia technologies for generative AI, 3D collaboration, simulation and autonomous machines. Supported by an expansive partner network, the workflow helps manufacturers plan, build, operate and optimize their factories with an array of technologies. These include: Omniverse, which connects top computer-aided design apps, as well as APIs and cutting-edge frameworks for generative AI; the Isaac Sim application for simulating and testing robots; and the Metropolis vision AI framework, now enabled for automated optical inspection. At Computex, Nvidia founder and CEO, Jensen Huang, showcased a demo of an entirely digitalised smart factory — an industry first for electronics makers. “The world’s largest industries make physical things. Building them digitally first can save enormous costs,” said Huang. “We make it easy for electronics makers to build and operate virtual factories, digitalise their manufacturing and inspection workflows, and greatly improve quality and safety while reducing costly last-minute surprises and delays.” Foxconn Industrial Internet, a service arm of the world’s largest technology manufacturer, is working with Nvidia Metropolis ecosystem partners to automate significant portions of its circuit-board quality-assurance inspection points. Innodisk is deploying Nvidia Metropolis to automate optical inspection processes on its production lines, saving cost and improving production efficiency. Pegatron, a leading electronics manufacturer and service provider, is using the reference workflow to digitalise its circuit-board factories with simulation, robotics and automated production inspection. Quanta, a major manufacturer of laptops and other electronic hardware, is using AI robots from its subsidiary Techman Robot to inspect the quality of manufactured products. Techman is leveraging Isaac Sim to simulate, test and optimise its state-of-the-art collaborative robots while using NVIDIA AI and GPUs for inference on the robots themselves. Wistron, one of the world’s largest suppliers of information and communications products, is tapping Omniverse to build digital twins of its automated […]

Fruit packing technology dramatically cuts packhouse labour needs

An intelligent robotic fruit packing machine that automates the most labour intensive job in the packhouse is proving to be a game-changer for post-harvest operators around the globe. Global Pac Technologies has officially unveiled the Aporo II robotic produce packaging machine which builds on the proven technology of the original Aporo I Produce Packer, first developed in 2018. The latest model can now accommodate twice the throughput, packing 240 fruit per minute, saving between two and four labour units per double packing belt. “Aporo II can be retrofitted across two packing belts instead of one, so it has effectively doubled the throughput and the labour saving that Aporo I could deliver,” explains Cameron McInness, Director of Jenkins Group – a New Zealand-based company which co-founded Global Pac Technologies with US-based Van Doren Sales Inc. “We have been rolling out this new machine with some key customers globally and the results have been dramatic. One of our Australian customers built a new packhouse and installed three of our Aporo II’s. That increased their packhouse production by 30-40 percent and reduced their labour by 50 percent. “Automating the process of placing fruit into trays then allows post-harvest operators to redeploy their scarce labour resources to areas where they can add more value.” McInness says Aporo II’s dual robotic heads are more consistent and reliable than human packers. The technology is now being used in France, the UK, Sweden, Belgium, the US, Australia and New Zealand – primarily to pack apples, and now stone fruit like peaches and nectarines. Work is underway to extend its use to other fruit varieties in the near future. “What’s unique about Aporo I and Aporo II is they are designed for really simple autonomous packing. The machine is very intelligent. It looks at the fruit, orientates […]

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ToolBox suite gives laser job shops a boost for industry 4.0

A new laser cutting and fabrication quoting tool suite is being introduced to Australasia and Asia-Pacific to save job shops time, and keep quotes accurate and consistent, no matter who is preparing them. The ToolBox digital tool kit from Tempus Tools Inc turns a CAD drawing into an accurate quote in seconds, and the time saved can be used to allow laser job shop staff and resources to be reallocated into areas such as business growth. Toolbox can also provide an innovative 3D unfolding service, whereby it can be fed full 3D schematics of a product and it will select precisely all the 2D sheet metal surfaces required to be cut by a laser workshop. It’s also possible to create the drawing without using any CAD software, using Toolbox’s Quick Part parametric parts library. Quick Part has a broad range of customisable parts, including brackets, flanges, gussets, and plates that can be adjusted to the specific needs of the user. “ToolBox is designed to put the tools in the hands of small laser cutting and fabrication workshops that are looking to grow their business. It helps with cleaning drawings, part creation or extraction, and laser cutting calculations, so the business can quote more jobs and expand its operations,” says Mr Felipe Lechuga, President, Tempus Tools. “With the shift to Industry 4.0, slow quoting processes just aren’t competitive anymore, so job shops need new tools to get the job done faster, more accurately, and with total consistency,” says Mr Lechuga. The laser cutting market is growing due to its importance to vital industries such as automotive, aviation, architectural and construction products, defense, engineering electrical, manufacturing, metals, mining and energy, shipbuilding and textiles. “Customers in these demanding industries need fast quotes. ToolBox empowers job shops, particularly smaller ones, to win more projects […]

Manufacturers can use ‘assets-as-a service’ approach to build better products

By Kevin Dherman, Chief Innovation Officer at SYSPRO Innovations and the evolution of technology has seen a positive shift in how businesses are able to capture data to help them make informed business decisions. In the span of a decade or two, businesses have progressed from the time intensive process of manually gathering data across the business to try to draw a meaningful conclusion from any further examination. The challenge was that a good data conversion seldomly made an impact across the value chain but thankfully, the rise of digitalisation and automation in manufacturing is resulting in the generation of a colossal volume of data. Today, new technologies are connecting the manufacturer directly to their operations and their customers like never before. With historical data as a foundation, manufacturers can fulfill a promise to end customers. They can track inventory anywhere in the supply chain as well as track and forecast delivery dates of raw materials as well as accurately forecast manufacture dates. One way in which manufacturers are collating data at the edge is through the Internet of Things or a network of interconnected sensors, instruments and other devices. Businesses are then able to access a single source of truth through their ERP system and use data insights to facilitate the improvement of productivity and efficiency. While data insights are clearly the route to improved operational efficiencies, the industry is also asking whether there is an opportunity to generate new revenue streams through data monetisation and the re-exploration of business models. Defining data monetisation Gartner defines data monetisation as the process of using data to obtain quantifiable economic benefit. Internal or indirect methods include using data to make measurable business performance improvements and inform decisions. External or direct methods include data sharing to gain beneficial terms or conditions from […]

How distributed manufacturing is reducing operational risk

By Mathew Hunter, innovation product marketing manager, Konica Minolta Distributed localised production has emerged as a counterpoint to globalisation as it places the production of goods closer to consumers or at the point of use. Using additive manufacturing means manufacturers can produce goods onsite, which delivers a host of financial, efficiency, and environmental advantages. Although globalisation can offer businesses many benefits, the trend towards distributed manufacturing is increasing. Particularly in recent times, this acceleration is due to factors such as: rising fuel prices, which has significantly increased long-haul shipping cost; concerns over climate change and its negative environmental effects; and the lack of control over stock levels, timing and import restrictions when relying on overseas supply lines. Distributed manufacturing uses additive manufacturing to place production sites across dispersed locations, which are interconnected and coordinated through technology. Sites can download designs and 3D-print them on the spot. Because this model relies on local manufacturing, producers have a higher level of flexibility and agility, providing faster turnaround times, quicker delivery of goods, and customised products. This can help manufacturers compete more effectively, particularly in a disrupted environment, as it reduces operational risks. By implementing a distributed manufacturing model, manufacturers can overcome many challenges currently impacting global trade, including constant trade wars and tariffs as well as pandemic-related border closures. Setting up local manufacturing operations also helps support innovation for individual manufacturers and helps the country as a whole gain more resource sovereignty. The New Zealand government has recently launched an approach to industry policy to help grow more innovative industries across the nation. Manufacturing is a key industry for New Zealand to grow and become a more productive, sustainable, and inclusive economy. The Advanced Manufacturing Industry Transformation Plan aims to: help lift the sector’s productivity, sustainability, inclusivity, and quality of work; and […]

Freedom to think

Top three applications for machine learning in manufacturing Machine learning means machines do not have to be programmed to perform exact tasks on a repetitive basis, they collect data and use it to make informed decisions about their next move. This allows them to correct any errors and improve their operational parameters. There are three key areas where manufacturers can benefit from this technology. Industrial maintenance According to McKinsey, artificial intelligence can generate a ten per cent reduction in maintenance costs, up to a 20 per cent reduction in downtime and a 25 per cent reduction in inspection costs. Machine learning is a significant player in this positive impact of artificial intelligence. In traditional predictive maintenance, engineers program the thresholds for a component’s normal operation into a supervisory control and data acquisition (SCADA) system. When the component deviates from normal operation, the system alerts an engineer of the developing fault. The problem with this approach is the lack of flexibility. It does not take into consideration variations in plant activity or the context of manufacturing processes. For example, a system may detect a sudden increase in a component’s operating temperature and interpret this as a developing fault, when in fact it is due to the machine being sterilised. Machine learning technology means predictive maintenance systems do not have to be programmed with normal operating thresholds. They use data from the factory floor and IT systems to monitor operational patterns and make informed decisions about what is normal and abnormal activity. Quality assurance There are two main ways machine learning can improve quality assurance (QA). Firstly, it enables assembly robots to continuously monitor and optimise their processes. Secondly, machine learning increases the capabilities of machine vision systems. Like with predictive maintenance, traditional machine vision systems for QA lack flexibility. For example, […]

New technologies can create huge numbers of meaningful jobs

Augmented reality can play a pivotal role in removing labour inefficiencies. In the US, recent jobs reports have generally been met with enthusiasm and positivity. Unemployment continues to drop to 10-year lows and most economists believe America is approaching “full employment.” Wage growth remains in positive territory. And yet, people are angry. Blue-collar manufacturing jobs have disappeared. Income inequality is increasing, and the once-steadfast middle class is being hollowed out. Their anger arises from a sense of economic insecurity and it is the idea that weaves together Brexit, Trump’s takeover of the Republican party, and Le Pen’s National Front. The acute disconnect is alarming. How can the US be at full employment and yet harbour such profound socioeconomic discontent? The Dignity of Work A reporter for the New York Times recently rode with a number of truck drivers to learn about their job. Truck drivers spoke at length about the low pay and health issues the job entailed. The title of the article was “Alone on the Open Road: Truckers feel like ‘Throwaway People.’” Much has been made of the looming devastation that self-driving technology will have on the 3.5 million truck drivers in the US, as well as how these millions of newly unemployed individuals will add fuel to the populist flames. The concern is misdirected. Digging deeper into the data clarifies this disconnect further. Many are in part-time jobs or are underemployed for their experience and skillset. Only 62% of Americans are even participating in the labour market, and a growing number of people in their prime working years have given up on trying to find a job. The populist language of modern politicians confirms this thesis. Americans are being “left behind.” Workers in the Rust Belt have become a “forgotten people.” People may have jobs, but they’re not the jobs they want. […]

Composites for car part manufacturing

The US Environmental Protection Agency (EPA) mandated in 2012 that the national automobile fleet should average 54.5 miles per gallon by 2025 in order to reduce reliance on fossil fuel and minimize emissions, many other nations have also implemented similar new standards. To meet these new standards the automotive industry has had to find new ways to make lighter cars without sacrificing their strength and structural integrity. Here Jari Sopanen, Regional Manager at leading composites manufacturer Exel composites explains why one of the best replacements for steel is thermoset components. Thermoset composites are formed using glass, carbon, or aramid fibres, which are then combined with resins such as polyesters, vinyl esters, epoxies, or phenolic resins. These composites are used in various industries but are particularly prominent in the manufacturing of aircraft and spacecraft parts. Thanks to research and development in the aerospace sector, composites are also being used across other forms of transportation due to the high demand for lightweight vehicles and components. This trend, called light-weighting, seeks to use innovative materials to reduce the weight of products. As a result, composite materials are being increasingly used in production, especially for automotive parts and components. According to the American Composites Manufacturers Associations, fiberglass is one of the key reinforcing materials used in the US thermoset composites industry. Thanks to its durable properties, it is a good replacement for steel in vehicle structural components, including drive shafts, bumpers and roof beams Reducing component weight is crucial for raising the efficiency of automotive systems. For example, carbon fibre has comparable properties to steel, but is only one-fifth the weight. Regardless of the mode of transport, it is easy to see the benefits that shaving this amount of weight from a vehicle will achieve. Additionally, when directly compared to steel, composite materials can […]

HandySCAN 3D scanner meets Boeing’s requirements

Creaform, the worldwide leader in portable 3D measurement solutions and non-destructive testing (NDT) solutions, has announced that its HandySCAN 3D metrology-grade 3D laser scanner can now be used for recording physical attributes of aircraft dents and blends on all models of Boeing commercial airplanes. Boeing has released a service letter with guidance on the use of 3D scanners for measuring dents and blends on airplanes. The SmartDENT 3D solution and the flagship HandySCAN 3D scanner were used in the process of guiding Boeing’s quality requirements for the service letter. “Creaform is proud to see leaders such as Boeing, turn to 3D scanning solutions for surface defect inspection. With SmartDENT 3D, our goal is to provide the most accurate damage assessment to our customers, so they can make informed and safe decisions, while getting their aircraft back flying with minimal down time,” said Jérôme Beaumont, Global NDT Business Manager at Creaform. Overview of SmartDENT 3D benefits: Speed: 80 times faster than the pit gauge technique. It is the fastest and most reliable aircraft surface damage inspection tool available on the market. Metrology-grade measurements for aircraft maintenance: The scanner is accurate to 0.025 mm (0.0009 in.) and has a resolution of up to 0.100 mm (0.0039 in.) with high repeatability and traceable certificate. Intuitive pass/fail assessments: With its intuitive design and real-time software visualization, Creaform’s NDT solutions ensure short learning curves and minimal operator experience influence on the accuracy of results. Live visualisation and portability: Weighting less than a kilo, the handheld scanner is the perfect tool for work in hangars or directly outdoors. Users can easily perform 3D surface inspection of any part of an aircraft on which they would use manual techniques—including on and under wings. In addition to complying with Boeing’s service letter, Creaform HandySCAN 3D scanners are listed […]

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