Bel Air's series of steps helps manufacturers improve their 3D part finishing process.
Additive manufacturing (AM), or 3D printing, is becoming a widely popular form of production. Although it comes with its own set of challenges, adoption of this process is accelerating. However, finishing, or post processing, for 3D printed parts remains a challenging task for most 3D part producers, including the medical, automotive, aerospace, and firearms industries. Bel Air has created a series of steps to help manufacturers create or improve the finishing of 3D parts.
In most cases, working with an expert like Bel Air is the best way to design a finishing process for a part. To get the most out of the experience, manufacturers should understand how the process works and how to measure the results of the process.
First, a 3D model can provide valuable information on how the part’s structure and size will affect post processing and help narrow down the machines, compounds, and media that can be used on the part. The 3D model, size, and geometry of the part will all affect the finishing process. For example, consider a large part with a complex geometry. Since there are many aspects associated with this geometry, the manufacturer should discuss background information on the part and its function with the customer. This will help decide which specific technologies to consider and provide vital information for creating a feedback loop to improve post processing.
The part may not be fully optimized for post processing – by suggesting alternative print layouts, post processing can be more expedient and productive. This step also aims to preserve and improve the cosmetic and functional components of the part. Once suggestions have been made and part design has been decided, manufacturers can consider the finishing needs of the part.
It’s important to consider the part’s purpose because it directly affects the details of the finishing process. Deciding whether a part’s finish should be for cosmetic and/or functional purposes is critical. Parts can be shiny, matte, or coarse along with several other surface qualities. The part can also be processed to a certain Ra value – a measure of the surface’s roughness. Additionally, manufacturers need to know how many parts they want to process a day and how consistent they want the process to be. In the mass finishing world, no two parts have the same exact finish – there are always slight variations. There will always be a few small defects in part processing, whether they come from printing or accidental wear and tear in post processing. Additional processes such as dyeing, coating, and electroplating can be done to improve the look and feel of finished parts. After all the criteria have been set, the parts are ready to be processed.
Sending a sample of acceptably finished parts can help create a more effective post process. Bel Air can analyze sample parts to determine their exact cosmetic and metric details using ZYGOT metrology data. Surface data is recorded using a contactless method, and a 3D image of the surface is created. Both provide an in-depth look into how surfaces can be improved.
After the part has been analyzed thoroughly, a sample process is determined based on the manufacturer’s needs, whether they are finish quality, price, and/or pure throughput. Machines, media, and compounds are recommended and selected for sample processes. Then, the processes are done and metrology is taken to determine the exact effects of each one. After this is completed, manufacturers should discuss the results and determine how to move forward. Additional equipment should also be considered to preserve machinery and media life and lower maintenance costs. More sample processes can be made, and manufacturer specifications can be changed in order to further improve or create a more realistic finish.
The new training option addresses the manufacturing skills gap and the need for more advanced machine tool operators.
To further develop the next-gen manufacturing workforce, FANUC America, a leading automation solutions provider, is expanding its CNC training offerings to include 5-axis simulation.
FANUC’s Machining Simulation for Workforce Development provides training for controls operation and part programming in a virtual environment. The Complex Milling Extension option combines FANUC’s CNC Guide and simulation software that can now operate as one of the three main 5-axis mill kinematics. The offering also includes training on a 3-axis mill and a 2-axis lathe for maximum configuration flexibility. Via a digital twin, the 5-axis machining simulation allows users to learn how to setup and operate three common advanced 5-axis milling machines: mixed type, tool type and table type.
Growing interest in 5-axis machining continues as more operations look to produce complex parts used in high-tech industries, such as aerospace and medical devices. As this sector of the machine tool business increases, the demand for 5-axis operators will exponentially grow. Finding qualified workers to fill these positions will challenge many employers, who are already facing a tight labor market due to the widely known manufacturing skills gap issue.
Training new or existing workers in an effective and innovative way will be key to bridging this gap. FANUC is committed to working with industry as well as educational partners to help fill the growing 5-axis training demand.
The addition of 5-axis simulation offers an immersive environment to practice and understand advanced machining techniques. Since 5-axis machining involves more complex machine setups, the simulation software effectively teaches users how to take advantage of the unique options and features. Additionally, the 5-axis machining simulation software allows operators to experiment with and prove out the machine setup and/or part program before modifying the actual machine.
For more information on the 5-axis machining simulation software as well as other CNC workforce development solutions, please visit this page.
As part of the Global Innovators Community, MachineMetrics will contribute solutions for a sustainable future.
MachineMetrics, a leading data and digital app platform for manufacturing, has joined the World Economic Forum’s Global Innovators Community, a group of the world’s most promising start-ups and scale-ups at the forefront of technological and business model innovation. As a member of the Global Innovators Community, MachineMetrics will engage with public and private sector leaders and contribute new solutions to overcome the current crisis and enable future resiliency. Companies invited to become Global Innovators will engage with one or more of the Forum’s Platforms to help define the global agenda on key issues.
“Amid major global disruptions brought about by the COVID-19 pandemic, it is a critical moment for innovative companies to bring forward new ideas and innovations to help protect communities and industries around the world,” says Bill Bither, CEO and co-founder of MachineMetrics. “As a leader in manufacturing’s digital transformation, we are proud to work alongside the World Economic Forum to build a more sustainable industry for the future.”
“The World Economic Forum is happy to have MachineMetrics join our Global Innovators community,” says Francisco Betti, head of advanced manufacturing and production, World Economic Forum. “Including new, innovative voices is essential to the work we do at the Forum, and we look forward to what MachineMetrics’ advanced manufacturing expertise will add to our projects, dialogues, and platforms."
Manufacturing remains the largest industry in the world with the least digitization. This lack of data leads to massive inefficiencies that affect every component of the manufacturing lifecycle. However, an estimated 60% of global manufacturing companies will use connected device data for analysis in the coming year, evidence that IoT is already driving unprecedented disruption in a notoriously slow-adoption industry for technology. Access to data can transform traditional manufacturing operations and supply chains into dynamic, sustainable, more resilient interconnected systems.
MachineMetrics aims to be the catalyst for the digital transformation of manufacturing. Their IIoT Platform is plug-and-play with no on-site set up required, enabling consumable machine data and insights in a matter of minutes. Today, the company supports several of the world’s top manufacturers, which leverage MachineMetrics to expedite time-to-value for their IoT programs and provide the foundation for scaling digital applications across their factories.
The two-day virtual event will focus on the latest developments in the fields of industry, energy, and logistics.
Hannover, Germany – For the first time in its history, HANNOVER MESSE will host a digital event focused on industrial transformation. HANNOVER MESSE Digital Days will start on July 14 with keynotes from business, science and politics as well as panel discussions, live chats, networking, and innovation presentations. Everything revolves around the questions of how industrial transformation can succeed and which steps industry must take to recover quickly from the consequences of the shutdown.
"With the Digital Days, we are creating an online platform for the entire HANNOVER MESSE community. We had to cancel the show this year due to the corona pandemic, but people still need to learn about the latest technological products and solutions and to talk with experts from all over the world. Because tomorrow's innovations are only possible when different industries and cultures exchange ideas," says Dr. Jochen Köckler, Chairman of the Managing Board, Deutsche Messe AG.
The HANNOVER MESSE Digital Days revolve around the content of the show. For example, the conference program focuses on topics such as Industrie 4.0, artificial intelligence, smart energy, and Logistics 4.0. Exhibitor products and solutions form the second layer of content. Networking also plays a prominent role: All participants can search for suitable business and cooperation partners and contact each other directly using the chat function.
One of the biggest highlights is the HERMES AWARD ceremony. For the first time, this internationally coveted technology prize will be awarded digitally. A jury chaired by Dr. Reimund Neugebauer, President of the Fraunhofer-Gesellschaft, chose the winner from numerous high-quality submissions. The announcement will be made on July 14.
For more information and to register, visit the show page.
Register for this free online webinar to learn how to navigate, successfully emerge, and position your company to thrive post COVID-19.
As destructive as COVID-19 has been, from a supply chain perspective it’s simply the latest disruption manufacturers must face. Lisa Anderson, MBA, CSCP, CLTD, president of LMA Consulting Group Inc., will address these disruptions and explain how manufacturing and supply chain executives can successfully navigate this latest challenge in the free webinar, Future-Proofing Manufacturing & the Supply Chain, taking place June 25, 2020 at 1 pm EDT.
Customers’ expectations are newly defined and ever-changing. The un-normal that’s emerging requires rapid customized products and services arriving at a customers’ doorstep prior to them realizing the need. Is your manufacturing and supply chain network geared to surpass customers’ expectations and prepared to be resilient to ever-changing conditions while growing profit and accelerating cash flow?
In this webinar, Anderson will discuss strategies to navigate, successfully emerge, and position your company to thrive post COVID-19. Attendees will be walked through key insights and proactive approaches to consider across the end-to-end supply chain, as well as strategy and tactics across all organizational functions.
Click here to learn more. Can’t attend the day of the event? A link to the recorded roundtable will be emailed within 7-10 business days to all registrants.