Industrie 4.0: Mein Har(t)z Brennt Part 1

“Turning and turning in the widening gyre

The falcon cannot hear the falconer;

Things fall apart; the centre cannot hold;

Mere anarchy is loosed upon the world,

The blood-dimmed tide is loosed, and everywhere

The ceremony of innocence is drowned;

The best lack all conviction, while the worst are full of passionate intensity.”

WB Yeats.

15 years after the Hartz reforms made Germany a tougher and more resilient place in which to work and live, decades-long semi-austerity has left the motor of the European economy coughing and sputtering in anticipation of a global Trumpcession. Amidst worldwide turbulence and upheaval, a baby boomer generation sets to retire, leaving the reins of Mittelstand companies in the hands of a TV generation trying to raise an internet generation. This could not have happened at a foggier time. China, the workshop of the world, is asserting itself and decidedly moving upmarket in many niches. Manufacturing excellence is not something that small German family firms put on awards on the wall, manufacturing excellence is the dream that one of the richest and most powerful countries in the world wants to attain. A million new immigrants have exposed long glossed over German societal fractures such as extreme right terror, nationalist violent groups of all stripes, a radicalized Antifa, new Germans not entirely absorbed and oops the ossi wessi divide or areas of economic backwardness didn’t disappear with the Trabant. Cooperation, social adhesion, catholicism, and identity; they are all ebbing or under siege. Even though roads seem in perennial repair; underinvestment in infrastructure has left the country looking less than spiffy.

It seems that if you move your government to Berlin, Berlin will look nicer while the country looks more like Berlin. Underinvestment in education has meant that in this area the nation lags European peers as well. Germany does invest cohesively in innovation but seems set to perennially lag behind the US and China on that front. Lack of VC capital, when compared to the US, means that there are far fewer startups, especially far fewer larger successful ones. Erstwhile staid institutions such as Deutsche Bank seem wobbly or indeed have been quite adept at carrying on as a giant hedge fund/Russian Money transfer scheme while masquerading as a boring financial institution. The Volkswagen scandal still weighs heavily on a collective culture of excellence and quality.

Over 100 years ago the German government had a goal for itself in the collective stumble to slaughter that was the First World War. The government’s goal was the: establishment of a Germany dominated customs union. 104 years on, two observations can be made:

  1. Germans are persistent
  2. Be careful what you wish for

Many people would have given up after the First World War, not the Germans. Many people would then have given up after the Second World War, not the Germans. They kept on going and finally after 100 years got their Germany dominated customs union. But, now what? A nation-state born out of a conflagration the German Federal Republic now has over 70 years of prosperity, growth, stability, and peace behind it. After turbulence and destruction, there was rubble and this was turned into a path to future riches and safety that would have seemed a feverish dream to those clambering through bomb crater hewn Allee’s. Germany is one of the most successful countries that the world has ever seen, but what is its place in a world that is seeing the demise of the nation-state and the rise of ultra-nationalism simultaneously?

Nihilism, apathy, and extremism grow as we enter the age of China and the caudillo. Civil society is for textbooks and what will the terrorists do once we’ve run out of acronyms for them? It is becoming increasingly clear that those left-wingers that shouted while standing on boxes for workers’ rights have essentially won, only to suddenly lose. All of their dreams from worker safety to pay, to vacations, to affordable housing have been granted. Meanwhile, the right has gotten its law and order with crime being reduced to next to nothing and violent crime being something you’re likelier to find on vacation than at home. Centrists have gotten their civil society a little bit of everything a la carte dream while länder press and public have power. Businesses are easy to start and are well regulated while labor unions have been so successful as to be useless. Essentially Germany has done such a good job of keeping its promises and attaining its dreams that it has no more hopes and dreams with which to feed a future thirst for that thing that is Germany.

Extremism is on the rise because they do manage to break through a cluttered media landscape with simple ideas and now it is Baader Meinhof Phenomena that dominate the things that we think about. Technocratic policies alienated many because they simply were too complex for a large segment of the populace  to understand. Embarrassed to ask, they become disenfranchised by the multisyllabic integrated policies and their fine-tuning. Alienated, they feel as if they were patronized by ‘adults in the room.’ Everyone, however, can join a discussion about what kind of headdress the supermarket check out girl should be allowed to wear. A resurgence is populism is therefore not because of the anti-immigrant, xenophobic, isolationist nature of these policies or indeed their objectives. Populism has grown due to the fact that it is simple to understand, talk about and spread in a confusing world. Populism is popular now because it is a series of hale spears designed to pierce the heart of modern democracy itself. Tossed by tossers who are nihilists themselves but do believe in their own call to power the populist policies are popular because they are simple, fit into a soundbite and are easy to talk about. As per Mr. Yeats, therefore, we can see ourselves in a place where indeed, the center is not holding and the good roam listlessly while the sheep are stirred by the truthful seeming simple burn that is hate.

How to counter this as a member of society which through policy and concerted effort has tried to create and maintain an equitable country for all? We must come up with new dreams as vibrant scary and hopeful as the ones of the past. From the land of Herder new ideas are emerging, in fact, that could, in fact, herd us all to a hopeful optimistic future where harmony reigns supreme. Having accomplished the rise of the human Germany now turns to the rise of the robot.

Images: Lisa, Trine, Cynthia, Stefan.

The post Industrie 4.0: Mein Har(t)z Brennt Part 1 appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

3D Hubs Announces $18 Million in Funding and New Dedicated US Office

Less than a year after 3D Hubs turned five and outlined its new strategy to become “a full-blown manufacturing platform,” the company turned away from its community 3D printing roots and announced that it would only be working with professional service bureaus to fulfill orders. This meant that if community members didn’t qualify as a Manufacturing Partner based on their order history, they were out of luck, as the company was becoming completely focused on B2B.

“2018 was the year in which we turned 3D Hubs from a 3D printing peer-to-peer marketplace into a B2B platform for all digital production, taking pivotal steps towards our automated and distributed manufacturing mission,” 3D Hubs CEO and Co-Founder Bram de Zwart wrote in a biannual update to his LinkedIn contacts.

“Since 3D Hubs had become the world’s largest peer-to-peer marketplace for 3D printing, it was a dificult decision in early 2018 to transition to a turnkey B2B manufacturing platform and even harder to pull it off. But with last years’ revenue tripling and $18 Million in new funding we couldn’t be more excited about this new strategy and 3D Hubs its future!”

Bram de Zwart

While there were obviously a lot of hurt feelings in the wake of this announcement, the company seems to be doing pretty well for itself after this decision. Yesterday, 3D Hubs announced that it had received $18 million in Series C funding, which will be used to help “build the future of on-demand manufacturing” and increase development of its online platform, among other important things.

One item the funds will be used for is rapidly expanding its team in the US, which is the company’s largest market with over 10,000 clients. So 3D Hubs will be opening a dedicated US office to best serve these customers, and is now trying to determine where the office will be located.

“For the new office location we’re currently deciding between Chicago, Minneapolis and Boston, cities that are deeply rooted in manufacturing and have great connectivity to the rest of the country and to Amsterdam,” de Zwart wrote.

Speaking of Amsterdam, 3D Hubs will be expanding its team there, and in the US, over the next few months. In an effort to grow from 65 employees to over 100, the company is currently hiring for a number of positions, including Business Develop Representative and Director of Sales.

3D Hubs made a lot of investments last year in automating some of the most important manufacturing process features, such as design validation, quoting, and smart order routing. Now, leveraging the data from 2 million produced parts, the company’s platform can instantly provide accurate quotes for 98% of its customer requests for services such as CNC machining, injection molding, and 3D printing. In addition, 93% of its order are automatically sourced through the supplier network, so that customers receive their parts twice as fast.

3D Hubs also expanded its popular quarterly trend report by including industry specials. For instance, the Q1 2019 edition takes a look at how the automotive industry is adopting digital manufacturing.

The company is also helping to educate the rest of the world about digital manufacturing, and has been busy developing new content that can better explain the benefits of this technology, and how best to design for digital manufacturing.

In fact, one of the recent efforts is actually working to turn some of the chapters in the company’s 3D printing handbook, which was published in 2017, into helpful video tutorials on its YouTube channel.

Discuss this news, and other 3D printing topics, at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

[Images: 3D Hubs]

3D Printing News Briefs: February 22, 2019

We’ve got some exciting dental news to share first in today’s 3D Printing News Briefs – Stratasys just announced its new full-color dental 3D printer at LMT Lab Day. Moving on, Farsoon has been busy developing an advanced pure copper laser sintering process, and Aether is working with Procter & Gamble on a joint development project. DyeMansion has announced a new UK distributor for its products, and three researchers address the challenges of adopting additive manufacturing in a new book about best practices in the AM industry.

Stratasys Introduces Full-Color Dental 3D Printer

This week at LMT Lab Day Chicago, the largest dental laboratory event in the US, Stratasys has introduced its new full-color, multi-material J720 Dental 3D printer which lets you have 500,000 color combinations for making very high resolution, patient-specific models. Its large build tray can print six materials at the same time, and it’s backed by GrabCAD Print software.

“Labs today operate in a very competitive space where differentiation counts on mastering the digital workflow and expanding into new products and services. The J720 Dental 3D Printer is designed to change the game – allowing levels of speed, productivity and realism the market has never seen,” said Barry Diener, Dental Segment Sales Leader for Stratasys. “This powers laboratories to meet the demands of a competitive market and push the boundaries of digital dentistry.”

See the new J720 Dental 3D printer at LMT Lab Day Chicago today and tomorrow at Stratasys Booth A9. It’s expected to be available for purchase this May.

Farsoon 3D Printing Pure Copper

Pure copper heat exchanger

Two years ago, after Farsoon Technologies had introduced its metal laser sintering system, the company’s application team began working with industrial partners to develop an advanced 3D printing process that could additively produce components made of pure copper. Copper is a soft, ductile metal with both high electrical and thermal conductivity, and it’s often used in industries like shipbuilding, electronics, automotive, and aerospace. But most additive copper is based on alloys, and not the pure metal itself, which is hard for lasers to regularly and continuously melt and can cause problems like thermal cracking and interface failure.

That’s why Farsoon’s work is important – all of its metal laser sintering systems can successfully create cost-effective, high-quality pure copper parts. The company’s process and unique parametric design is able to meet custom needs of customers, and to date, it’s launched 13 process parameters for metal powder sintering, including pure copper. Some of the parts that have come out of Farsoon’s recent collaborations include a pure copper heat exchanger, which featured a 0.5 mm wall thickness, complex spiral geometry and was printed in a single piece. Farsoon is open for additional partners seeking to further develop the 3D printing of pure copper and other specialized materials.

Aether and Procter & Gamble Begin Joint Development Project

Aether CEO Ryan Franks and Director of Engineering Marissa Buell with an Aether 1

San Francisco 3D bioprinting startup Aether has entered into a two-year joint development agreement with Procter & Gamble (P&G) in order to develop 3D printing and artificial intelligence technologies. The two will use the multi-material, multi-tool Aether 1 3D printer as a technology creation platform, and will create several hardware and software capabilities that hope to automate and improve P&G’s product research applications and develop a next-generation Aether 3D printer. An interconnected network of computer vision and AI algorithms aims to increase automation for multi-tool and multi-material 3D printing, while high-performance cameras will enable new robotics capabilities. Aether is also working on additional software that will help P&G automate and speed up image processing.

“Aether is working with P&G to completely redefine 3D printing.  It’s no longer going to be just about depositing a material or two in a specific pattern. We’re building something more like an intelligent robotic craftsman, able to perform highly complex tasks with many different tools, visually evaluate and correct its work throughout the fabrication process, and constantly learn how to improve,” said Aether CEO and Founder Ryan Franks.

DyeMansion Names New UK Distributor

3D print finishing systems distributor DyeMansion, headquartered in Munich, announced that Cheshire-based 3D printing services supplier Europac3D will be the UK distributor for its range of machines. Per the agreement, Europac3D will now offer all of the AM finishing systems in DyeMansion’s Print-to-Product workflow, which includes its Powershot C powder blasting system, DM60 industrial coloring system, and the PowerShot S, which delivers homogeneous surface quality to 3D printed, powder-based plastics. Because of this, Europac3D is one step closer to achieving its mission of being a one-stop shop for 3D printing, scanning, and post-processing services.

“DyeMansion’s post-production systems are worldclass and add the all important finish to additive manufacturing,” said John Beckett, the Managing Director of Europac3D. “Their systems are perfect for companies or 3D print bureaus that have multiple SLS or HP 3D printers and allow us to extend our offer by providing market leading additive manufacturing finishing systems for 3D-printed polymer parts.”

New 3D Printing ‘Best Practices’ Book

We could go on and on about the many benefits offered by 3D printing (and we do), but there are still industry executives who remain unconvinced when it comes to adopting the technology. But a new book, titled “Additive Manufacturing Change Management: Best Practices” and released today, is here to provide some guidance for those still holding back. The book, which addresses some of the challenges of adopting 3D printing, was published by CRC Press as part of its Continuous Improvement Series and written by Dr. Elizabeth A. Cudney, an associate professor of engineering management and systems engineering at the Missouri University of Science and Technology, along with Divergent 3D’s VP of Additive Manufacturing Michael Kenworthy and Dr. David M. Dietrich, who is an Additive Manufacturing Engineering Design Fellow for Honeywell Aerospace and Dr. Cudney’s former doctoral student.

Dr. Cudney said, “If company leaders are interested in bringing additive manufacturing online, this book can help them decide if it makes sense for their industry.

“There’s often a lack of planning, a lack of understanding, a resistance to change and sometimes fear of the unknown. Our hope is that this book will provide a good road map for managers to advance additive manufacturing at a faster pace.

“We wanted to take a look at how companies can roll out a new technology, new processes and equipment and integrate that in such a way that you have a good product in the end.”

In the 17-chapter book, the authors present what Dr. Cudney refers to as a ‘road map’ for business leaders looking to adopt 3D printing. The eBook format costs $52.16, but if you want that shiny new hardcover version, it will set you back $191.25.

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Better than a Digital Twin, The Need for the Digital Triplet

The Digital Twin is a concept that is being established by the Enterprise CAD software crowd as well as people working in industrial automation. Heard among many a chin-chin with white wine and a smile; the digital twin could refer to just how well this term pairs with a higher “share of stomach” of manufacturer spending. Or it could very well relate to just how well this concept goes down with the Industrie 4.0 crowd along with with a reinheitsgebot beer and dreams of renewed German precision manufacturing hegemony.

The digital twin as a concept refers to the idea that in a digital manufacturing world mass customization coupled with software will mean that each and every single product in a company’s inventory will have a (perhaps) unique file encompassing all of the settings and necessary production information for that one part. A million unique hearing aids will all have accessible trackable digital twins that specify when and how they were created.

One can easily see how as a storage company this would make one salivate. For a manufacturer, as agile Chinese companies nip as one’s Achilles heels a renewed push into integration and complication with a side order of software could be just what staves off the competition and keeps everyone A6’s and A8’s for a while. Integration, software integration and plugging one’s product into the aorta of a firm sound very compelling. Once your process or machine is wrapped around the main artery along with ERP and PLM, they’re never going to rip any of that out. We have cured the patient forever; he need only keep taking our insulin. Forever revenue, annual maintenance fees, and a more high tech product, what’s not to like? What’s more, rather than make a device and sell it once we can write code and sell it lots of times. Perhaps this is a path for our stodgy firm to get a better multiple as well.

For manufacturers afraid of a future that they don’t understand, a vague, fluffy wave of a safety net sounds compelling as well. Track all of the products? Track all parts? Analyze all of the parts. Compliance on everything all of the time. Would you say no? After CRM, PLM, and ERP the digital twin could be the next multi-billion dollar dream of total control through software. For governments, the digital twin represents all of their dreams in one, and it seems like a future surefire innovation subsidy darling. Mittel GmbH, a family firm founded in 1810, the largest manufacturer of specialized hand tools for ski lifts in WestElbe Ostfalen, has implemented the digital twin to produce custom tools more efficiently using digital manufacturing in Germany. Perhaps in this century, European subsidies will produce mountains of code instead of butter.

Perhaps you can feel a slight skepticism on my part towards the digital twin. Just a smidgen maybe. Having worked in software, I’ve never seen it as a refuge for altruists. Historically much of software’s labor-saving potential has seemed to be absorbed by the vendor rather than have been created for the benefit of the client. I do however believe in digital manufacturing, and that 3D printing is quickly becoming a viable mass manufacturing technology for millions of highly detailed end-use parts. For that to happen, something like the digital twin has to exist. I had high hopes for something a bit more elegant, robust and open: a stuff DNA or sDNA where all of a files ingredients, parameters of the design, rights, and attributions are included in all 3D printing files themselves in an open format. I still think that this is a much better idea, but the digital twin with its fluffy enterprise software husk and the meaty, dense interior is a veritable beef wellington of profits compared to the ceviche thin earning potential of adding sDNA to all of the things in a universally accessible and free format.

They will PowerPoint this into our heads, and it will become what we need to want. Assuming then that the digital twin will, therefore, become commonplace I’ve been giving the concept some thought. I believe I’ve come up a much improved (and far more profitable!) addition to the idea. Enter: the Digital Triplet.

During production, each individual part will need one record of its precise making, and this will exist for the life of the product, available for tracking, querying, and analysis. We should keep this virtual sibling for reference, warranty, process optimization, and simulation. But, what could make it even more valuable? If a third sibling were added: a digital version of the product which entails everything that has happened to it throughout its lifetime. By implementing a “separation of concerns” between the recipe of what we thought we made and how the actual thing has been treated and has performed. Through doing this, we can compare what we thought we wanted to make and what we actually obtained. The third sibling would also be editable and expandable by notes from installers, customers, maintenance personnel and can be updated with new information on new replacement parts, telemetry, and IoT as well as other sensor data. Through this way we can after a year compare all of the versions of a product made on a single day with their deployed versions and actually find out how our products are doing in the wild.

By having a digital triplet we can truly have the product, its digital copy and a file of its actual use in the wild as three separate things which can all be analyzed and tracked. Interoperability of environments, systems, software, parts, and people can all be compared and continually updated. A manufacturer can not only see how well its parts have performed but also how well those serviced by Hans did. Manufacturers can track how well products do in certain countries and begin to develop more intelligent hypotheses on product life, maintenance cycles, and real-world performance. Complex systems suffer from concurrent interaction and feedback loops from various real-world forces as well as layers of interacting systems. By logging and tracking all of these in the log triplet, the effects of different firmwares, software updates and versions on part performance and interaction can be gaged.

As more firms adopt iterative versions of product development and more agile engineering methods we will have many more interactions of many different parts upon each other. With 3D printing, especially files, slicing and toolpath generation will have effects on part strength and longevity. With only the digital twin one could tell that a part was made on a particular day with a specific machine. But, you wouldn’t be able to understand what has happened to the part. The digital twin is just the product and its birth but what is its biography? What has happened to it over time? Perhaps if we learn that all of the parts that fail five years later were installed on days which were humid and rainy, then we can begin to understand the effect that life in the real world has had on that particular thing. With the complexities of additive thrown in it is through this process that we can finally begin to understand not just how unique things are made but how they live their lives as products in the real world.

https://www.quora.com/Have-3-D-printer-manufacturers-agreed-upon-a-universally-accepted-programming-language-that-accepts-templates-while-also-permitting-user-friendly-customization/answer/Joris-Peels

Images Creative Commons Attribution: Joel Cooper, Thomas and Phil Dolby.

Sintratec launches all-in-one SLS 3D print and post-processing system

Feeding the 3D printing industry’s apparent demand for peripheral/auxiliary devices, the new SLS machine from Swiss machines manufacturer Sintratec is promising “print, depowder and prepare” all in one system. Named the Sintratec S2, SLS 3D printing is completed in this system by a modular Material Core Unit, Material Handling Station, Blasting Station and Polishing Station. Together […]

AM-Flow Offers Automated Solution for Sorting 3D Printed Parts

At formnext this week, Dutch company AM-Flow is introducing its new Vision Robot, a tool that automatically removes and sorts 3D printed parts. Automation is becoming more and more of a part of additive manufacturing, but where it often stops short, the company points out, is when the 3D printing process starts. Humans are still commonly required for removing parts from machines and sorting them, which results in extra work, time, cost and sometimes human error. The Vision Robot removes humans from the equation, by automatically sorting parts.

According to AM-Flow, the robot requires only one operator to perform the amount of work that eight people would be needed to do normally. The Vision Robot can identify and sort anywhere from 200 to 10,000 parts per day, cutting labor costs by 80 percent. It’s highly accurate, with 95 percent correctness the first time in number one recommendations, and 100 percent correctness in its top three recommendations. It has shown close to zero false positives.

The Vision Robot works in three modes: manual, continuous and semi-continuous. It can be custom-made depending on the type of 3D printer farm it’s being used with, and it is built from industrial-grade components. It seamlessly integrates with other AM-Flow modules, and features a user-friendly touch screen operator console.

Part recognition takes less than one second per part, resulting in up to 1,200 parts identified per hour. The return on investment is instant, says AM-Flow, as soon as the automation results in one fewer hire for post-processing alone. It enables both high mix and high volume, says Stefan Rink, CEO of AM-Flow.

“This is the golden key unlocking industrialization and true end-to-end digital manufacturing in 3D-printing environments,” he adds.

Customers have several options, including buying the Vision Robot outright, leasing it, or a pay per part program.

AM-Flow’s goal is to accelerate the industrialization of additive manufacturing, and it offers several other modules, including:

  • AM-Expert
  • AM-Logic
  • AM-Sort
  • AM-Route
  • AM-Package

With these products, AM-Flow is striving to automate as much of the additive manufacturing process as possible. The company isn’t the first to develop a system for automating the picking and sorting of 3D printed parts; Voodoo Manufacturing is also working on a complete lights-out factory solution for 3D printing, and other companies are also taking steps to simplify and automate certain areas of post-processing. One concern may be that solutions like this could cost jobs, and that can’t be ignored, but automation isn’t always a matter of eliminating jobs so much that it is freeing up workers to spend more time on the more technical requirements of 3D design, for example. AM-Flow wants to eliminate menial labor, essentially, with its robotic products.

Formnext is taking place in Frankfurt, Germany from now until November 16th. You can visit AM-Flow at Booth H17 in Hall 3.1.

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GE Additive Announced that Concept Laser’s M LINE Factory 3D Printing System Will Be Delivered in Q2 2019

A little over two years ago, GE acquired a 75% stake in metal 3D printing leader Concept Laser. Ever since then, GE Additive has been working to review and redesign the system, software, and design architecture of Concept Laser’s M LINE FACTORY 3D printer so that it’s in line with established GE processes. The modular system has also been undergoing beta testing with some selected customers. But today at formnext in Frankfurt, GE Additive announced that its first Concept Laser M LINE FACTORY systems will finally be delivered to customers in Q2 of 2019.

The M LINE Factory provides excellent reliability and automation, which in turn drives scalable, economical series production on an industrial scale – something that most current standalone machine solutions cannot achieve. As the technology continues its transition from prototyping to production, the demand for quality 3D printers, along with operators to run them and floor space to house them, is rising.

“The positive impact the M LINE FACTORY can have on our customers’ operations and their bottom line is huge,” said Jason Oliver, the President and CEO of GE Additive. “It’s important we provide technologically advanced systems that are reliable and add value to our customers. M LINE FACTORY delivers on those commitments.”

The system is an important part of GE Additive’s focus on providing reliable, repeatable 3D printers that are ready for series production. The M LINE FACTORY has a maximum build envelope of  500 x 500 x up to 400 mm³ (x,y,z), and is optionally equipped with one to four laser sources, each one delivering 1,000 W of power.

During the last two years of lifetime and rig testing, the company identified several areas for improvement that have since been incorporated, such as the onboard software system, which offers real-time, in-situ process monitoring, modularized architecture, and superior exposure strategies. The 3D printer’s automation and in-machine architecture have been improved, and its ease of service, scalable modular system design, serviceability, process control, and thermal stability have all been enhanced.

The set-up and dismantling processes, along with part production, actually occur in two independent machine units, which can either be combined or operated separately from one another, according to the customer’s preference. This makes it possible to run production processes in parallel, instead of sequentially, which increases the output quantity and availability of the process chain and lowers downtime.

The M LINE Factory LPS, which stands for Laser Processing System, increases the laser ‘on’ time by separating the pre/post processing unit from the individual work process, while at the same time maintaining an integrated machine design. Instead of forming a single continuous unit, the LPS is made up of an independent powder module, build module, and overflow module, which are of a uniform size and can each be activated individually now for the first time. An easy to use internal transport system is used to automatically transport the modules, and to maximize the efficiency of the system’s footprint, the modules can be stacked up in a series alignment as well.

Additional features of the M LINE Factory LPS include:

  • Improved laser productivity potential due to increased overlap within the build field
  • Frontload transport system of automated internal transport system

A flexible configuration makes it possible for the build and process time to dictate the LPS to the ratio of the M LINE Factory MHS, or Material Handling Station. This processing unit, which comes with an integrated sieving station, is for powder management and pre/post processing, and automates both the upstream and downstream stages of the production process.

Additionally, the MHS uses automation, digitization, and interlinking to provide interfaces to more conventional manufacturing methods. The MHS has high safety standards, including an automated module lidding system that contains full powder and inert gas, water-flood passivation of filters, contactless powder handling, and no manual handling in the process chamber.

To learn more about the innovative M LINE Factory, which will ship to customers in Q2 of 2019, visit GE Additive at formnext this week in booth D30, Hall 3.

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[Images provided by GE Additive]

Russian Researchers Develop Neural Network for Metal 3D Printing

3D printing is not a simple process, particularly metal 3D printing. It involves a great deal of complex mathematical modeling, with calculations that can take weeks for even the most basic parts. But scientists from Peter the Great St. Petersburg Polytechnic University have developed a neural network for metal 3D printing that is trained with a large number of parameters, which allows for the faster production of parts as well as the ability to use discovered dependencies to manufacture new parts.

Neural networks are computing systems used to process large data inputs. Researchers at the university used this method to obtain 3D printing process parameters and ensure the stability of the process.

“This was very important for us, since the metal transfer, which takes place in the course of printing parts from wire, is a very complex process characterized by competing physical effects; it has, however, a critical impact on the quality of the printed part,” said Oleg Panchenko, Head of the St. Petersburg Polytechnic University’s Laboratory of Light Materials and Structures SPbPU.

The network was developed in the Mathlab modeling environment, and all data was entered manually. A tool exists for the automatic acquisition of printing process parameters, but so far this data set is being processed online. Next, the researchers will develop an online system based on a neural network that will be learning continuously. The parameters will be added to the system automatically, while their tuning will take place in the course of printing. The researchers believe that the system will improve the quality of parts as well as increase the speed of developing process parameters for further manufacturing.

The neural network is already being used to assess the quality parameters of manufactured parts – for example, if the welding process is stable, if the metal is being melted and transferred correctly, etc. The scientists have also used the network to develop stable printing modes for manufacturing mastheads. They have applied for a patent for the new technology.

“We are the first to use neural networks in electric arc deposition,” Panchenko said.

He added that neural networks will soon find applications in additive manufacturing as well. The researchers believe that the use of similar approaches in the future will allow for the creation of fully automated self-learning systems able to continuously improve the quality of manufactured parts without human supervision.

The neural network developed by the Russian researchers is another step towards the overall automation of additive manufacturing, which has the potential to not only speed up the process and improve the quality of parts but to reduce the risk of human error, which is high when complex mathematics are involved. Metal additive manufacturing still suffers from a great deal of wasted time, money and material due to failed builds, but with advancements such as this one, those failures can potentially be greatly reduced in the future.

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts below. 

[Source: Sputnik News/Images: SPBPU Media Center]

 

Ford and trinckle Partnering to Automate Design of 3D Printed Production Tools

3D printed lift assist

Popular automotive manufacturer Ford, which has long used 3D printing to fabricate assembly tools and was recently recognized for its work with the technology, is now partnering up with award-winning software company trinckle in order to automate the design process for its 3D printed production tools. The two companies will present the joint project next week during formnext.

“The additive manufacturing itself is no longer the dominating cost factor limiting the scalability of the application. Up to 50% of the total costs per tool are caused by the manual design, which is the new bottleneck. For each new line and each special edition, these tools must be specifically designed to position the badges with exact accuracy,” explained Lars Bognar, an engineer with Ford Research & Advanced Engineering Europe. “This design task is not a trivial one, as the tools have to adapt precisely to the free-form surfaces of the car body sheet. It can easily last between two and four hours to create an appropriate AM-ready design. Time that is hard to spend for the designers, who are already working at full capacity. In the worst case, a short-term demand can result in a delay of assembly because the corresponding tools are not available. It was time for us to rethink the design process from scratch, and that’s when we came across the trinckle team.”

Based in Berlin, trinckle, a 3D printing service and software company, specializes in product configuration and automated design. The company uses its cloud software paramate to create software applications, which can integrate the user into the process, for the automated design of 3D printed products across a wide range of industries, including automotive.

Many automotive manufacturers use 3D printing to fabricate assembly aids and hand tools, like fixtures and jigs. There are many advantages, including lower weight and production costs and faster availability. Ford, which currently has over 50 different 3D printed tools in serial production, is working with trinckle to further scale the applications of the technology.

Bognar and his fellow engineer Raphael Koch didn’t want to settle for just saving a little money, and decided to, as trinckle put it, look “at the AM application as a whole.” They decided to use a hand tool called a labeling jig, which places model badges on the body of a vehicle, as an example.

trinckle developed an internal application for Ford so it could efficiently generate these tools by creating new jig designs in just minutes. Employees can upload the car body’s model data, and the necessary badges, through an intuitive user interface. Then, with just a click of the mouse, standard elements like edge guides, handles, magnet mounts for fixation, and text fields can be easily added. Software algorithms generate the tool’s geometry so it fits the contour of the car body.

“The trinckle software application does not only dramatically reduce manual design times and costs, but also streamlines the entire process,” said Koch. “We enable our employees on the shop floor to take over more responsibility and relieve our designers at the same time. The latter can focus on their core activities again.”

Now, instead of lasting two to four hours, the design process only takes 10 minutes, thanks to the straightforward handling provided by paramate. Because AM-compliant design expertise is not necessary, assembly line employees can easily design 3D printable tools on their own and independently carry out tool optimization iterations.

Using automation to design 3D printable labeling jigs is only the first step in the right direction for Bognar and Koch, and in the near future, other additive tools will likely undergo similar automation.

To learn more about this work with Ford, and its other business applications, visit trinckle at booth C07 in Hall 3.0 at formnext in Frankfurt next week. Bognar and Dr. Ole Bröker, the Head of Business Development at trinckle, will also be presenting the joint project at the TCT Conference during the show.

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Digital Metal Introduces Fully Automated Additive Manufacturing

 

 

 

 

 

Digital Metal introduced its binder jetting 3D printing technology back in 2013, though its printer, the DM P2500, wasn’t made commercially available until last year. Since its introduction, Digital Metal technology has produced more than 300,000 components, and the printers are capable of producing up to 40,000 components at a time in serial production. Digital Metal is at the forefront of true production-level additive manufacturing, and now the company is about to take a huge leap forward with the introduction of a fully automated production concept.

The new process will be controlled by a robot, eliminating virtually all need for human hands. The robot will feed the 3D printer with build boxes and then move the boxes for post-treatment in a CNC-operated de-powdering machine that is combined with a pick-and-place robot. The parts will be placed on sintering plates as the remaining powder is removed and recycled. The first robot will then move the plates to the sintering furnace, where debindering and sintering will take place. This can be used either for batches or for continuous production.

“Most AM technologies show a very low level of automation,” said Ralf Carlström, General Manager at Digital Metal. “Our aim is to change that. With the new no-hand production line, our customers can further improve their productivity and lower the production costs. Almost all manually intensive work can be eliminated and in addition the powders removed in the cleaning machine can be recirculated in the process, thus minimizing waste. As we see it, the Digital Metal technology is now applicable for serial production of high-volume components.”

During the de-powdering stage, the CNC-controlled movements are based on the information from the printing process. All of the removed powder is collected and recycled without any degeneration of properties.

“We believe there is a huge potential for our unique technology,” said Carlström. “Not only is it very fast and cost-effective, it is also able to create complicated and highly detailed designs with wide material choice.”

Other companies have been working toward full automation in the additive manufacturing process; one example is Project Skywalker, which was initiated by Voodoo Manufacturing. Digital Metal’s process, however, is more complex as it involves the extra steps of de-powdering metal parts, rather than simply removing them from the build plates. This brings additive manufacturing closer to being a real large-scale production method, removing the need for human intervention throughout the process. Digital Metal describes itself as “making great strides into territories previously ruled by conventional manufacturing technologies,” and that’s never been truer as it creates a hands-off 3D printing factory.

Digital Metal’s technology is an extremely precise type of binder jetting; the company isn’t just pumping average components off the production line. Skeptics of additive manufacturing as a legitimate manufacturing process will need to take a hard look at what Digital Metal is doing; its new automated production process takes the technology a big step forward in challenging more traditional manufacturing processes.

Digital Metal will be at the formnext conference next month, which is taking place in Frankfurt from November 13th to 16th.

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[Images: Digital Metal]