A publication of AUTOMATION

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CONTENTS
Join SME
MARCH 2021 VOL. 163, NO. 3 [Link]/join

Cover: The longstanding trend

ION
AUTOMAT
A publication of

toward manufacturing automation

[Link] | March
2021

has been accelerated by the

COVID-19 pandemic, which is
also pushing automation into new
areas. Cobots in particular, such
as the one pictured on our cover,
are easier to implement than their
traditional cousins. (Photo provided
by FANUC America)

FEATURES
34  Automation in the Age of COVID-19
ED SINKORA,CONTRIBUTING EDITOR
Safer, faster, and more intelligent
solutions aid industry in a pandemic.

42  Automation for Everyone

GEOFF GIORDANO, CONTRIBUTING EDITOR

Automation was once only for big factories,

but now small job shops can benefit as well.

SHOP SOLUTIONS 50  The Connected Control

KIP HANSON, CONTRIBUTING EDITOR
26     30     The Internet and cloud-based computing are changing how
Bike Maker Discovers Advanced Toolholding manufacturers operate CNC machine tools. Is your shop ready for it?
Time and Cost Savings
with Specialty Toolholder
Secures Part Quality
for High-End Job Shop
56  Parting and Grooving for the Long Haul
BILL KOENIG, SENIOR EDITOR
When Trek Bicycles, based Precision Swiss Products
in Waterloo, Wis., recently Inc. of Milpitas, Calif., Providers of parting and grooving tools continue to innovate one
invested in a five-axis pursues jobs that require of the toughest applications in machining.
machine, it had to make a
decision about which tools to
tight tolerances combined
with intricate, complex 60  Simulation Software Meets the Need for Speed
use. Trek needed reach more geometries. Some jobs PATRICK WAURZYNIAK, CONTRIBUTING EDITOR
than rigidity or high-power may require half a dozen The latest additions for CNC toolpath simulation add speedier
cutting. While needing high operations with very programs, better accuracy and digital twin capabilities.
accuracy and rigidity, frequent small tools. To hold tight
tool changeovers meant tolerances, 90 percent of
shrink-fit tools would take the shop’s collet toolholders
too much time. The solution are Rego-Fix Super High-
they found was the MEGA Precision ER16 collets. In
Micro Chuck from BIG Kaiser addition to its ER collets,
Precision Tooling Inc. The slim the shop relies on Rego-
nut and simple collet clamping Fix powRgrip toolholders,
turned out to be the best of which can be loaded and
both worlds for Trek. Reach unloaded quickly, for its
issues were eliminated and milling machines. Because
programming to eliminate no heat is used, tools can be
excessive tilt became easier to used immediately after a tool
accomplish. change.

2 Manufacturing Engineering | March 2021

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CONTENTS CONNECT &
ADENGAGE
INDEX
PLAN–DO–NETWORK–LEARN
DEPARTMENTS
6 Up Front APRIL
ALAN ROOKS, EDITOR IN CHIEF

GM Electrifies its Future Feature articles in this issue:

• Wohlers & Associates:
9 SME Speaks AM Outlook
GRAHAM BREDEMEYER, ZVERSE INC. • AM in Aerospace Applications
SME MEMBER SINCE 2020
• Servo Drives and Motors
Assessing and Reducing Technical Debt
• Machine Tool Maintenance
in Design and Manufacturing
• Assembly Systems
12 Advanced Manufacturing Now
EDWARD STOCKLINE, APPLICATION ENGINEER
PROMESS INC. MAY
PPE Helps Dental Students Complete Training Feature articles in this issue: Special Section:

14 Advanced Manufacturing Now

• Industry 4.0 for Small
to Medium Enterprises
Laser

COLIN FROST, COO, CARR LANE MANUFACTURING

• Indexable Tooling
Using Spring-Loaded Fixtures in Automation
• Laser-Based Measurement
16 NewsDesk
COMPILED BY BILL KOENIG,SENIOR EDITOR
JUNE
Boeing Looks to Move On From 737 Max Crisis
Feature articles in this issue: Special Section:
22 Additive Manufacturing Update • Swiss-Style Machining Tooling & Workholding
JILL CHRISTNER, PRESIDENT AND GM OF THE AMERICAS • Abrasive Machining
SLM SOLUTIONS GROUP
• Rotary Transfer Machines
The Next Chapter in AM: 12-Laser Printing
• Tool Balancing
33 SME Education Foundation Report • Holemaking
ROB LUCE, VICE PRESIDENT,
SME EDUCATION FOUNDATION
Pine Bush High School and Saginaw ISD
Change Learning Approaches in the Age of COVID

66 Company Profiles
75 Product Previews
77 Classified Ads
78 CEO Roundtable
An Insider Perspective on Although reasonable efforts are taken to ensure the accuracy of its published material, SME is
not responsible for statements published in this magazine. Readers are advised that SME shall
Manufacturing’s Future not be liable to any person or company for losses or damages incurred as a result of accepting
any invitation or offer contained in any advertisement published in Manufacturing Engineering®.
Copyright © 2021 by SME. Photocopy information: Users registered with the Copyright Clearance

80
Center, 21 Congress St., Salem, MA 01970, can purchase copies at $2.00 each referring to serial
fee code 0361-0853/88/$2.00. All other photocopying without the permission of SME is prohibited.
Viewpoints Reprint information: For tearsheets, reprints, and bulk orders, write Chris Mahar, cmahar@[Link].
Available on microfilm/microfiche from University Microfilms International, 300 N. Zeeb Rd., Ann
DAVID SUICA, PRESIDENT FASTEMS LLC Arbor, MI 48106. Canada Post Publication Mail Sales Agreement No. 1436813

Dispelling Factory Automation Myth #1

81 Ad Index

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4 Manufacturing Engineering | March 2021

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UP FRONT
A LETTER FROM THE EDITOR
1000 Town Center
Suite 1910
Southfield, MI 48075

Editorial Staff

GM Electrifies its Future

Editor in Chief
Alan Rooks
847-239-0070
arooks@[Link]
Editor in Chief
Smart Manufacturing
GENERAL MOTORS dropped a fuel not made via traditional machining Brett Brune
213-332-4076
bomb on the auto industry at the end processes. Suppliers will have to bbrune@[Link]
of January. Specifically, it said the fuel reassess and retool—and fast. Senior Editor
of the future for many of its vehicles It’s no coincidence that President Bill Koenig
313-425-3058
will be electricity, not gasoline. For an Biden has committed to transitioning bkoenig@[Link]
iconic company like GM, that news is the U.S. economy away from oil, gas Senior Technical Editor
Bruce Morey
beyond big. and coal and toward solar, wind and 313-425-3256
GM has pledged to stop making other clean energy. The Biden admin- bmorey@[Link]

gasoline-powered passenger cars, istration is expected to announce by Associate Editor

Chris Mahar
vans, and SUVs by 2035, a major pivot April that it will introduce rules requiring 313-425-3160
point for the legendary U.S. automaker. cars to reach an average of 51 miles cmahar@[Link]

“As one of the world’s largest auto- per gallon by 2026. The proposal will Contributing Editors
Geoff Giordano
makers, we hope to set an example of likely include additional provisions geoffgio@[Link]
responsible leadership in a world that is designed to boost the production and Kip Hanson
kip@[Link]
faced with climate change,” GM CEO sales of electric vehicles. In addition,
James Lorincz
Mary Barra said on LinkedIn. the bellwether state of California jameslorincz42@[Link]
“GM has said it would invest will stop sales of gasoline-powered Ed Sinkora
$27 billion in electric vehicles and automobiles within 15 years, according ed@[Link]

associated products between 2020 to an announcement by Gov. Gavin Patrick Waurzyniak

pwaurzyniak@[Link]
and 2025, outstripping its spending Newsom in September.
Ilene Wolff
on conventional gasoline and diesel [Link]@[Link]
ALAN ROOKS
Editor in Chief
vehicles. That figure includes refurbish- Plenty of Company Business Staff
Vice President
ing factories and investing in battery GM is said to be following in
SME Media
production in conjunction with LG the footsteps of other carmakers. Dave O’Neil
313-425-3260
Chem, a South Korean battery maker,” Volkswagen plans to launch upwards doneil@[Link]
wrote Steven Mufson in an article in of 70 new electric models in the next Audience Manager
The Washington Post. 10 years, increase EV production to 22 Mary Venianakis
905-755-0783
GM said that by 2025, about 40 million during this decade, and spend mvenianakis@[Link]
percent of its U.S. models will be $33 billion to electrify its other vehicles. Digital Product Manager
Marty Watson
battery-powered electric vehicles, and Ford is spending $11.5 billion through 313-425-3099
it has promised to make its factories 2022 on new EVs. Both companies are mwatson@[Link]

and other facilities carbon neutral by said to be chasing Wall Street darling Digital Engagement Manager
Courtney Dobson
the year 2040. Tesla, which also plans to increase 313-425-3108
What does this mean for the sales of its all-electric auto fleet. cdobson@[Link]

metalworking industry, which supplies So, what could go wrong here? Creative Staff
Senior Graphic Designer
GM and other automakers with Plenty. A different presidential adminis- Barry Sloan
parts—including traditional drivetrains? tration hostile to alternative fuels could 313-425-3195
bsloan@[Link]
First and foremost, it will bring market take office in the U.S. Customers could
Address &
disruption on a vast scale. Fully electric reject EVs. But even with those risks, Subscription Changes
313-425-3264
vehicles require a completely different it appears that automakers have seen magazines@[Link]
set of parts, including many that are the future, and it is electric.

6 Manufacturing Engineering | March 2021

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 SME SPEAKS
GUEST EDITORIAL

Assessing and Reducing Technical Debt

in Design and Manufacturing
TECHNICAL DEBT is not on your balance sheet, eventually become debt as the world around them
not addressed on your roadmap and often an evolves. If you have ever sent a legacy 2D-CAD
afterthought, but ultimately can be the difference file to an on-demand manufacturing company
between executing swiftly and being paralyzed only to find out they would not quote your work
as you scale, grow and support your product(s). without a 3D-CAD file, you may have experienced
Technical debt is the cost of design decisions made how paralyzing technical debt can be. The reality
that do not position your product for future growth. is, oftentimes, addressing this type of debt is not
Most of my career has been at the intersection a priority until you are in a situation like this, where
of mechanical engineering, software engineering you need a mission-critical part manufactured that
and material science. Sitting at the intersection was designed 30 years ago and is only saved in
has given me a look into the differences between a 2D format. It is at this point of need that you
the development processes in each discipline. have to decide whether to redesign the part in 3D,
While there is good cause for significant differences manually, ask a partner to do so or attempt to find
in development workflows, I believe each could a different vendor that will accept and quote the
benefit from adopting patterns from one another. work as-is. For a mission-critical component, this
In the world of software development, technical process can mean losing tens of thousands of
debt is an “early and often” consideration as dollars in productivity or worse.
2D-CAD files are not the only form
of technical debt that may be living in
your design and manufacturing assets.
GRAHAM
For example, assets that do not contain BREDEMEYER
full definitions for a product, post-pro- ZVerse Inc.
SME Member
cessing requirements that are not called Since 2020
out, lack of interoperability requirement
Converting 2D-CAD to 3D-CAD files at scale remains the roadblock callouts and many more are all forms
standing in the way of the digital manufacturing journey for
legacy and MRO parts. ZVerse’s automated solution removes this of technical debt that may accrue in
obstacle, ushering these parts into the digital manufacturing realm your assets and result in manual work
at a lower conversion cost and faster timeframe.
that will be repeated time and again
engineers determine how to best structure data when assets are put to use without a system and
and systems to support future development. In process in place to update/maintain these assets.
doing so, they avoid future rework as they add
new features and modules to their product. In Processes Can Lead to Technical Debt
addition, to the extent that it is possible, they also Development and business processes can
avoid creating assets and data structures that are unknowingly be a source of compounding technical
unusable as entirely new products are created. debt. Arguably, this is a higher-risk form of technical
Where does technical debt come from? debt than asset depreciation as this debt accrues
systematically. In addition to occurring systemati-
Assets Depreciate as the World Evolves cally, this debt tends to build on top of other debt
Just like any asset you own, if left unmain- because it is built into a process that is recurring in
tained, design and manufacturing assets your organization. Process-driven technical debt

March 2021 | [Link] 9

SME SPEAKS

can include things such as: lack of continuity between product • Maintainability: Is this asset something that can be main-
requirements and user needs, unclear interoperability require- tained to support future processes and development?
ments, lack of a roadmap, inconsistent DFM requirements, While these are important factors to consider when
unrecorded group knowledge, lack of input from stakeholders assessing technical debt, there may be many other factors
in the process and many more. Given these process failures, that make an asset or process prone to creating or holding
technical debt is often allowed to accrue, unchecked and technical debt. I would highly recommend considering any
compounding. Ultimately, this leads to assets that will depreci- factors that might impact this in your organization.
ate further over time as the organization around them evolves
or assets that will need to be recreated entirely as more Addressing Technical Debt
information is presented that was not captured in process. Although there are many ways to address technical
debt that are specific to each individual organization, there
How You Can Assess Technical are some overarching paths you might want to consider.
Debt in Your Organization For example, if you have identified a significant backlog of
Design and manufacturing assets are a great starting technical debt in legacy assets such as 2D-CAD files, it is
point when assessing where technical debt exists in your important to prioritize those assets by risk of need and begin
organization. Not only can you quickly determine any tech- converting those files into assets that give you maximum
nical debt that may be associated with your assets directly, optionality for production or design rework. This way you
but if you follow the chain of ownership of the assets, you never find yourself in the tough position of “paying off”
can backtrack the processes that were gone through that debt when you desperately need a part or design change.
allowed the debt to either be created, accrue or persist. For example, the quickest and most cost-effective way to
When assessing an asset or process for risk of technical transition that debt off of your CAD asset balance sheet is to
debt, it is helpful to look for the following characteristics: find, assess and convert those assets into 3D-CAD models
• Extensibility: Is there anything standing in the way of using advanced automation.
extending the function of a given part or assembly? Aside from lingering technical debt on assets, if you
Does this process support extending to new variables? identify processes that are generating technical debt in your
• Scalability: Is the asset able to scale in production with organization, it is important to re-engineer processes to work
the details provided? Can this process scale without as much of this out of the process as possible. To ensure key
generating assets that carry technical debt? processes are not generating technical debt, you might want

2021 SME OFFICERS INTERNATIONAL DIRECTORS 2021 SME EDUCATION

AND DIRECTORS Jeffrey A. Abell, PhD, FSME, PE
General Motors
FOUNDATION BOARD
PRESIDENT
OF DIRECTORS
Edye S. Buchanan, CMfgT
Michael D. Packer, FSME BriskHeat Corp. PRESIDENT
Lockheed Martin Aeronautics Co. (retired)
Robert W. Ivester, PhD, FSME Joseph A. Kann
2021 SME President
Department of Energy Cobble Creek Solutions
PRESIDENT-ELECT
Lonnie J. Love, PhD, FSME VICE PRESIDENT
Dianne Chong, PhD, FSME, NAE
Oak Ridge National Laboratory Frank W. Ervin III
The Boeing Co. (retired) Piston Group LLC
VICE PRESIDENT Dean S. Phillips
Link Systems SECRETARY/TREASURER
James W. Schlusemann John F. Miller
Prosperia International LLC Susan M. Smyth, PhD, FSME, NAE Siemens Digital Industries Software
TREASURER National Science Foundation/U.S. Army
DIRECTORS
Winston F. Erevelles, PhD Rebecca R. Taylor Adam Claytor
St. Mary’s University The National Center for Manufacturing Sciences Coltrane Logistics LLC
SECRETARY Albert J. Wavering, FSME Valerie I. Freeman
Vincent W. Howell Sr., FSME, CMfgE National Institute of Standards and Technology
Washington Park High School
Corning Inc. (retired)

10 Manufacturing Engineering | March 2021

to make sure the following are in place: good model-based • Valerie I. Freeman, Manufacturing and Robotics Teacher,
definition practices, strong organizational use of PLM/PDM Washington Park High School, Racine, Wis.
tools, organizational use of tools that capture input from all • Wayne F. Frost, LSME, CMfgE, Deere & Co. (retired),
stakeholders early in processes, a transparent roadmap, Waterloo, Iowa
the use of a strong DME (Digital Manufacturing Enablement) • Andrew M. “Andy” Jones, Portfolio Manager,
platform, and many more tools and processes that can all be Seizert Capital Partners, Birmingham, Mich.
good for helping to reduce technical debt. • Robby Komljenovic, Chairman and CEO,
Acieta, Milwaukee
2021 SME Education Foundation • Arthur F. McClellan Jr., Head of Supplier Diversity,
Board Officers and Directors Take Office Valeo, Detroit
The SME Education • Chris Rake, Vice President of Programs, FIRST,
Foundation’s 2021 Manchester, N.H.
Board of Directors have • Kyle Riegel, Field Sales Engineer, Schunk Carbon
taken office. As the Technology, Waterloo, Iowa
governing body of the • Joseph A. “Joe” Tate, Second District Representative,
Foundation, the board Michigan House of Representatives, Detroit
is comprised of leaders • Marion Wells, Founder, Human Asset Management,
from industry, academia as well as community leaders. Flossmoor, Illinois
2021 SME Education Foundation Officers: • Meghan West, Vice President and CEO, CNC Software
• President — Joseph A. “Joe” Kann, President, Inc., Vernon, Conn.
Cobble Creek Solutions, Racine, Wis. The SME Education Foundation Board of Directors will
• Vice President — Frank W. Ervin III, Group Vice assist and support Foundation staff in executing a five-
President, Piston Group LLC, Southfield, Mich. year strategic plan, including its commitment to diversity,
• Secretary/Treasurer — John Miller, Senior Vice President, equity and inclusion for minority and female students,
Siemens Digital Industries Software, Frisco, Texas across all activities and initiatives offered by the SME
2021 SME Education Foundation Directors: Education Foundation.
• Adam Claytor, CEO and President, Coltrane Logistics, Officer and director photos and biographies are
Detroit available online at [Link]/about-smeef/leadership.

Wayne F. Frost, LSME, CMfgE

John Deere Waterloo Works (retired)
2021 SME Gregory A. Harris, PhD, PE
Auburn University
Andrew M. Jones
MEMBER COUNCIL Teresa J. Rinker, PhD
Seizert Capital Partners CHAIR General Motors
Robert Komljenovic William R. Sniadack Phillip S. Waldrop, PhD, LSME
Acieta Neles Corp. USA Inc. Georgia Southern University (retired)
Arthur F. McClellan Jr. CHAIR-ELECT Michael R. Watson, LSME, CMfgE
Valeo Jennifer C. Fielding, PhD AAF/Flanders (retired)
Air Force Research Laboratory Jason B. Wolf
Christopher Rake
FIRST IMMEDIATE PAST CHAIR Air Force Research Laboratory

Kyle M. Riegel Brett A. Peters, PhD EXECUTIVE DIRECTOR & CEO

Schunk Carbon Technology University of Wisconsin-Milwaukee Robert Willig
Joseph A. Tate COUNCIL REPRESENTATIVES CHIEF FINANCIAL OFFICER
Michigan Legislature Zachary P. Bibik Craig Connop
Vestas Blades NA CHIEF OPERATING OFFICER
Marion Wells Steve Prahalis
Human Asset Management Vesna Cota
VMMI CONTACT SME
Meghan West [Link] / leadership@[Link]
Gabriela Darras
CNC Software Inc.
Caterpillar Inc. 800.733.4763 / 313.425.3000

March 2021 | [Link] 11

ADVANCED MANUFACTURING NOW
INNOVATION IN MANUFACTURING PROCESSES

PPE Helps Dental Students Complete Training

THE COVID-19 PANDEMIC shut down the Independence Township, Mich., fire department
University of Detroit’s dental education programs and an assisted living facility in Flint, in April.
in early 2020, and reopening them depended in
part on securing adequate supplies of personal Challenge, Meet Solution
protective equipment (PPE) to keep the students In May, Dr. Mike Pyatenko, DDS, Assistant
safe. Given the worldwide shortage of PPE, Professor at the University of Detroit Mercy
that was not an easy challenge to overcome, Dental School, read about the project in a local
but it had to happen before the students could newspaper and saw an opportunity to help get his
continue their education. students back to work.
At the same time, employees at Promess “The face shields Promess was producing
Inc., Brighton, Mich., were assembling an ad hoc caught my eye,” said Pyatenko, “so I reached
team of management, assembly and mechanical out to Promess to see if they could help us. They
engineering personnel with the goal of finding responded with samples for us to test and then
a way to produce PPE for local hospitals, first supplied enough to equip 288 of our students,
responders, dentists, traveling nurses, homeless which would get them through a whole semester.”
shelters and nursing homes in Southeastern Promess donated 320 face shields to the
Michigan. Promess is a manufacturer of advanced program to be used by first- and second-year
industrial assembly systems and components, students. The full PPE suite consists of a med-
typically used on assembly lines to make engines ical-grade gown, single or double face masks,
and transmissions for cars, internal compo- goggles or eyeglasses with side shields, gloves
nents for dishwashers and washing machines, and the Promess-made face shields.
EDWARD
STOCKLINE
and equipment that makes medical devices. All students are trained in the proper donning
Application Engineer Producing PPE was not part of its regular skill and doffing of their PPE. The face shields are
Promess Inc.
set, but the team was determined to produce cleaned with approved surface disinfectants
emergency supplies of PPE and, with the support between uses to prolong their service life.
of Promess management, they did. Pyatenko expected the face shields to remain
Since business was slow during the onset of serviceable for an entire semester.
the COVID-19 pandemic, instead of laying off “Needless to say, the University of Detroit
employees the company shifted to temporarily Mercy School of Dentistry is very appreciative
manufacturing PPE. Stephanie Price, software that Promess was willing to help us remove a
engineer for Promess, sourced the elastic straps, significant stumbling block toward our students’
plastic sheeting, and foam needed to create education and safety,” he said.
face shields and set up a manual assembly line. The University of Detroit Mercy Dental School
Employees were taught how to assemble the has been educating dentists and hygienists for
components and they produced thousands of more than 86 years. From its Detroit campus, the
face shields; when business returned to normal a School is dedicated to serving the City of Detroit
month later, Promess had plenty to share. and surrounding communities through its clinic
The first products were shipped to St. Joseph and outreach programs. These include senior
Mercy Hospital in Howell, Mich., Children’s outreach, a clinic at University Health Center at
Hospital in Detroit, several Brighton-area dentists’ the Detroit Medical Center, and a mobile clinic
offices, a group of local traveling nurses, the serving elementary school students.

12 Manufacturing Engineering | March 2021

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TO THE CORE
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ADVANCED MANUFACTURING NOW
INNOVATION IN MANUFACTURING PROCESSES

Using Spring-Loaded Fixtures in Automation

PART HOLDING FIXTURES are critical for Spring plungers have a cylindrical plunger
precisely holding and locating parts. Most such with a rounded end. Spring plungers are well
fixtures use locators for positioning. No matter suited for a variety of applications, such as the
how well a fixture is designed, unless the parts are workpiece ejector. They can also be integrated
properly positioned against the locators—every into other fixture elements to provide force in any
time—mistakes will occur. Automation only makes necessary direction.
this problem worse because unlike humans,
robots are, generally, unable to make fine adjust-
ments to workpiece positioning.
Spring-loaded devices are a common
solution to reliable part positioning. A key feature
is that when the workpiece is positioned horizon-
tally, spring-loaded devices play the additional
role of retaining the workpiece before and after
clamping. In automated systems and pallet pools,
this function is critical to prevent damage to the
work center.
There are a wide variety of spring-loaded
devices on the market, including spring locating
pins, spring stop buttons, ball plungers and spring
plungers. Here are some practical tips on their Spring stop buttons are available with a spherical
contact button, flat face, or flat face with tag.
features and how best to use them. (All images provided by Carr Lane Manufacturing)
COLIN FROST
COO
Spring locating pins push the part against
Carr Lane fixed locators. This ensures proper contact Spring plungers are available in various lengths
Manufacturing
[Link]
during clamping. Spring locating pins help and end pressures, in stainless and mild steel. They
reduce errors by correctly positioning the part are also available with Delrin plungers for applica-
against the locators. In addition, the pins also tions where marring is a concern. Spring plungers
eliminate the need for a “third hand” when have nylon-type locking elements on the threads.
clamping some parts. Their small size and Part sensing uses spring-loaded devices
compact design make them useful for smaller as the most efficient way to ensure the proper
parts or confined spaces. A protective rubber loading of workpieces, but verification should
seal around the contact pin helps seal out chips be used to prevent expensive errors. When a
and coolant. workpiece is not properly loaded, and automated
Spring stop buttons are another commonly clamps are signaled to perform, operation clamps
used spring-loaded device. These units work can be easily damaged. This process interrupts
much like spring pins, but they are designed production and results in downtime. There are two
for parts where more travel or force is needed. types of part sensors: physical contact sensors
Spring stop buttons are made with three and proximity sensors.
different contact faces. The first is a spherical Air-sensing rest devices allow one or more
button contact; the other two have flat contacts. rest buttons to act as both a rest button and a
The flat-face contacts are made either with or sensor. A modular unit consisting of a threaded
without a tang. body is installed in a fixture, which holds a

14 Manufacturing Engineering | March 2021

precision floating plunger. This plunger has a reamed or Clamp position monitoring: Once it has been deter-
tapped hole available in a choice of three diameters and mined that the workpiece has been loaded properly, the
accepts any height of standard press-fit-type rest buttons. workpiece can be clamped. Before machining can begin it
Proper placement of a workpiece on the air rest button is ideal to determine that the clamps are in the appropriate
assembly causes the plunger to fully retract into the body. position. Typically, this position monitoring is only available
This seals off airflow, which increases the overall pressure on clamps powered through pneumatic, hydraulic, or
of the system (30 psi maximum air pressure). This pressure electric means.
value can be read using an analog or digital pressure sensor, Adjustable pneumatic position monitoring uses a
which can then be tied into a PLC or control system. small pneumatic cylinder that is contacted by a bolt attached
The primary advantage of a physical contact sensor is
that it is difficult to “fool” or “foul.” This is a common issue
in the subtractive manufacturing process, which produces
metal or plastic chips. These chips can build up around a
sensor and send a false positive. The air sensing rest button
further reduces the potential for fouling by positioning the
sensor under the workpiece.
There are applications when a physical contact sensor
is not possible or appropriate. They include applications
with light workpieces, high-speed sensing applications, and
applications with complex geometry.
Through-hole rest buttons are non-contact sensors
consisting of a 0.06" (1.52-mm) through hole that allows air An adjustable pneumatic Schematic of an electric
position monitoring device. position monitoring device.
to travel through and detect whether a part is loaded using
an air-gap measurement sensor. These sensors use back to a clamp arm to depress the cylinder, increasing pressure
pressure, created when loading the part, to measure the in the system that can then be monitored by a gauge. This
distance between the end of the rest button and the work- system is used most often in applications where workpiece
piece. Unlike physical contact sensors, non-contact sensors size varies slightly from part to part, such as sand castings.
can be mounted in a variety of ways. The through-hole rest Pneumatic position monitoring uses a switch rod con-
button also contains a #10-32 tapped hole on the shank for nected to a signal sleeve inside of a housing. The signal sleeve
installation of a threaded nipple for easy air-line installation. creates back pressure within the pneumatic monitoring loop,
which can be monitored using a gage.
This type of device requires additional
space below the fixture.
Electric position monitoring uses
adjustable inductive proximity switches
and a switch rod. Unlike pneumatic ver-
sions, they typically require no additional
sensors, nor do they increase plumbing
complexity. They are not typically
suitable in applications that require them
to be disconnected frequently. Coolant
and metal chips also present hazards
to electrical components. Special care
is required when using electricity in
machine tools.

March 2021 | [Link] 15

NEWS DESK
TRENDS AND IDEAS IN MANUFACTURING

Boeing Looks to Move On From 737 Max Crisis

B
oeing Co. in January agreed corporate culture. The 737 Max is one The question is whether outsiders
to pay more than $2.5 billion of Boeing’s most important aircraft. agree with Calhoun, and that remains
because of fatal crashes Boeing had been viewed as an to be seen. Calhoun’s memo acknowl-
stemming from problems enterprise with engineering excellence, edges that Boeing still faces challenges
with the 737 Max. The company is an image that took a huge hit following in rebuilding its image. “While we
looking to the settlement as a way to the crashes that killed 346 people. deeply regret the conduct described
move on from a corporate crisis. The 737 Max was grounded in March in the agreement, I am confident that
The Chicago-based maker of 2019 as a result. In late 2019, one it isn’t reflective of our employees as a
aircraft will pay the U.S. government Boeing CEO lost his job and now it is whole or the culture or character of our
a $243.6 million fine; another $500 seen as a company that placed profit company,” Calhoun wrote.
million to families of those killed in two over safety. The CEO may be confident. But
737 Max crashes; and $1.77 billion Boeing is fighting to change all that. his memo isn’t the last word. Boeing’s
to its airline customers for losses U.S. regulators in November approved performance from here on out will tell
the aircraft’s return to the air. the tale.
The company is working with —Senior Editor Bill Koenig
regulators in other countries
as well. Manufacturing Expected
Boeing wants to put the to Expand in 2021
737 Max controversy in the Manufacturing should expand this
past. Current CEO David year as the sector continues to recover
Calhoun, who took com- from the COVID-19 pandemic, the
mand in early 2020, sent a Institute for Supply Management said in
memo to employees. A copy a forecast.
was embedded in a tweet
by Reuters reporter David
Shepardson.
Calhoun’s memo said
The Boeing 737 Max.
former Boeing employees
demonstrated “deep disre-
stemming from the grounding of the spect” to the U.S. Federal Aviation
737 Max. Administration (FAA) concerning the
The U.S. Justice Department 737 Max and “intentionally” failed to
agreed to defer prosecution for three inform regulators about key changes in
years as long as Boeing “abides by the its design.
obligations” of the accord, according to “This is a substantial settlement of
a company statement. After that time, a very serious matter,” Calhoun wrote.
charges will be dismissed. The CEO said the settlement was Manufacturing revenue is forecast to rise 6.9
Issues with the 737 Max cost “the right thing to do.” It was a move percent in 2021 compared with a 1.3 percent
decrease last year, according to ISM.
Boeing much of its reputation. that “appropriately acknowledges
Investigations into what happened how we fell short of our values and “I think we’re back to a growth
revealed problems with Boeing’s expectations.” cycle,” Timothy R. Fiore, chair of

16 Manufacturing Engineering | March 2021

the group’s Manufacturing Business Slow Auto Recovery Is Forecast GF Machining Solutions Shifts
Survey Committee, said on a confer- The global auto industry will Sales Model in Some States
ence call. “Business needs clarity, it experience a slow recovery in 2021 GF Machining Solutions LLC,
needs certainty.” from the COVID-19 pandemic, analysts Lincolnshire, Illinois, is transitioning in
The forecast is based on a survey of at IHS Markit said in December. “We’re phases to a direct sales and support
purchasing and supply executives in 18 recovering off the bottom,” Colin model in several key states.
industries by Tempe, Ariz.-based ISM. Couchman, an IHS Markit analyst said. Effective Jan. 1, GF Machining
The survey was conducted in December That bottom, he said, was April 2020. Solutions began to directly support
after the U.S. presidential election. ISM California, Indiana,
also produces a monthly manufacturing Iowa, Kentucky,
index, known as the PMI. ISM forecast Minnesota, Nevada,
that manufacturing revenue will rise 6.9 North Dakota,
percent in 2021 compared with a 1.3 Ohio, Oregon,
percent decrease last year. South Dakota,
The institute said 15 of 18 industries Washington and
expect revenue to increase. Those Wisconsin, which
sectors include transportation equip- were previously
ment, non-metallic mineral products, served by Ellison
machinery, primary metals, and Technologies.
fabricated metal products. “GF Machining
Respondents also reported they Solutions
The global auto industry will experience a slow recovery in 2021
were operating at 85.7 percent of and Ellison
from the COVID-19 pandemic, according to IHS Markit.
capacity at the end of 2020. That was Technologies
up from 75.9 percent in May, when “Some economies managed to get have enjoyed a successful partnership
manufacturing had been hammered to grips and are now close to being over the years and this transition was
by the COVID-19 pandemic. COVID secure,” he added, referring to a mutual decision on the part of both
Factories in various industries China. “Elsewhere, lockdowns have companies,” said Phil Hauser, presi-
closed plants starting in March to been used but really haven’t controlled dent and head of market region North
slow spread of the virus. Plants later it,” he added, referring to Europe. & Central America for GF Machining
reopened with new safety procedures. In addition to those regions, the Solutions. “We are excited to take
Vaccines have been developed United States is enduring a second these important steps to be closer to
although there have been problems in COVID-19 wave, with widespread our customers.”
getting them administered. Fiore said outbreaks across the country. Orders placed before Dec. 31 were
respondents in the survey indicated “For some economies, the strategy to be handled by Ellison Technologies
optimism that the bulk of the U.S. appears to be to wait for the (COVID- in cooperation with the GF Machining
population will be vaccinated by the 19) vaccine,” Couchman said. “The Solutions direct sales team. All new
end of this year. general opinion is we’re starting to see orders taken after Jan. 1 will be
The survey also forecast that capital more of a brighter light at the end of accepted and supported directly by GF
expenditures in manufacturing will the tunnel.” Machining Solutions.
rise 2.4 percent in 2021, compared In North America, auto plants were The expansion of GF Machining
with a decline of 2.4 percent last year. shut down starting in March 2020 to Solutions’ direct sales and service
Respondents also expect that employ- try to slow the spread of the virus. support organization is backed by its
ment levels will increase by 2.5 percent Factories reopened in May with new growing team of sales managers, field
compared with 2020 levels. safety procedures in place. service engineers, application engi-
—Senior Editor Bill Koenig —Senior Editor Bill Koenig neers and phone support associates.

March 2021 | [Link] 17

 NEWS DESK

The company’s after-sales service

team will be further strengthened and
all support efforts will be streamlined
and coordinated through GF Machining
Solutions’ customer service organiza-
tion, according to the company.
Customers in affected states
have been contacted directly by GF
Machining Solutions.

GWS Tool Group Acquires

Taurus Tool & Engineering
GWS Tool Group, Tavares, Fla., has
acquired Taurus Tool & Engineering,
which is based in Batavia, Illinois. It is
Taurus Tool & Engineering’s manufacturing facility. (Provided by Taurus)
the first acquisition in 2021 for GWS
Tool Group, following three previous Taurus is a manufacturer of preci- the categories of both HSS and car-
acquisitions in 2020. sion custom cutting tools, primarily in bide holemaking and milling tools. The

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complex HSS and carbide step tools GWS’ CEO. “On the carbide side, they training equipment and interactive,
for aerospace and automotive appli- bring a host of complementary skill multimedia e-learning courses, has
cations, custom thread-on modular sets to our organization, while bolting joined LIFT as a Silver Member,
tooling and combination tools for the on new capability in the areas of expanding its long-term relationship
elimination of multi-tool operations. high-speed tools and custom mod- with the institute.
The company features a 25,000 ft2 ular tooling technology know-how. Amatrol, based in Jeffersonville,
(2,323 m2) facility, rebuilt in February Previously, GWS has had to bypass Ind., designs, develops and manu-
2015 and outfitted with the latest certain niches like HSS tooling, but factures technical training systems,
CNC grinding and inspection equip- now we can offer our customers and interactive eLearning, hands-on sim-
ment. “With the addition of Taurus, partners in distribution another reason ulators and more to train tomorrow’s
GWS further solidifies its position as to consolidate with GWS.” global manufacturing workforce.
the premier multi-disciplinary manu- Since 2016, Amatrol has partnered
facturer of high-performance cutting Amatrol Joins LIFT as Member with LIFT to provide virtual and
tools in the marketplace today,” GWS LIFT, the Detroit-based, U.S. hands-on training capabilities as part
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NEWS DESK

well as Operation Next, a training and CEO of Desktop Metal. “EnvisionTEC announced its ongoing support for the
credentialing program that provides is a true pioneer and responsible for Texas Rocket Engineering Lab (TREL)
a blended learning curriculum to many of the leading technologies at the University of Texas.
active duty soldiers within their last six widely used today to produce end- EOS GmbH is based in Krailling,
months of service. The program is now use photopolymer parts through Germany and maintains North
expanding across the country. additive manufacturing. Together, American offices and tech centers in
“We are proud of the LIFT Desktop Metal and EnvisionTEC have Novi, Mich., and Pflugerville, Texas.
programs we are supporting, like an opportunity to shape the future EOS is providing TREL—a colle-
Operation Next and IGNITE, which are of Additive Manufacturing 2.0 and giate rocket laboratory committed
truly having an impact on manufac- transform how parts are made around to providing students the resources
turing in the U.S.,” said Paul Perkins, the world.” and guidance needed to succeed
president, Amatrol. “Becoming a LIFT EnvisionTEC has more than 5,000 in the space industry—with CAD
member will help us continue to grow customers across a broad range of training, professional counsel,
our relationship with the institute and industries, including medical devices, material resources and 3D printing
help both of us ‘move the needle’ jewelry, automotive, aerospace, and of advanced rocketry components
in advanced manufacturing talent biofabrication. In addition, the company that are lighter and allow for more
development.” is active in the dental market, and more complicated geometry than traditional
than tripled the number of Envision machined parts.
Desktop Metal to One dental shipments from 2019 to These components will be
Acquire EnvisionTEC 2020. EnvisionTEC says it has more mission-critical to TREL’s Halcyon
Desktop Metal Inc., Burlington, than 1,000 dental customers using its rocket—a 28' (8.53-m) tall liquid
Mass., a developer of mass printers for end-use parts. bipropellant rocket designed to fly to
production and turnkey additive man- the edge of space—for the Base11
ufacturing solutions, agreed to acquire ARCH Global Precision Space Challenge.
EnvisionTEC Inc., Dearborn, Mich., a Announces Acquisition The Challenge is an international
global provider of volume production ARCH Global Precision, Bloomfield competition that tasks student-led
photopolymer 3D printing solutions for Hills, Mich., has acquired LISI Medical teams with launching a liquid-bipro-
end-use parts, for total consideration of Jeropa Inc., Escondido, Calif. pellant, single-stage rocket to the
$300 million, consisting of a combina- A subsidiary of LISI Medical, the Karman Line, which, at an altitude of
tion of cash and newly issued Desktop Jeropa plant is a leading contract 100 km, would shatter the previous
Metal stock. manufacturer of high-precision medical collegiate altitude record for a liquid
The transaction is expected to implants, instruments, and other bipropellant rocket.
close in the first quarter of 2021, devices serving a variety of segments As the students take on this
subject to customary closing con- in the orthopedic, dental, and cardio- challenge, EOS will provide design and
ditions. Following completion of the vascular markets. production support as TREL students
acquisition, EnvisionTEC will operate The newly acquired plant and work to produce the rocket’s “Havoc”
as a wholly-owned subsidiary of operations will join ARCH Medical engine—a regeneratively cooled,
Desktop Metal. Solutions, bolstering ARCH as a LOx–RP-1 fueled engine with a unique
EnvisionTEC Founder Al Siblani diversified supplier in the medical regenerative cooling geometry that
will continue to serve as CEO of the device market. has been configured for advanced
EnvisionTEC business. additive manufacturing techniques. In
“I’m thrilled to partner with Al EOS to Support Texas Rocket addition to the Havoc engine powering
and the EnvisionTEC team to bring Engineering Laboratory the rocket, EOS will help produce
significant growth to the additive EOS, a supplier of industrial 3D aerodynamic fins to control Halcyon
market,” said Ric Fulop, founder and printing for metals and polymers, has during flight.

20 Manufacturing Engineering | March 2021

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ADDITIVE MANUFACTURING UPDATE
ADVANCES IN ADDITIVE MANUFACTURING

The Next Chapter in AM: 12-Laser Printing

Manufacturing Engineering: You recently customers—especially those with higher produc-
introduced the NXG XII 600, said to be the world’s tion quantities—while providing a build chamber
first 12-laser 3D printer. What was the driver large enough for most aerospace parts.
behind this decision? ME: What does the end user need to know
Jill Christner: As a technology pioneer about operating a 12-laser machine? What is the
responsible for co-inventing the SLM process in build strategy?
1996, we were also the first
to offer a dual-laser system
in 2011, followed by the first
quad-laser machine two years
after that. We really have just
one goal at EOS—to change
the future of manufacturing
forever. Because of this, it
is imperative that as SLM
Solutions evolves, as does
our technology, that this
evolution maps to the needs
of our partners. Many of these
customers are knocking on the
door of serial part production,
JILL CHRISTNER SLM Solutions has introduced what it calls the world’s first 12-laser
President and GM
and although SLM Solutions’ 3D printer, the NXG XII 600. (Provided by SLM Solutions)
of the Americas current portfolio helps support
SLM Solutions Group
low-volume production, the industry’s needs Christner: Our patent-pending scan field
don’t stop there. Neither do we. partition strategy will distribute the workload to all
ME: Can you tell us about the laser technol- lasers while minimizing laser interaction. This will
ogy? Is it 12 discrete lasers, each with its own ensure maximum productivity for our customers.
optical train, or something else? And do 12 lasers ME: How can you ensure sufficient melt pool
cost 12 times as much? monitoring, fume evacuation, and synchronized
Christner: There are 12 1,000-W lasers, laser power with so much going on at once?
providing productivity up to 20 times faster than a Christner: The NXG XII 600’s gas flow system
single-laser printer and five times that of a quad-la- is the result of years of intensive work. There is
ser printer. Our Double Jump Speed technology consistent shielding gas flow over the entire build
enables build rates of 1,000 cm3/hr, and the chamber, made possible through optimized inlets
tailored laser scanning system is designed for and outlets that help to achieve homogeneous
redundant coverage of the entire build area by the part properties. Engineers have also integrated a
12 lasers. Similarly, the machine also has 12 indi- state-of-the-art thermal management system that
vidual compact scanners with advanced features maintains a constant substrate plate temperature
such as zoom capability, giving unparalleled control that is independent of the lasers’ power input.
of the laser spot. Simply put, the NXG XII 600 was ME: What happens now with the SLM-series
developed to reduce the overall part cost for our machines? Will there be additional members

22 Manufacturing Engineering | March 2021

of that family, or does the NXG-series represent the next H2 Binder Jet beta machine to support its internal and
evolution at SLM Solutions? external customers. Jacob Brunsberg, leader of the Binder
Christner: The NXG XII 600 represents an independent Jet product line at GE Additive, suggested in a press release
family of products that encompass the many features that that the company’s goal is to make additive mass production
have launched alongside its release. That said, we will a reality in every industry, and intends to leverage Binder Jet
continue to enhance our portfolio in order to cater to different technology as the means to reach that goal. Said Brunsberg,
market needs. “Attracting partners like Sandvik—with know-how in industri-
ME: Tell us about the Zoom function. Why was this alizing innovation, deep materials knowledge, and a shared
needed, and is it unique to the NXG? vision for the potential of additive technology—remains a
Christner: The Zoom function provides a tailored laser cornerstone of our Binder Jet commercialization strategy.”
focus size, enabling spot size definition via a double-lens
system that is integrated into all 12 optics. As an example, Fusion3 Gets a REACTOR
contours can be built with 80-µm spot size while in the same Fusion3, a Greensboro, N.C.-based 3D printer builder,
layer a cross-hatch area can be built using a 160-µm spot has partnered with software and electronics provider Create
size. Even larger spot sizes can be set via a defocus function It REAL, Aalborg, Denmark, to deliver REACTOR 3D printing
as well. This allows users to utilize higher laser power and software for use with Fusion3’s F410 FDM (fused deposition
therefore increased build rates, but still achieve fine detail. modeling) 3D printer. Fusion3 said the software’s capabilities
ME: Has your company introduced any other new go beyond slicing, and that it includes an interface that
technology recently? Will any of the NXG’s advancements
trickle down to the SLM generation?
Christner: Many of the features launched with NXG
XII 600 are retrofittable and could be integrated into our
current portfolio of machines. So with regard to recent SLM
Solutions developments, stay tuned … there’s more!
ME: You mention integrating the NXG XII 600 “into your
existing supply chain.” Please elaborate.
Christner: It has always been a goal of the additive
industry to supplement current traditional manufacturing
methods with a true AM production system. With the SLM The REACTOR 3D printing software from Fusion3 boasts
capabilities beyond basic slicing. (Provided by Fusion3)
Solutions portfolio, I believe we have accomplished this,
but the NXG XII 600 pushes this trend even further. It can guides users through the build setup; enhanced part quality
increase productivity while reducing the overall cost per part. via Create it REAL’s adaptive print algorithms; and the ability
As a result, customers are able to make highly complex to apply “modifiers,” or weight, strength, and print time
parts in multiple quantities, allowing them to better meet their settings, to different sections of a print job.
production demands. “Fusion3 is focused on delivering affordable, high-per-
formance 3D printers to our commercial and high-end
Sandvik Additive Manufacturing education customers,” said Fusion3 CEO Chip Royce. “The
Becomes Strategic Partner with GE Additive addition of REACTOR takes our printers’ performance to
GE Additive, Cincinnati, has made atomized metal even higher levels.”
powder supplier Sandvik Additive Manufacturing, Sandviken,
Sweden, a strategic partner in its Binder Jet Beta Partner EOS, Texas A&M Develop AM Education Program
Program. Sandvik will work closely with GE Additive to EOS North America, Novi, Mich., has partnered with
become a certified powder supplier for a range of Sandvik’s Texas A&M University to offer an additive manufacturing (AM)
Osprey alloys that complement GE Additive’s and its own professional development program. Using a combination of
materials portfolio. The company will also use GE Additive’s virtual and conventional learning methods, it leverages the

March 2021 | [Link] 23

ADDITIVE MANUFACTURING UPDATE

metal AM equipment provider’s applied engineering group, Dual-Purpose PEEK for Composite Parts
Additive Minds, to offer hands-on training, providing partici- For the past year, Zortrax SA, Olsztyn, Poland has worked
pants with information on the latest powder bed processes. with the European Space Agency (ESA) to develop a means
These include direct metal laser solidification (DMLS) and to manufacture high-performance composite parts from two
selective laser sintering (SLS), as well as an understanding blends of PEEK filament, using dual-extrusion technology
of other AM processes, metal and polymer materials for on the Zortrax Endureal industrial 3D printer. It appears the
AM, design for AM, case studies, best practices, trouble-
shooting, and more. The partnership recently completed its
first session with NASA. The program’s open discussion,
instructor interaction, presentation of case studies and tools,
and mixture of “theoretical” and “practical” approaches were
among the top highlights noted by participants.

U.S. Air Force, Essentium in Long-Term AM Deal

The U.S. Air Force has awarded a multi-year contract to
Essentium Inc., Pflugerville, Texas, intended to accelerate
the military’s deployment of additive manufacturing. The 3D
printing solution provider will help drive the development of
AM for applications in tooling, ground support, maintenance The ability to incorporate structural elements and electrical wiring
repair and overhaul (MRO), and flight-certified parts for in a single component will be a key benefit for the aerospace
industry. (Provided by Zortrax)
military aircraft and ground vehicles through both the Air
Force and the National Guard Bureau (NGB). This contract partners have been successful, having delivered the first
prototype composite parts made from standard PEEK and
an experimental, electrically-conductive PEEK developed by
the ESA. “Weight reduction is always a key design goal in
aerospace engineering and it can be done by building parts
with multiple purposes,” said Michał Siemaszko, head of
R&D at Zortrax. “That is what we aim to solve by 3D printing
PEEK components with electrically-conductive paths.”

Trade Group Promotes AM’s Green Benefits

The Additive Manufacturer Green Trade Association
(AMGTA), a global trade group that promotes the environ-
mental benefits of AM, announced that 12 AM companies
from eight countries have joined the organization. These
New materials and manufacturing processes will protect and include Sintavia LLC, Taiyo Nippon Sanso Corp., QC
advance the U.S. Air Force’s competitive and strategic capabilities. Laboratories Inc., AMEXCI AB, Danish AM Hub, EOS, GE
(Provided by Essentium)
Additive, Materialise, the National Manufacturing Institute
is part of more than $550 million deployed through the Scotland, Siemens Digital Industries Software, SLM
inaugural Strategic Financing (STRATFi) initiative to identify Solutions Inc. and Stryker. The AMGTA was launched in
and promote “big bet” technologies that have the potential November 2019 to promote the environmental benefits
to protect and advance the future dominance of the U.S. Air of AM over traditional manufacturing, and is a non-com-
Force and its service members. The contract will also help mercial, unaffiliated organization open to any additive
the NGB advance its ability to speed the production of parts manufacturer or industry stakeholder that meets criteria
for aging fleets of air and ground vehicles. relating to production or process sustainability.

24 Manufacturing Engineering | March 2021

Sigma Labs Partners with Northwestern
Metal 3D printing QA software developer Sigma Labs,
Santa Fe, N.M., is partnering with Northwestern University.
The company expanded its PrintRite3D In-Process QA
capabilities by developing hardware and software for use in
directed energy deposition (DED) additive processes. The
new technology will be installed onto a customized, open-ar-
chitecture DED system for validation and testing, the Additive
Rapid Prototyping Instrument (ARPI), which will be located
at Northwestern’s Advanced Manufacturing Processes
Laboratory (AMPL) in Evanston, Illinois.

Wabtec Joins Neighborhood 91

Wabtec Corp., Pittsburgh, a global provider of equipment,
systems, and services for the freight and transit rail sector,
is the first manufacturing anchor tenant at Neighborhood Sporting equipment, ducting and bellows, and end-of-arm tooling
91, an additive manufacturing production center that is part are just a few of the applications for GoProto’s 3DElastoPrint parts
service. (Provided by GoProto)
of the Pittsburgh International Airport’s 195-acre Innovation
Campus. Neighborhood 91 is said to be the first develop- manufacturer HP, Palo Alto, Calif. The new elastomer is for
ment in the world to condense and connect all components use with HP’s Multi Jet Fusion (MJF) system and is a flexible
polymer based on thermoplastic amide (TPA), ideal for any
part design requiring a lightweight, rubber-like material.
GoProto has introduced 3DElastoPrint, a 3D-printed parts
service utilizing the new material. “We instantly recognized
the massive market potential and its ability to help us provide
customers with production-grade parts with no tooling and
all of the benefits of 3D printing,” said President and CEO
Jesse Lea. “We’re not going after parts we can inexpensively
produce using conventional methods; we’re going for the
things that haven’t been addressed well before.”

A rendering of Wabtec’s 11,000 ft2 (1,022 m2) AM facility at HP Universal Build Manager Powered by Dyndrite
Pittsburgh’s Neighborhood 91, expected to open in the spring HP’s new Universal Build Manager, powered by the
of 2021. (Provided by Wabtec)
Accelerated Geometry Engine from Dyndrite Corp., Seattle,
of the additive manufacturing and 3D printing supply chain is said to be the industry’s first GPU-accelerated AM build
into one production ecosystem. “Additive technology is a prep and management solution. Announced during a virtual
key focus area for us that provides new capabilities to drive event, Dyndrite Day, the Universal Build Manager is said to
innovation where traditional manufacturing could not,” said be an OEM- and process-agnostic tool boasting “unprece-
Eric Gebhardt, Wabtec’s chief technology officer. dented performance, scalability and workflow automation”
for AM end-users. It also supports multiple production-grade
GoProto Introduces 3DElastoPrint AM technologies, as well as a plug-in architecture that
GoProto Inc., San Diego, a service bureau and HP rapid enables 3D printer manufacturers and software developers
manufacturing partner, has created a new parts service to create machine-specific capabilities.
based on a co-branded powder developed by chemical Additive Manufacturing Update is edited by Contributing
company Evonik Industries, Essen, Germany, and 3D printer Editor Kip Hanson, kip@[Link]

March 2021 | [Link] 25

SHOP SOLUTIONS

The prototyping machine shop where Trek Bicycle tests and

creates its latest innovations. (All images provided by Trek Bicycle
and BIG Kaiser Precision Tooling)

TREK BICYCLES

Bike Maker Discovers Time and Cost Savings

with Specialty Toolholders

B
icycles are one of the oldest modes of transportation, “Every time we run a part, it’s something new that we just
but that doesn’t mean they haven’t evolved with the fresh programmed,” said Cory Marty, senior engineering techni-
times. Having built bikes in Wisconsin since 1976, cian at Trek’s Prototype Development Lab. “Our turnaround time,
Trek Bicycle knows this evolution well. It has been on from when an engineer puts in a project to the time they have
the front lines of the electric bike movement and other equipment something in their hands, is about 10 to 14 days. We don’t get the
advances like cycling lights, computers and sensors. luxury of setting up an old job or running multiples of anything.
Trek Bicycle, based in Waterloo, Wis., is a bicycle and cycling A lot of the work we do is with tight, deep pockets—common
product manufacturer and distributor under the brand names stickouts are about 6-8×D. Every part is a first-off. Everything is
Trek, Electra Bicycle Co., Bontrager, and Diamant Bikes. Trek 3D-surfaced, organic shapes.”
bicycles are marketed through 1,700 independently owned When Trek recently invested in a five-axis machine tool, Marty
bicycle shops across North America, subsidiaries in Europe, Asia, had a big decision to make about which tools would get the most
South Africa, as well as distributors in 90 countries worldwide. out of the new machine. Due to its deep-pocket cutting jobs, Trek
Every idea a Trek engineer has for a new technology or needed reach more than rigidity or high-power cutting.
how to integrate it passes through the company’s Prototype Using CAM software, Trek could program a three-axis tool
Development Lab. It’s where things like frames and accessories path that recognizes when the tool will collide with the model.
are experimented with and machined to make Trek’s most It automatically starts tilting the tool axis out of the way to
innovative ideas come to life. adjust for toolholder clearance. But, with standard ER 32 or 16

26 Manufacturing Engineering | March 2021

 MANY STATES STRUGGLE TO REDUCE THE BARRIERS TO DOING BUSINESS.
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SHOP SOLUTIONS

toolholders in a deep and tight pocket, the

machine had to tilt significantly to clear
the body of the holder, which resulted in
unnecessary axis movements or potential
machine collisions.
“Every time we added an extra exten-
sion or cobbled something together, we
knew we would be adding runout,” Marty
admitted. “We were looking for tooling
that was similar to shrink-fit holders, with
the shape and accessibility you could get,
but we weren’t ready to step up to a full
$30,000 shrink-fitting package that limited
us to one or two diameters.”
Considering the work the lab does,
easy changeover was also of critical
importance. Marty explained he has to Cory Marty of Trek Bicycle and his team use MEGA Micro Chucks from BIG Kaiser
to machine lightweight and complex bike components.
set up 10-15 tools, changing tool lengths
each time, for each part Trek works on. The heating and After browsing tooling catalogs in search of holders that
cooling cycles involved with shrink-fit tools would simply be could be quick and easy to handle and with dimensions that
too time consuming. would allow access to tricky pockets, Marty invited Mark
Sazy from BIG Kaiser Precision Tooling
Inc., Hoffman Estates, Illinois, to come
demonstrate the company’s MEGA Micro
Chuck. The chuck’s narrow body, with nut
diameters as slim as 0.394" (10 mm), is
supported by a shallower taper angle that
boosts the holder’s rigidity and limits the
extreme angles needed to reach down
into deeper pockets.
“MEGA Micro Chucks were designed
for the exact scenario Cory was dealing
with in the prototype lab,” said Sazy, who
specializes in value-added sales at BIG
Kaiser. “The prototype lab is a place where
everything is under a microscope in a way.
All eyes are on the details. It was great to
have the opportunity to demonstrate our
tools under those conditions—that’s where
the value is clearly evident, with what we
refer to as the ‘economy of quality.’ ”
Marty decided to purchase one package
of 15 MEGA Micro Chucks to use with all of
Trek’s cutters 0.25" (6.35 mm) in diameter
Trek has been building bikes for almost 50 years. According to Trek, the Madone SLR
(pictured) is one of the world’s most sophisticated road bikes. and under. “The quality of the toolholders

28 Manufacturing Engineering | March 2021

A closeup of machining at Trek Bicycle using MEGA Micro Chucks,
which provide extreme rigidity in longer reach situations, according
to BIG Kaiser.

themselves was just phenomenal, better than I’ve seen on any

toolholders before,” Marty said. “The finish on every single
surface of the holder is just fantastic and that just screams quality
when you pull it out of the box.”
The slim nut and simple collet clamping turned out to be the
best of both worlds for Trek, according to Marty. “The MEGA
Micro Chucks have the same profiles and shapes of shrink-fit

‘The quality of the toolholders themselves was

just phenomenal, better than I’ve seen on any
toolholders before. The finish on every single
surface of the holder is just fantastic.’

holders with the versatility of collets,” he said. “You can use

basically any size shank you want. They’re balanced a lot better,
so they don’t vibrate as much as the ER 32s that we were
running previously.”
The extreme tilts the programming software once had to
adjust for have been eliminated. “I’d say probably 50 percent of
our reach issues were resolved just by changing holders without
manually changing the way things are programmed. The machine
only has to tilt maybe 10 degrees out of the way to get down into
the pockets. We’re able to reach into places
we weren’t before without extravagant,
cobbled-together extensions, and all with
higher speeds, feeds and finishes.”
As with any specific technology or
equipment, shrink-fit holders have their
unique advantages. And, as with every
shop, the cost or time required for the per-
fect solution isn’t always an option. Marty
knew exactly what he needed, though—
easy changeover and access—and through
research and trial found the alternative that
could deliver on a budget.
For information on Trek Bicycle, visit
[Link] or call 800-585-8735.
For information on BIG Kaiser Precision
Tooling Inc., visit [Link] or call
The MEGA Micro Chuck’s extremely slim body and nut design provides superior balance
and concentricity and is ideal for reaching into confined areas, according to BIG Kaiser. 888-866-5776.

March 2021 | [Link] 29

SHOP SOLUTIONS

Norbert Kozar, CEO of Precision Swiss Products, selected Rego-Fix

powRgrip (PG) toolholders and ER collets for consistent precision
in machining tightly toleranced products. (All images provided by
Precision Swiss Products and Rego-Fix Precision Tool)

PRECISION SWISS PRODUCTS

Advanced Toolholding Secures

Part Quality for High End Job Shop

F
rom the moment Norbert Kozar, CEO, took charge of “The tighter the tolerance, the more critical it is to control
Precision Swiss Products Inc. in 2007, he steered the runout, so the ER collets and holders we use must provide
Milpitas, Calif.-based job shop on a trajectory toward consistent precision,” he said. “Also, less tool runout means
achieving both ISO 13485 certification and AS longer tool life. For us, every 0.0001" [0.003 mm] of runout causes
9100 certification in a few short years. From that point on, Kozar a significant percentage of reduced tool life.”
focused on pursuing only those jobs that involved extremely For one part the company machines, a 0.010" (0.25 mm) diam-
difficult components and materials—a strategy that has continued eter end mill is used on a five-axis mill. “With very thin part-wall
to keep the shop successful. thicknesses, a cutter that is running out could actually introduce
The strategy comes with challenges. undue stresses into those walls because the tool is essentially
What makes the jobs at Precision Swiss Products tough is banging against the wall as opposed to cutting it, which affects
a combination of tolerances as tight as ±0.00015" (0.0038 mm) the integrity of the part,” said Kozar.
and intricate, complex geometries that can require as many as Precision Swiss Products has 45 machines, 19 of which are
half a dozen operations with very small tools. The majority of the Swiss-style screw machines. Other equipment includes wire EDMs,
shop’s milling cutters and drills are well under 0.5" (12.7 mm) in seven turning centers (two of which are automated with a robot and
diameter and most are carbide and diamond tipped/coated. The run parts 24/7), four five-axis milling machines, two HMCs and four
performance of such tooling, according to Kozar, depends on VMCs. And across all of these machines, 90 percent of the shop’s
highly precise toolholding systems. collet toolholders are Rego-Fix Super High-Precision ER16 collets.

30 Manufacturing Engineering | March 2021

 In addition to its ER collets, the shop relies on Rego-Fix powRgrip
(PG) toolholders for its milling machines and will soon incorporate
the holders into its Swiss-style screw machine operations that
currently run safe, non-slip Rego-Fix IntRlox MX Mini Nuts. For fast
and precise tool mounting, Precision Swiss Products also acquired
a Torco-Block benchtop tool assembly assistant unit from Rego-Fix
that saves the shop’s torque wrenches from damage.
“Besides costing less than heat shrink,” said Kozar, “the
PG system and ER collets contribute significantly to extending
cutting tool life while also further improving part quality. What
differentiates the Rego-Fix holders from every other type we have
used is consistency in performance and holding power as well as
producing the least amount of TIR as possible.”
He went on to say that, for its diamond-tipped drills, for
The Torco-Block benchtop tool assembly assistant unit features
instance, the shop must run highly precise collets. “If we tried to a built-in torque meter and interchangeable indicator rings for
use sloppy, subpar collets,” said Kozar, “our tipped drills would different ER series holders, saving the shop’s torque wrenches
from damage.
literally destroy themselves. This is why we have to use Rego-Fix.”
The Rego-Fix PG toolholding system relies on the interference not slip off the nuts once properly engaged. These smaller ER
between holder and collet to generate tool clamping force. Unlike collet nuts feature an anti-slip design that uses rounded locking
other clamping systems where heat or hydraulics is used to expand grooves located around the nut profiles as opposed to end face
the material, the PG system uses the mechanical properties of the surfaces. Wrenches grip from the sides of the nuts, and the action
holder material to generate tremendous gripping force with runout of tightening or loosening temporarily locks wrenches in place.
below 0.0001" (0.003 mm). PG units take less than 10 seconds According to Kozar, as a heavy user of ER collet nuts,
to press in a tool or remove it from the holder. Because no heat is Precision Swiss Products was constantly replacing torque
used, tools can be used immediately after a tool change. wrenches that operators damaged through inconsistent and over
The work areas for the shop’s Swiss-style machines, espe- tightening. To remedy this problem, the shop uses its Torco-Block
cially smaller models, offer limited room for operators to change benchtop tool assembly assistant unit, which features a built-in
out worn or broken tools, so Precision Swiss Products secures torque meter and interchangeable indicator rings for different
them with intRlox MX Mini Nuts, which guarantee wrenches will ER series holders. Together, these features eliminate the need
for individual torque wrenches for every
toolholder. The unit therefore eliminates the
detrimental results of excessive runout that
results from over torquing.
Precision Swiss Products first encoun-
tered Rego-Fix products thanks to Pat
Murphy and the staff from Western Tool &
Supply Co., along with Kenbil Engineering
Inc. Prior to that, Kozar had considered
heat-shrink toolholders but was concerned
about harmful fumes from residual coolant
on the heated holders, which led him to the
Rego-Fix toolholding alternative.
Currently, in terms of the market seg-
ments it serves, Precision Swiss Products
Job lot sizes for the shop’s 19 Swiss screw machines that run 24/7 are typically between
a couple hundred up to tens of thousands of pieces on an annual basis. is about 60 percent medical, 30 percent

March 2021 | [Link] 31

SHOP SOLUTIONS

aerospace and 10 percent semi-con-

ductor. It employs about 100 people
and is approximately a $14 million
company, a value it has achieved in part
thanks to the loyalty of its clients, 80
percent of whom are repeat customers.
Job lot sizes for the shop’s screw
machines are typically between a
couple hundred up to tens of thou-
sands of pieces on an annual basis.
To achieve this level of output, the
shop’s 19 screw machines run 24/7.
On the milling side, job lot sizes can
be as few as 20 pieces and as many
as 500. The shop also has some jobs
that are ongoing and involve thousands
of pieces needed on a monthly basis. Rego-Fix powRgrip toolholding units take less than 10 seconds to press in a tool or remove it
Jobs involve materials that range from from the toolholder. Because no heat is used in the process, tools can be used immediately
after a tool change.
superalloys like Inconel, Nitinol, Haines
242 or Hastelloy to various other metals and plastics. jobs, the shop is ITAR compliant and AS 9100 REV D, ISO
For its medical customers, the shop produces heart pumps, 13485, and ISO 9001-certified.
heart valve delivery systems, eye surgery tools, brain implants Besides its expertise in producing high-precision, complex
and stents along with collar bone, spine and ankle implants. On parts, the shop excels on the metrology side of the business. The
the aerospace side, Precision Swiss Products makes a lot of shop uses several in-house Zeiss coordinate measuring machines
flight-critical hardware, including several for DX-rated jobs from (CMMs) and other high-end metrology systems along with special
the U.S. Department of Defense (DoD). It also manufactures inspection software that collects data for live SPC on the shop
parts for Holographic VR goggles used to instruct pilots as well floor. “It gives the shop the ability to collect data literally as a part
as doctors. For the defense industry, jobs involve components is being produced,” Kozar said. “Quality doesn’t stem from the
that go into strategically vital vehicles and aircraft. For such QC department; it lives on the shop floor.”
He added that the shop’s success starts
with its people. “You have to have the right
individuals in the right positions. Then add
the best machines, paired with the best tool-
holding, like what we get from Rego-Fix. If a
shop sacrifices quality for cost, it will show
up in the final product. The moment where
we tried to take a short cut just to save a few
dollars are the moments we failed,” he said.
“I’d rather walk away from a job than lower
my quality standards to be competitive.”
For information on Precision Swiss
Products Inc., visit [Link]
or call 408-433-5880. For information on
Medical and aerospace parts produced by Precision Swiss Products with tolerances as
tight as ±0.00015" (0.0038 mm) have intricate, complex geometries that can require as
Rego-Fix Tool Corp., visit [Link]
many as half a dozen operations with very small tools. or call 317-870-5959.

32 Manufacturing Engineering | March 2021

SME PRIME

Pine Bush High School and Saginaw

ISD change learning approaches in
the age of COVID
In the wake of COVID-19, educators at Pine At Saginaw ISD in Michigan, the back-
Bush High School and Saginaw Intermediate to-school experience in Fall 2020 included
School District (ISD) — both of which are part a combination of remote, hybrid and
of SME’s PRIME (Partnership Response In face-to-face learning.
Manufacturing Education) program — have A hybrid plan was implemented at the
taken creative approaches to learning. Saginaw Career Complex (SCC), Saginaw ISD’s

A
countywide career and technical education
t Pine Bush High School in New center, which has a full build-out of the SME
York, students returned to school PRIME program in its Engineering and Advanced
virtually in early September, adher- Manufacturing Academy. Students are divided
ing to a traditional nine-period day into two groups, with Group A getting hands-on
consisting of 35-minute periods with a 10-minute instruction on certain days and Group B taking
break between classes. Manufacturing and its turn on other days. On days when they’re
engineering students are utilizing PRIME-funded not physically on the SCC premises, students
Tooling U-SME online coursework. engage in remote learning via PRIME-funded
“It’s going to be an extended period of Tooling U-SME online classes.
time before we truly have our full complement “I think this whole COVID thing has been
SME EDUCATION of students back in the building,” says Aaron scary for a lot of folks,” says Jennifer Geno,
FOUNDATION Hopmayer, the principal at Pine Bush. director of career and technical education for
With remote learning, hands-on training Saginaw ISD. “You just don’t know where the lay
is the biggest challenge facing teachers of the land is, so I’m very pleased that programs
and students. While online certifications are as they relate to the PRIME initiative have
available, Hopmayer says they don’t substitute not been cut. People in our districts are very
for meaningful, hands-on, practical instruction, committed to this project.”
either on the 3D printer, laser cutter, mill or lathe.
“How do you say to a kid, go 3D print this — oh, This article has been condensed. Read the full article
I’m sorry, you don’t have a 3D printer at home. at [Link]/prime.
And how do you use the Haas mill when you
don’t have that ability?”

DIscover the best way to enhance your talent pipeline. Visit [Link]/me now.
AUTOMATION
Collaborative robots are easier to
implement in part because they can
be trained by manually dragging the
robot head where you want it to go.
(Provided by FANUC America)
Automation
in the Age
of COVID-19

Safer, faster, and more intelligent

solutions aid industry in a pandemic

ED SINKORA
Contributing Editor

T
he longstanding trend toward manufacturing
automation has understandably been accelerated
by the COVID-19 pandemic. Roughly a year into
the crisis, it’s a good time to ask about longer
term impacts. Has the pandemic pushed automation into
new areas? Have suppliers made automation more flexible?
Easier to implement?
By their nature, collaborative robots (cobots) are easier
to implement than their traditional cousins. Because cobots
are designed to share a workspace with their human
counterparts, as a matter of routine, they often don’t require
guarding and can fit into relatively small, occupied spaces
(when confirmed by safety risk assessment). They’re also
easier to set up, said Dick Motley, the Director of FANUC
America Corp.’s authorized system integrators group in
Rochester Hills, Mich. He explained that a user can, in part,
train FANUC’s CRX series cobots by literally grabbing the
arm and leading it around. This makes “setup of a simple
application really straightforward and intuitive. You’ve got
robotic automation that can be deployed quickly.” He added
that “there’s a growing ecosystem of peripheral suppliers for
grippers and pedestals for the robot to sit on, and different

March 2021 | [Link] 35

AUTOMATION

provisions to easily address the utilities that go out to the They didn’t have the physical space to do a traditional robot
robot’s end-of-arm tool.” implementation with the stopping distance calculations and
The bad news is that cobots are slow. Even though all the things that go into a traditional robot cell. Their only
they’re built with sensors that limit the force they’ll impart automation option was to put in a cobot. … If you go slow
if they come into contact with something, “it’s pretty tough enough, a cardboard box is probably not going to hurt you.”
to meet safety standards at high speed,” explained Motley.
“Because regardless of how sensitive your contact sensing Safe and Easy for Humans
This is not to say that traditional robots can’t operate in
proximity to people, or that they’re very difficult to set up.
Or that slow-moving cobots can operate without guarding if
they’re handling something sharp or otherwise dangerous.
To address these concerns, FANUC and other OEMs have
systems that “restrict either the motion range or the speed of
the robot” to allow for intermittent interaction with a human,
explained Motley. FANUC calls its safety architecture “Dual
Check Safety,” or DCS. “Maybe you want to establish a
‘keep out’ zone on one side of the robot while an operator
loads parts or something that the robot is going to retrieve.
You enable a software constraint to keep the robot from
going there, typically reinforced by a light curtain or a safety
mat or a scanner. But then, once the person leaves that
loading zone, the robot can be right back up to full speed.”
Motley also pointed out that “adjustments to DCS can be
done in FANUC’s Roboguide offline programming environ-
ment simulation package. They can be done with a laptop
attached to the robot, or with one of our user interface
devices, whether it’s our iPendant or our new Teach Pendant
tablet.” The new tablet-based interface is particularly easy to
use, said Motley. “It’s a whole new programming style that’s
not even close to computer language. It’s a drag-and-drop
icon timeline.”
Promess is automating its Electric Workstation with a cobot
and eliminating the need for a separate inspection station by At Promess Inc., Brighton, Mich., Director of Application
incorporating a camera (right). The upper indexer is a tool changer, John Lytle reported that the pandemic has accelerated his
offering staking, pressing, probing, or rotating tools (shown in
multicolors), depending on what process is needed. company’s effort to make its Electric Press Workstations per-
(Provided by Promess)
form additional functions. Promess had already made it easy
system is, you’re trying to defy physics if you’ve got some- to add its units to a production line by making them compact
thing moving really fast and then need to immediately bring it and self contained, with an integrated light curtain to prevent
to rest.” So although you might think cobots would be taking injury to the operator. “They automate assembly with sensing
over the world of automation (and COVID-19 era sales have that determines if it made a good part, and you can put them
been explosive), their applicability has limits. wherever you want and adapt to things as they change in the
Motley referred to “a relatively low-speed palletizing oper- plant.” Promess has added ancillary functions and enhanced
ation” at the end of a customer’s manufacturing lines as a the information the units are able to communicate to the rest
good fit for a cobot. “They were making two to four cases of of the factory. For example, in addition to pressing two parts
product a minute, with an incredible density of conveyor lines together and confirming that the measured force and travel
feeding these products down to the end to be palletized. were as expected and the assembly is therefore good, the

36 Manufacturing Engineering | March 2021

Work Station might also take dimensional measurements
and pass that information along. This eliminates the need for
a separate gaging station.
Performing such measurements requires cameras and/
or lasers, and Promess integrates the technology such that
the end-user still gets a stand-alone, “plug and play” unit.
As Lytle explained, “We’re focused on making it simple for
the end user, so it’s not like a big science project requiring
a camera technician, a PLC expert, a high-level integrator,
and so on. We have a software team of 20 people here,
working every day to make it easy. So when the customer
gets a Work Station, it’s already set up. They’re just entering
parameters.” He added that cameras can do more than
measure parts. They can also be used for part orientation. Automating logistics—with its diversity of items and need for
speed—is driving the development of AI and advanced image
This enables more complex arrangements, like being able processing. (Image provided by ABB Robotics USA)
to automatically pick from multiple parts on a pallet. Plus
Promess has integrated cobots for automatic part load/ Work Station that simplifies the transfer line and contributes
unload. The end result, as Lytle sees it, is a multi-function to social distancing, while also sending data to the other

March 2021 | [Link] 37

AUTOMATION

equipment in the plant “via the Internet or Intranet to make a Given the inconsistencies of the forms of the protein,
decision about what to do.” meeting this challenge required both a smart camera system
and AI to orient the robot grippers. “There’s also quick
More Intelligent and Flexible payback on limiting the protein lost in making the cut,”
According to Joe Chudy, general manager of ABB added Chudy. “So the vision technology you use, with water
Robotics USA, Auburn Hills, Mich., “all industries, in large knives or other techniques to cut this material as close as
and small installations, are looking for ways to remove people you can, is a big deal. Learning how the protein is presented
from their processes.” The biggest increase in demand—a to the robot, where the vision system should go, and how
boost that can be tied directly to the pandemic—is in you should orient it, all factors into the application.”
medical manufacturing, packaging/logistics, and food Long term, Chudy thinks, advances in AI driven by these
processing. The latter two are particularly challenging, given challenges will also be applied to the metalcutting world. For
their need for extreme speed in the face of inconsistent example, random bin picking capability is improving due to
improvements in AI, he observed, “as
well as de-palletizing and some of the
logistic [tasks]. Acquisition times are really
what matters in random bin picking.
How quickly can I locate that part? How
fast can I go get it? It’s the same in the
logistics market.” Chudy believes speed
is important and processing the volume
of image data required to pick the parts
has until now limited those applications.
“[Now] we’re seeing those applications
flourishing in this market as the technol-
ogy grows and becomes stronger and
less maintenance-intense,” Chudy said.
He said fixtureless welding and smart
welding are also being studied, in which
With smart scheduling software and versatile pallet handling, Fastems’ higher end “you’re presenting the piece and part to
automation systems enable the manufacture of different products over extended periods a camera and it’s deciding how to weld
without human intervention. (Provided by Fastems)
it, and the tolerances, and measuring
inputs. As Chudy put it, “it’s no secret that Amazon can’t the gaps, and doing all the things a traditional programmer
hire enough people and can’t automate quickly enough. The would do. It works well in the lab, but we have not imple-
same is true of WalMart and everyone else in that space. mented it in production yet.”
But the quantity and diversity of the items you have to pick Vision technology is central to these systems. And as
up and sort quickly forces you to implement some form of AI Chudy put it, that used to “make a lot of guys in the metal
(artificial intelligence).” industry nervous,” because vision systems previously
Chudy said the food processing industry is also hard required specialized technicians to install and maintain. “Now
pressed and driving automation innovation. He described these newer applications are able to self monitor.”
meat cutting and packing as an inherently miserable environ- Motley also spoke of vision technology as a tremendous
ment for humans to work in, with the pandemic only adding enabler that has gotten easier to implement. “When you
to the woes. And the “protein” (as the industry refers to their give a robot eyes to be able to adapt to the environment,
product) varies from piece to piece. “We asked ourselves that enables all kinds of things in terms of reduced cost
if we could debone a chicken. What could we do with the for setting an application up, reduced changeover time,
wings? Things like that,” recounted Chudy. fewer changed parts, better flexibility, higher reliability, and

38 Manufacturing Engineering | March 2021

in-process inspection.” He said FANUC’s new 3D vision has caused some companies to buy and automate single
technology, called 3DV, offers “a versatile, compact sensor machines just to quickly re-shore a certain product. But
that can easily be built into end-of-arm tooling on a robot. whether Fastems delivers a large FMS or a robot for a single
The robot literally carries its eyes
around with it rather than having just a
stationary sensor, although stationary
sensors still have their place.” And a
3D point cloud provides the robot with
much more information than a flat 2D
image, he added. With more infor-
mation about what’s in front of it, “the
robot’s control is better able to decide
what to do next.”

Manufacturing in Metal
Handling packaging and protein
is a lot different than a typical metal
working application. So, as Dave
Suica, president of Fastems LLC,
West Chester, Ohio, explained, gripper
technology is changing. “We have

DISCOVER THE KEY TO FASTER

CHANGEOVER
started going to servo-controlled grip-
pers. A lot of the parts are deformable.
A regular power gripper can apply
too much force, more than what’s
needed to overcome the friction factor
to lift the part. With servo-control, Because robots don’t take breaks.
you go to a position, and then it has
an override for how much pressure it Bluco modular fixturing allows you to retool
applies.” More generally, Suica said a fixture in less than half the time it takes for
people are tending toward “higher standard tooling. Partner with our
end” automation that doesn’t require experienced team to design a system
manually changing grippers in order to that can hold a variety of parts
switch jobs. “With smart automation
with one modular kit, on a
and automatic gripper changes, and
customized spine or table.
computer control versus a PLC, you
Just show us your part
and we’ll help you
can make it dynamic. You can switch
make it better.
from part A to part B to part C without
any people there. We have systems
that run for 72 hours autonomously.”
While Fastems is best known for
large flexible manufacturing systems
Call 800.535.0135 for Solutions ™
(FMS), its handles the entire range
of robot and pallet handling config- 30 YEARS OF EXCELLENCE I [Link] ®

urations. Suica said the pandemic

March 2021 | [Link] 39

AUTOMATION

machine, “it still has a full line of manufacturing management

software,” said Suica. “It still has scheduling. It still has the
capacities to run different parts at different times.” Fastems
prides itself on being able to integrate with a company’s ERP
system for predictive and dynamic scheduling. “So, as the
ERP system changes the requirements, we automatically
change the sequence of what part gets made when, such
that you maintain your flow without building inventory.”
Returning to the packaging and assembly challenge, Motley
said FANUC’s automotive roots have served it well. “Our ability
The ability to automatically change grippers makes robots even
to dispense a bead of sealant to seal up a car body prior to more flexible. Fastems is also using more servo-controlled
painting, and coordinating that very tightly with robot motions grippers to handle deformable parts without damage.
(Provided by Fastems)
such that when you go fast, you don’t get a thin spot in the
sealant bead … and when you go slow around a corner you might have a Google device. A third person could be using
don’t get a big, thick pile up …” contributed directly to being Windows 10 on a laptop. With an HTML5-based interface on
able to dispense adhesive in assembly operations. the machine, they would all see the same thing in a similar
way. HTML5 makes your machine platform independent.”
Remote Control Moves to HTML5 HTML5 provides better mobile access to business
The increase in automation and social distancing driven intelligence too, said Bibra, along with geolocation. With
by the pandemic has in turn highlighted the need for remote geolocation, he pointed out, you can limit remote con-
monitoring capabilities. Remote monitoring isn’t new, and nections to devices that are in specific locations, thereby
virtually all control, automation, and machine manufacturers improving security. For example, you could limit a remote
offer such solutions. But Fagor Automation–USA, Elk Grove connection to an employee’s house, but not elsewhere, to
prevent access if the employee lost his phone. What’s more,
added Bibra, “HTML5 is without limits. Depending on the
power of the logic you write, or the power of the human-
machine interface you create, it can provide the Nth degree
of freedom in the sense that the person on the other end can
have access to anything.” That means you could empower a
remote connection to not just monitor activity, but also enter
machine commands, like cycle start or cycle stop. In other
words, remote control is the ultimate in social distancing.

FYI
ABB Robotics USA
248-391-9000 / [Link]
Fagor Cloud software enables machine monitoring on any Internet
browsing device with the correct credentials, and Fagor’s use of
HTML5 ensures the interface appears the same on any device.
Fagor Automation—USA
(Provided by Fagor Automation—USA) 800-423-2467 / [Link]

FANUC America Corp.

Village, Illinois, recently went a step further by accelerating the 888-FANUC-US / [Link]
release of an HTML5 based control architecture. As General Fastems LLC
Manager for North America Harsh Bibra explained, HTML5 866-702-0611 / [Link]
is not only browser based, it’s “consistent across multiple Promess Inc.
browsers. One person might be using an iPhone. Another 810-229-9334 / [Link]

40 Manufacturing Engineering | March 2021

 ADVERTORIAL

Long-Term Partnership Yields Long-Term Growth

IN THE CONVENTIONAL MACHINE TOOLS MARKET, OKK Corp., a high-quality machine tool manufacturer and
customers want to kick the tires, look someone in the eye, one of Methods’ premier builders. And, he found some other
and know when they call, someone shows up with the right benefits once the machine was up and running. “For a big
parts, right tools, and right attitude. machine, it’s pretty quick, too,” he added.
J&E Precision Tool Inc. and Methods Machine Tools share However, Methods did more than deliver and install
a rich history. Both family-owned businesses are based in machines, Labrie recalled. Methods has shipped parts during
Massachusetts and came from humble beginnings – J&E off-hours and installed machines at a moments’ notice. In
Precision is headquartered in Southampton, Mass. and one instance, Labrie said, J&E Precision was beginning to fall
began with one machine, while Methods is located in nearby behind on a particular order. Methods stepped in immediately,
Sudbury, Mass. and was founded with three employees and allowing J&E Precision to use its technical center in Sudbury,
a handful of refurbished machines. Mass. The aerospace/defense part manufacturer was soon
Jon Labrie, VP of Operations, recalls the aerospace/ using Methods tools at a Methods facility to machine parts.
defense component manufacturer wanted more than a Methods has leveraged its experience and expansive line
machine tool supplier. J&E Precision needed a partner that of builder partners to supply J&E with dozens of machine
could give them the support and service they needed to tools throughout the years.
grow and prosper.
Enter Methods Machine Tools.
Labrie said Methods’ decades of knowledge and service
has made them the ideal partner. The two companies have
been working together since 1986.
“The service at Methods has always been second to
none,” Labrie said. “They have a good stock of parts, and
those guys know what they’re talking about.”
During Labrie’s tenure, one challenge came in the
mid-2000s when the company accepted several new
contracts and was looking to get into electrical discharge
machining (EDM). J&E Precision produces high-quality parts
Cutting Demo on the OKK VM76R. (Provided by Methods)
for industries that require stringent tolerances and rely on
firm deadlines. The company wanted to use one machine to But the benefits of partnering with Methods go far
make various parts for different jobs, from millimeter wave- beyond the machines and parts. “It’s the service and quick
guide products to hooks for a retrofitted submarine door. responses,” Labrie said. “You can pick up the phone and talk
“We needed a machine big enough to handle the parts,” to someone pretty quickly.”
Labrie explained. The FANUC RoboCut wire EDM offered For J&E Precision, that quick response come from Ray
what the company was looking for. “The service behind Navarro. Navarro has partnered with J&E Precision for
it made a huge difference in our purchasing decision,” years, working closely with them to get the necessary parts,
he added. When the company began to explore five-axis machines, and setups on time.
machining, it turned to Methods for expertise. Methods J&E Precision recently expanded with a 24,000 ft2 facility
supplied J&E Precision with its first five-axis machine. in nearby Westfield, Mass. Labrie said, there is only one thing
J&E began to take on other contracts that necessitated he’s on the lookout for. “We will need to fill that space,” he
new machinery. “We didn’t have machines big enough, first jested. “So you better have some supply, Ray.”
off,” Labrie said. “Second, we were looking for something tough Find out more about how Methods combines best-in-class
and rugged.” Labrie didn’t have to look long. His search led precision machine tools, automation solutions, engineering
him to a 50 taper vertical machining center (VMC) built by expertise, and lifetime service at [Link].

Advertorial
AUTOMATION

Automation for Everyone

Automation was once only for big factories, but now small job shops can benefit as well

GEOFF GIORDANO
Contributing Editor

A
utomating job shops is protective equipment (PPE), coupled An OB7 cobot loads a raw blank into the
main spindle of a nine-axis Quicktech
accelerating, driven by with a need to protect workers, has also S-32 ATM mill/turn center. (Provided by
the combined influence of ramped up shops’ automation efforts. Absolute Machine Tools)

Industry 4.0, the continued The benefits of automation, clearly

shortage of skilled manufacturing labor amplified during the pandemic, were
and the COVID pandemic. summarized neatly by Courtney Ortner,
The availability of more customized chief marketing officer for Lorain, Ohio-
robotic and material conveyance based Absolute Machine Tools: “With
options than ever is helping smaller the use of cobots (collaborative robots),
manufacturers produce more while you have a work partner and you don’t
moving operators to more value-added have to worry about social distancing.
tasks. The surging demand for personal Also, many shops are losing workers to

42 Manufacturing Engineering | March 2021

quarantine, so this allows a shop to con-
tinue to run even with the loss of staff.
And we can’t forget lights-out manu-
facturing capabilities are more common
because of the use of automation; even
with a cobot, you can set a job up on
a Friday night and by Monday morning
it’s done—oftentimes allowing you to be
ahead of your production cycle.”

March of the Cobots

Robots are often the first thing
people think of when the topic turns to
automated manufacturing. Their human-
safe variant, cobots, continue to improve
in ease of setup, flexibility and payload.
All Axis Machining of Dallas struggled to automate the operation of old machinery. When
Since their introduction 15 years the company discovered the open integration architecture through the Universal Robots+
ago, units from Universal Robots (UR), platform, it automated six operations with cobots. (Provided by Universal Robots )

Walter innovations are

setting standards

Walter innovations are setting standards worldwide

As a premium manufacturer of metal cutting tools, Walter enjoys an excellent reputation among customers and users
worldwide. Whether it is innovative milling bodies and indexable inserts, new drill concepts or multi-stage thread milling
cutters, Walter is setting standards across the industry. In these challenging times, Walter is working like never before with
our partners on efficiency and productivity while keeping an interest on the health of everyone involved.

[Link]

March 2021 | [Link] 43

AUTOMATION

Boston, have become a mainstay in job shops, particularly touchscreen; other robots often are specially built for a
in high-mix, low-volume environments. With a 16-kg particular orientation. Cycle times are also reduced, particu-
payload version (UR16) introduced in 2019, UR continues larly as UR cobots can be configured with a dual gripper to
to push the boundaries of where robots can fit in to a simultaneously unload a finished part and insert a new blank.
production workflow. Critical to UR’s flexibility is the ability to combine its
2020 has been an especially busy year, noted Joe cobots with an array of third-party equipment and software.
Campbell, UR’s head of marketing for North America. Two These are accessed through the UR+ program, “a kind of
themes have emerged: pandemic-driven reorganization and app store” for UR, Campbell said. Mechanical, electrical
the embrace of new production models. and software interfaces for UR robots are published, and
third parties develop products to meet
those specifications. “More importantly,
they submit them to us for testing and
validation. If we say a gripper is plug-
and-play, it is—because we tested it.”
Included in UR’s ecosystem of 288
peripherals are part magazines, vision
systems, sensors, mounting options,
robot covers and apps. For instance,
Beacon by Hirebotics lets operators
monitor cobots via the cloud. “You can
look at production statistics and make
adjustments on the fly,” Campbell said.
In March, the UR+ program was
expanded to include application kits that
combine components like grippers with
To prevent shop equipment from sitting idle, Acieta’s CX1000 is mounted on a mobile software “to solve a particular appli-
platform that one worker can move easily so it can be quickly set up at different machines
around the shop. Collaborative robots can continue running while the operator is loading/ cation problem.” One kit, by Robotiq,
unloading parts and can even run nonstop during breaks and overnight if there are enough
inbound parts. (Provided by Acieta)
features an orbital sander, mounting
hardware, vacuum hoses and software
Small shops in particular—pressed to efficiently use that lets users program a sanding protocol for a product like
every inch of limited real estate—are deploying cobots to furniture or cabinetry. “You can program complex contours in
keep workers socially distanced, he noted. “If you’ve got a minutes, not days,” Campbell said. Meanwhile, UR’s ActiNav
cluster of three tools, you put one or two cobots in to give kit is a flexible machine loading kit that lets users take parts
the operators breathing room.” from a bin and load them into various machines at a precise
Additionally, shops are awakening to how cobots can orientation. “You can introduce a new part into the system in
boost the bottom line. “Shops are taking a different look” at less than an hour.”
the weekdays-only schedule “and finding the manufacturing Another key to getting shops to adopt automation is the
team is open to more flexibility.” One UR customer created option of virtual training. UR recently passed a milestone of
a weekend shift and found that many team members training more than 100,000 operators online through the UR
embraced the new opportunity. In other instances, shops Academy, which features free training modules in program-
that previously featured one skilled operator who performed ming and deploying UR cobots.
machine setup and loading have added cobots for the load- “If you have to send your three lead machinists off-site for
ing function while the operator oversees multiple machines. the better part of a week to get trained, your production is
UR units save shops hours in setup time. They can be crushed,” Campbell said. Small shops are “really attracted to
set up to function on a floor, wall or ceiling through the the ability to do 90 percent of their training online.”

44 Manufacturing Engineering | March 2021

Fast Loading for the Future the robot with different part sizes. The operator only needs
In addition to the automation pressures of the pan- to enter the part parameters, and the system automatically
demic, reshoring production to the U.S. is another major adjusts the program to run the new parts. The robot grippers
driver of robots and loading equip-
ment for job shops.
“Manufacturers and job shops that
have been historically slow to adopt
robotics are beginning to embrace
robotics more than ever,” said Jake
Corning, product manager and
mechanical engineer for Acieta LLC,
Waukesha, Wis. “As there are more
knowns than unknowns, both interest
and orders have increased since
the pandemic began. They see the
benefit that robotics offer in keeping
their machines running and parts being
made even in times of social distancing,
sick employees, and/or shutdowns that
are impacting production capabilities.”
Additionally, with the global supply
chain disrupted, “they also see that the
pandemic is going to bring a tremen-
dous amount of onshoring back to the
United States. They will face an even
more significant labor shortage than
they did prior to the pandemic if they
fail to embrace automation. Ultimately,
despite the tragedy that the pandemic
has inflicted in our country, U.S. manu-
facturers are already more comfortably
embracing robotic technology and are
seeing the benefits that will improve
their competitiveness, improve workers’
job satisfaction and loyalty, and deliver
to the American consumer more
competitive prices.”
Acieta offers a range of solutions
particularly suited to high-mix, low-vol-
ume routines, Corning explained.
“The FastLOAD CX1000 and
CR2000 systems are intended to be
easy to use for first-time robot users,”
he said. “Our touch screen interface for
the CR2000 makes it very easy to run

March 2021 | [Link] 45

AUTOMATION

and part fixturing are flexible for a wide variety of part sizes For job shops automating for the first time, a great
so that many different parts can run on the same system.” starting point is the collaborative CX1000, Corning said. By
Changeovers on the CR2000 can be done in minutes, freeing up workers from repetitive tasks, automation lets
and the CX1000, CR2000 and DR2000 systems are them “learn how to program or do maintenance on a robotic
designed so the robot can continue running while the opera- system. An operator who previously tended one machine
tor is loading or unloading parts. “This enables the machines can now manage robotic systems on multiple machines.”
to work nonstop during breaks, lunches and even outside of
shifts as long as there are enough inbound parts.” Solving Essential Problems
Mounted on wheels, the CX1000 is easy to maneuver on With its intimate understanding of machining and job shops’
the shop floor. It is also available with multiple quick-change unique needs, Methods Machine Tools Inc., Sudbury, Mass.,
fixturing cart options and uses FANUC’s CRX-10iA/L robot, helps manufacturers automate with an eye toward bringing in
“which has a very easy-to-use touch screen interface more business while creating a more skilled workforce.
with drag-and-drop programming icons,” said Corning. “We need more good machinists,” asserted John Lucier,
“When your challenges are more complex or larger scale, FANUC automation manager for Methods. “That’s what
our custom solutions can also be designed for high-mix, robots help us with. Robots help shops get more jobs so they
can put more machinists to work.” A
well-trained machinist is not loading and
unloading machines, “he’s setting them
up, picking tools and writing programs.”
Like other suppliers, Methods has
seen a spike in pandemic-related
automation, he said, particularly for
producing ventilator parts.
Prior to the pandemic, Lucier recalled
visiting plenty of low-volume shops
that were looking at automation for the
first time. Medium-volume operations
that change cells two or three times a
week to produce roughly 5,000 parts
are becoming common, and Methods
provides the conveyor-based Job Shop
An LR Mate robot taking workholding from the carousel to be loaded into the RoboDrill. Cell Pro line for those environments.
(Image provided by Methods Machine Tools)
Adjustable lane dividers allow rapid
low-volume part runs by using technologies such as vision, changeover between small and large parts. Another popular
end-of-arm tool changers, and flexible fixturing.” option is a series of drawers featuring a steel or aluminum
Acieta’s accompanying machine tending cells have plate with holes for 20 to 40 parts.
proved popular, Corning noted. “They are standard robot Workholding is another major consideration, Lucier
systems designed to work with a wide variety of parts. added; automated vises are a relatively simple solution. “It
Since they are pre-engineered standard products, they are doesn’t have to be complex, with swing clamps and things
much less expensive than a traditional custom system and like that. It could be something like a good old chuck or
are able to be delivered in as little as one week. All three vise with pneumatics or hydraulics to open and close, and
systems can tend multiple machine tools at one time. In you’re making your own jaws—not unlike what a lot of
addition, our CX1000 and CR2000 systems utilize col- shops are doing with runs of about 50 parts.
laborative robots, which help maximize floor space usage For lower-volume parts, even as low as lot sizes of one,
because they don’t require safety fencing.” Methods offers the Plus-K and Plus-K 60 robotic rotary

46 Manufacturing Engineering | March 2021

storage carousel systems. “We’re not making the robot instance, he often reminds shops that they can machine their
part-specific; the robot is set up to bring generic workholding own steel or aluminum grippers. And, tweaking the programs
in and out of the machine, whether it’s a little vise or pallet. pre-supplied on robots can be easier than CNC programming.
The robot is set up to grab a common
feature on the front of the workholding.”
Parts are loaded into a manual vise, and
the robot is pre-programmed to act like
a pallet loading system; no end-user Browse Carr Lane Mfg.’s
automation tooling
programming is necessary. This system
also enhances the standard tool offering
on the RoboDrill, going from 21 to an
optional 161 tools.
systems for new solutions

Through Hole Air Rest Buttons

Screw Rest Button

The IMA Mobile app from Mitsubishi Electric

Automation provides a simple method for
monitoring CNC machines. (Image provided
by Mitsubishi Electric Automation)

With solutions such as these, job

shops typically see return on invest-
ment in less than 12 to 18 months.
“Our goal is to convince you to run it
two or three shifts—to take a robotic
cell, fill the infeed system with parts
and go home at 5:00 PM, and get two
to six hours of run time. If I can get an
Pivoting Edge Clamp
automated system that handles 80
percent of the work you plan on doing,
we’re doing pretty darn good.”
Informing Methods’ solutions is a 314.647.6200
[Link]/automation
longstanding connection to job shops
and knowledge of how they work, noted
Lucier, himself a machinist by trade. For

March 2021 | [Link] 47

AUTOMATION

The company’s automation integration group is keenly aware compensation claims for the company—and workers don’t
of the issues surrounding machine tools, from coolant and call in sick as often either, saving [the shop] a lot of money.”
chips to tool rotation, tool life, deburring and more. As other shops have found, the increased availability of
“If you’re going to put robots on machine tools, you want operators for other tasks often means “they have more time to
a robot integrator who does that,” Lucier concluded. “The contribute to the overall processes, like quality-control checks.
benefits of robots should not be challenging to justify.” They are more involved in process management rather than
simply pushing buttons and are less bored and fatigued.”
Assessing Need, Adding Speed Obtaining those benefits can be surprisingly cost effec-
Understanding a job shop’s needs for automation tive, Ortner added. “Our cobot line from Productive Robotics
begins with a thorough evaluation of the volume required to starts at $34,900 for the basic CNC package. You can go
increase productivity. from basic CNC package and upgrade to a fully integrated
When hired by a client, said Absolute’s Ortner, “we do a cell using several cobots, conveyors, in-process gaging and
system layout, decide best practices to automate—conveyor part presentation methods.”
systems, robots, raw material handling, finish part handling—
then design it in CAD to ensure all the pieces fit in their floor Monitoring For More Output
plan, all the while working within their budget.” To help shops keep jobs on schedule and run more proj-
In addition to offering an array of standard automation ects unattended, Mitsubishi Electric Automation Inc., Vernon
equipment, from cobots to part handling to monitoring, Hills, Illinois offers its MTConnect-based Integrated Machine
Absolute “offers a turnkey package,” said Ortner. “We Analytics (IMA) for machine monitoring. The IMA Mobile app
source what we feel is the best solution and work with those offers an easy-to-install entry into machine monitoring.
suppliers to ensure success.” With IMA, shops “are able to better understand produc-
tion, which helps with accurately scheduling jobs to take
full advantage of their available machines and work hours,
as well as more accurately bid for more jobs,” said Robert
Brodecki, IMA mobile service product manager for Mitsubishi
Electric Automation.
The only hardware required is Ethernet cabling and a
hub/switch if connecting multiple machines, and it takes
as little as 5-10 minutes a machine to set up, he explained.
“With the low cost point, users can see ROI within days,
especially if they’re running unattended or lights-out
production and have lost production time due to a machine
faulting out and not finding out until later on. With IMA
Mobile’s notifications, you’ll know within 10 to 15 seconds if
U.S. manufacturers are turning to robotic technology to improve their a machine has stopped cutting, no matter where you are.”
profitability in the competitive manufacturing industry. Collaborative
robots can continue running while the operator is loading/unloading Machine monitoring improves throughput significantly, he
parts and can even run nonstop during breaks and overnight if there added. “Just looking at execution state, a lot of job shops
are enough inbound parts. (Image provided by Acieta)
usually have machines running jobs between 25 and 40
Absolute’s experience in sourcing the right equipment percent of their available time. Through simple monitoring of
clearly pays off, she noted. “One client using an OB7 cobot current status via IMA Mobile, they can quickly move that to
is getting 20 percent more efficiency and a lot less scrap in 50 percent or more by being able to immediately attend to
a shift. They are able to reduce delivery times by two weeks any machine that has stopped production for any reason.
on this particular run, which opens up the machine or cell for This is actual data straight off the machine, too; it removes
additional work for a higher ROI. Also, because they don’t the guessing game of how long the machine was cutting, in
have to do repetitive tasks as often, there are fewer workers idle, or off.” Available machine hours are expanded by running

48 Manufacturing Engineering | March 2021

more shifts with fewer workers—or unattended—without lost realized they weren’t going to be able to avoid automation
production because of an unexpected stoppage. and remote working solutions any longer, they’ve been
With IMA Mobile, operators can move to value-added tasks moving these projects to the top of the list.”
“knowing that the app will notify them
when the job is finished or interrupted by
something that needs attention.”
With relatively low cost of entry, Introducing the
Brodecki noted, IMA lets users
“understand their production and FDG-700
make improvements, as well as start
simpler, unattended machining projects Double-sided
while being assured their machines
are continuing to run. Since it’s all built grinder
around the MTConnect standard, if a
user decides to move to a more in-depth, High-precision digital
pneumatic system
customizable monitoring system, they
don’t need to pay to have their machines
High-precision contact
connected again; they simply point the
micro measure system
new software to the MTConnect Agents
and machine data is quickly accessible.”
Great rigidity from high horsepower
That ease of entry has been spindle with gear box
particularly important to automating
in the time of COVID, he concluded. Temperature controlled
“It makes sense, since companies are coolant system
looking to automate more, but it’s hard
to know exactly where and how without Ergonomically designed for greater
accurate production data to identify the efficiency and productivity
areas to automate. At the beginning
Finer workpieces in
of the pandemic, many companies we larger quantities
were talking with were still on the fence
about machine monitoring. As the All this and more. In no time flat.
pandemic has worn on and companies

FYI Nothing
Acieta LLC
844-422-4382 / [Link] could be finer
Absolute Machine Tools Inc.
800-852-7825 / [Link]
➤ Learn more at [Link]/FDG700
Methods Machine Tools
877-668-4262 / [Link]

Mitsubishi Electric Automation Inc.

847-478-2100 / [Link]/
fa/en

Universal Robots
844-462-6268 / [Link]

March 2021 | [Link] 49

CONTROLS

The Connected Control

The Internet and cloud-based computing are changing how
manufacturers operate CNC machine tools. Is your shop ready for it?

KIP HANSON
Contributing Editor

E
thernet ports first started Klaus Schwab published a paper in FANUC offers two data analytics
programs, MT-LINKi and FASData
appearing on CNC lathes 2015 stating that the world had entered (shown here), both able to capture
and machining centers more a Fourth Industrial Revolution. vast amounts of machine tool data.
(Provided by FANUC America)
than 20 years ago. The Welcome to 2021. It should be evi-
MTConnect machine tool communi- dent by now to machine shop owners,
cation standard made its official U.S. CNC programmers, and manufacturing
debut at the 2010 IMTS in Chicago. engineers that the machining industry
Manufacturers began talking about has changed significantly over the past
cloud computing and the Industrial two decades. CNC machine tools are
Internet of Things (IIoT) shortly far smarter than they once were, able
afterward, terms that would become to generate significant amounts of
mainstream when German economist data about all that’s going on behind

50 Manufacturing Engineering | March 2021

the glass. Manufacturing software has also gotten smarter,
offering interoperability and cloud-based capabilities only
dreamed of at the turn of the century.
Whether all of this technical wizardry is a good thing or
not is up for debate. Some might argue that life on the shop
floor is already challenging enough—who needs Big Data and
smart machinery when there are barely enough hours in the
day to get parts out the door? Others see Industry 4.0 and all
that it entails as the clear path forward for manufacturers, and
anyone who doesn’t embrace it will soon be out of business.

Gaining FOCAS
Heidenhain customers can install the company’s StateMonitor
The truth lies somewhere in between. Paul Webster, software on their corporate network or in the cloud, although the
director of F.A. Engineering at FANUC America Corp., company suggests that “on-prem” installations are more secure.
(Provided by Heidenhain)
headquartered in Rochester Hills, Mich., noted that CNC
machine tools have been network- and Internet-ready since gaining a complete picture of shop floor activities becomes
before Y2K. Shops choosing to ignore this capability are no more difficult than glancing at the dashboard of what-
still chugging along just fine, thank you, and will continue ever monitoring software gathers this data.
to do so for years to come. And yet,
few would argue that machine tool
connectivity and the greater visibility to 6-axis Tool Grinding Machine Grindsmart®630XW
machining processes thus enabled is High-efficiency synchronous spindle motors, highest radius contour accuracy
never a bad thing, and may make the Boring bar geometry, neck and shank-end in one setup
Wide grinding range Ø .004" to 3/4"
difference between a profitable job and
one you’d just as soon forget.
“We introduced our FOCAS API
(application programming interface) in
the early 90s, as well as fiber optic and
then Ethernet ports, so connecting a
CNC has been easy for quite some
time now,” he said. “The hard part has
always been figuring out what data you
need and what you’re going to do with
it once you have it.”
This data includes alarm histories,
feed rate and spindle override settings,
servo motor and spindle temperatures,
power consumption, macro variables,
and much more, all of which can
be pulled from the machine tool on
a continuous and automatic basis.
Add to this various operator-supplied
inputs—job number, production
status, cutting tool consumption, and
[Link]
even part quality information—and

March 2021 | [Link] 51

CONTROLS

In FANUC’s case, this is MT-LINKi, a brand-agnostic machine tools and software systems to a properly secured
analytics platform able to monitor more than 1,000 CNC corporate network,” he said. “There’ve been many instances
machine tools at once, as well as FASData, a production where shops have been hacked and forced to make ransom
monitoring program. Other control builders offer similar payments. Granted, these attacks are typically accomplished
solutions, as do many machine tool builders, cutting tool through email and not through the machine tool control, but
suppliers, and third-party software developers. All provide it’s a concern nonetheless. This is why the NTMA (National
the means to gather what is admittedly a mountain of data Tooling and Machining Association) has begun offering
and present it in a way that makes sense to humans, giving seminars showing manufacturers how they can protect
them the ability to react to trends and potential problems themselves against these types of cybercrime.”
long before they can negatively impact production levels. Despite this, Ledvon admits that the cloud is a technology
trend that will only gain momentum. What’s needed to
The Cloud Conundrum mitigate any associated risks are good IT housekeeping
The question then becomes where is the best place to practices. Install a robust firewall between the shop’s
store this data and house the software used to analyze it? network and the outside world. Avoid direct CNC-to-cloud
Should both be located in the cloud at an off-site hosting connections by downloading external files, software pro-
facility and managed by dedicated hardware and software grams, and patches to a secure internal server, then check
specialists? Or is an “on-premise” installation more appropri- them with anti-virus software before distribution. Train all
ate, using whatever internal IT talent the shop possesses? computer users how to manage passwords, spot malicious
emails and websites, and protect corporate information. The
list goes on.
“Considering that the control is the nerve center of any
machine tool, I don’t feel that the convenience of cloud
access is worth the risk of exposure to the Internet,” said
Ledvon. “None of this stops manufacturers from implement-
ing an Industry 4.0 strategy, however. By all means, they
should network their machine tools and begin collecting data
for analysis. Doing so will give them the information needed
to set up machines faster, reduce cycle times, maximize tool
life, and gain all the other advantages offered by today’s CNC
controls and software systems.”

Real-time machine condition and part quality monitoring is Native Talent

just one of the many benefits offered by Siemens Industry’s Another component of Industry 4.0 is the digital twin,
SINUMERIK One controller. (Provided by Siemens Industry)
which in this case refers to a virtual but highly accurate
Webster and the others interviewed for this article largely and comprehensive representation of a CNC machine tool.
agreed that, while the former is often the more secure and According to Vivek Furtado, head of digitalization—machine
cost-effective approach, many shops remain skittish about tools for Siemens Industry Inc., Elk Grove Village, Illinois,
part programs and production data leaving their facility. So digital twins streamline the design and deployment of CNC
does Gisbert Ledvon, director of business development machinery, ultimately making manufacturers more efficient.
for machine tools at Schaumburg, Ill.-based Heidenhain “Our SINUMERIK One controller is known as a digital
Corp. He noted that customers can install the company’s native, in that it was built from the ground up to support the
StateMonitor software wherever they wish, but promotes digital twin and other enabling technologies,” he said. “It
onsite installations whenever possible. gives CNC machine tool manufacturers the ability to create
“Our philosophy is that customers should protect their a virtual version of a lathe or machining center containing all
intellectual property, and to us, that means connecting their of its kinematics and operating characteristics. This greatly

52 Manufacturing Engineering | March 2021

reduces engineering time and development costs, and This intelligence extends to the machining process as
assures that the product will meet the end-users needs.” well. Siemens, FANUC, and third-party solution providers
Digital twin-capable controllers serve other purposes. such as Caron Engineering offer adaptive control capabilities
They speed the training of new
employees and reduce the chance that
one will crash an expensive machine
tool. They allow estimators to more
accurately quote jobs, engineers to
develop optimized manufacturing
processes, and CNC programmers to
validate G-code and cutting tool selec-
tion before sending work to the shop
floor. Once there, they make machine
tool operation easier with enhanced
graphics and greater usability.
Anyone with a high-end CAM
system or PLM software might say they
can accomplish most of this without
an advanced CNC control. And while
there’s no arguing that these and other
software platforms’ capabilities have
increased dramatically over recent
years, machine tools that partake in
the digital thread provide machine
shops with an important tool, one that
enhances data exchange and closes
the loop on interoperability.
The Possibilities Are Endless
Adapt and Overcome with the Versatile E-Speed
Digital twinning aside, Furtado
ONE-PIECE & MODULAR ELECTRIC MOTOR SPINDLES
suggested that CNC controllers are
becoming much more intelligent • Versatile for Lathes, Machining Centers, Custom
and user-friendly, with functions and Machine Applications and Robotic Applications
features that any smartphone user • Maximum Speed 80,000 rpm
will recognize. “Most of us remember • Maximum Output 1,200W
that we once used our phones to call • Accuracy Less than 1 µm
people,” he said. “Today, they let you
monitor your health, search for infor- Flange and Straight Motors/Spindles Available in:
mation, place orders for products, and ø20mm | ø22.8mm | ø25mm | ø30mm | ø40mm
so on. Newer generations of controllers
offer similar functionality. They’re able to
process information and prepare data in
ways that allow it to be more effectively
utilized by their human operators, or by [Link] | Phone: (847) 843-7664 | Toll Free: (800) 585-4675
other systems.”

March 2021 | [Link] 53

CONTROLS

that continuously monitor spindle and axis loads, machine mentioned earlier. “Controls of the future will be equipped
vibration, and similar factors that affect cutting tool life and with 5G, and the data they generate can then be sent
part quality. These smart systems then adjust machining wirelessly at speeds up to 10 gigabits per second (Gbit/s) to
parameters in real-time, optimizing material removal and so-called edge devices,” he said. “We expect that within a
eliminating potential problems. few years, this technology will fundamentally transform how
Fagor Automation Corp., Elk Grove Village, Illinois, is another manufacturers gather information from the shop floor.”
control provider with its eye on the Industry 4.0 prize. Harsh The downside to Industry 4.0 is the lack of skilled workers
Bibra, general manager for North America at Fagor, explained able to understand and work with advanced technology.
that its ARFS (Adaptive Real-time Feed and Speed) control Bibra said retraining will be needed as manufacturers
does all this and more, but noted that this type of sensor-based become more tech-savvy. However, any concerns over tribal
technology can also be used for predictive maintenance. knowledge and the loss of experience due to employee
attrition and retirement should become ancient history.

Visiting the Store

Jim Kosmala, vice president of engineering and technology
at Okuma America Corp., Charlotte, N.C., attributes much
of today’s increased connectivity to the use of PC-based
controls. “A lot of people forget that Okuma is not only a
machine tool builder, but also makes its own servo systems
and controllers. These run on Microsoft Windows and use an
Intel chip, both of which provide easy connectivity.”
PC-based controls also make it easy to install various
software programs onto the control—at the start of the COVID
pandemic, for instance, Okuma customers could collaborate
Fagor’s ARFS (Adaptive Real-time Feed and Speed) control offers
adaptive control capabilities that continuously monitor spindle and with others using Microsoft Teams, sharing screens or giving
axis loads, machine vibration, and other values.
(Provided by Fagor Automation)
others remote control as needed. “That’s the whole idea
behind our App Store,” Kosmala said. “Users can download
“We also offer our i4.0 Connectivity Pack,” he said. “This and install whatever they need directly on the OSP control,
allows users to collect machining data, of course, but also eliminating the need for a separate PC. It represents entirely
do things like send condition-based alerts, tune the machine new possibilities for collaboration and connectivity.”
tool and update its firmware, change parameter settings, and One of these apps is Okuma’s Connect Plan, which
so on, all from a mobile device or remote computer.” allows users to monitor CNC machine tools and gather
operational data. It works with most any brand or vintage of
The Biggest Bottleneck machine tool as well as robots and other forms of automa-
Bibra sees big changes ahead. Aside from the increased tion. According to Kosmala, however, Connect Plan uses an
use of IIoT-capable sensors and accelerometers in machine AI algorithm to look at the available information and identify
tools, together with more intelligent controllers, the factories trends that a human might miss.
themselves will become smarter. Artificial intelligence (AI) well Consider the manager of a turning department, who
beyond the adaptive capabilities just mentioned will become notices after weeks of looking at data collection reports and
prevalent, opening doors to the automated decision-making dashboards that a certain lathe always starts up 10 minutes
necessary for widespread lights-out manufacturing. late each morning thanks to the operator’s coffee habit, or that
All of this will quite literally gain speed given the develop- the spindle temperature on the grinder closest to the shipping
ment and subsequent roll-out of 5G cellular networks, Bibra department drops every time they open the loading door.
suggested. These will not only increase Internet bandwidth Kosmala explained that AI picks up on these trends much
and reduce latency, but possibly alleviate the hacking fears more quickly than a human, giving supervisors the ability to

54 Manufacturing Engineering | March 2021

address potential problem areas sooner. What’s more, this the plant, so much the better. It’s all about increasing efficiency
information is stored in a database, so when the supervisor and machine uptime, both of which are more easily accom-
leaves the company, there’s no loss of knowledge. plished using modern CNC controllers.”
“Deming told us that without data,
you’re just another person with an
Direct Corporate Support
opinion,” Kosmala said. “The IIoT and We respond in 30 minutes or less!
Industry 4.0 are about collecting that
C A M S y s t e m

The only CAM system

you’ll ever need

[Link] Support from 8:00am EST

support@[Link] to 6:00pm PST

Because Okuma’s OSP control is PC-based,

it’s easy to download and install software
from the company’s App Store and other
sources. (Provided by Okuma America)

n
is

ur
ax

illT
5-

data and making use of it, ultimately

M
turning it into knowledge. That’s the first
step for anyone on this journey. We now
have virtual conferencing, and the ability
to check machine status or production
levels from anywhere, and access to
remote tools that simplify automation. If
you can do that without having to go into
in on
e
yl

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FYI
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is

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Sw

Pr

Fagor Automation USA

847-981-1500 / [Link]

FANUC America Corp.

888-326-8287 / [Link]

Heidenhain Corp.
847-490-1191 / [Link]

Okuma America Corp.

ni d

704-588-7000 / [Link]
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Siemens Industry Inc.

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800-879-8079 / [Link]/cnc

March 2021 | [Link] 55

CUTTING TOOLS

Parting and Grooving

for the Long Haul
Providers continue to innovate one of
the toughest applications in machining

BILL KOENIG
Senior Editor

S
ome trends in machining USA Inc., Franklin, Tenn. “More tool life Horn’s 960 system mounted to a standard
BMT connection, with opposite hand
remain constant. Machine and predictability, better chip control replacement cassette shown.
speeds continue to increase. and surface finish. These demands (Provided by Horn USA)

Difficult-to-cut materials have not changed in many years, nor

are used more frequently. The desire will they change anytime soon.”
for better cooling, chip control and Added Steve Vanderink, national
reliability remains. product specialist for grip products at
“Users are always demanding the Iscar USA, Arlington, Texas, “Users
same thing,” said John Kollenbroich, are demanding ease of indexing of
head of product management at Horn the insert with accurate repeatability

56 Manufacturing Engineering | March 2021

while increasing productivity with rigid support and strength Kollenbroich said. “This switch in axis feed directs forces
in the pockets—all while keeping an eye on the economics. back into the holder instead of against the holder. The
The market wants it all. Innovation is the driving force for improved strength allows for feed rate increases of two or
solutions to the market’s needs.” three times that of standard X-axis part-off applications.”
Higher machine speeds are also a big part of the demand Iscar has had a series of product launches to address
on tools. “As the machines get more capable of higher customer demands. “Cut Grip is one of the most complete and
speeds and torques, and the demand to get more out of comprehensive grooving lines on the market,” Vanderink said.
the same tool constantly increases, manufacturers have to “Iscar promotes and champions the GTO (groove turn oper-
respond accordingly,” said Sarang Garud, product manager ation) as a cornerstone process for this line. Straight grooving
at Walter USA LLC, Waukesha, Wis. and then turning side to side utilizing all edges of the insert
As a result, toolmakers continue to step up their game. reduces cycle time while producing excellent part finishes.”
“As tool designers, we need to increase the pocket
security of our grooving platforms to allow customers the
freedom (to) turn in all directions,” said John Winter, turning
specialist at Sandvik Coromant, Fair Lawn, N.J.
“We are seeing the increased usage of Y-axis grooving
and parting-off. By using this axis of the machine, we are
able to increase cutting data, allowing our customers to
reduce their cycle times,” he said. “Machine tool builders are
adding features to their machines that allow for the use of
the Y axis. Also, builders are looking at increasing the stroke
of the Y axis, allowing for increased diameters where you can
use Y-axis part-off tools.”

Coolant and Coatings

At Horn USA, the company is offering coolant on more
of its products. “This includes part-off and grooving holders
and even some inserts,” Kollenbroich said. “Getting coolant
to the cutting edge has many advantages. For one, having
a more accurate delivery method for the coolant direction The Sandvik Coromant CoroCut QD platform can part-off in
both the X and Y axis and can also face groove, according to the
helps in cooling the work zone. It also offers the benefit of company. (Provided by Sandvik Coromant)
chip breaking when used with higher pressure applications.”
The company also looks to coating for product improve- Another example: “Heli Grip is a game changer due to
ment. “We offer coatings that are capable of handling heat its unique twisted geometry, enabling depths of cuts to go
better, which in part-off and grooving is always a challenge,” beyond the second edge of the insert without damaging it.”
he said. He said that results in “much deeper depths of cut—groov-
Kollenbroich described how Horn addressed that chal- ing and excellent groove turn capabilities.”
lenge with its 960 part-off system. “This is a cassette-based,
coolant-through design that offers a major upgrade in Low Vibration, Longer Life
blade stability,” he said. “This additional stability results in Walter USA has adjusted the way it clamps its inserts.
great improvement in tool life. Customers can realize gains “Usually the grooving inserts are held either through a
of double or triple the tool life while showing dimensional self-clamping mechanism or through a ‘top-clamp’ screw-
improvements in flatness and surface finish.” down mechanism,” Garud said. “The more secure the insert
Horn also offers a Y-axis part-off system. “This system in the pocket, the lesser the tendency of vibration and longer
uses the Y axis of certain lathes as feed direction,” the insert life.

March 2021 | [Link] 57

CUTTING TOOLS

“Also, lower vibrations lead to less

pitting of the tool pocket, increasing
toolholder life,” Garud continued. “The
new patented design by Walter for
our DX18 inserts securely clamps the
inserts on three sides.” It also has “a
secure prismatic base: a V-shaped top
groove for the top clamping finger and
a small double-faceted groove at the
back of the insert to seat it securely in
the insert pocket.”
Sandvik Coromant works to make
its products flexible. Winter said that
Walter’s side-access insert clamping screw offers quick indexing on gang tooling.
with CoroCut 1-2 “you can part-off, (Provided by Walter USA)
groove, face groove and do high-feed
machining of hardened steel. The CoroCut QD platform can delivery, remove chips from the work zone. This helps
part-off in both the X and Y axis and face groove.” improve tool life and overall performance.”
Vanderink of Iscar described other considerations.
Machines, Jet Coolant and Holders “Jet cut tooling is vital today,” he said. “Iscar has taken
Improvements in machine tools have also altered the great care in making sure coolant is introduced to the cutting
way companies design tools. “The biggest improvement in edge of the insert even when high pressure is not accessible.
machines that I have noticed is more machines are running Data has shown that in all cases this makes a difference in
high-pressure coolant,” Kollenbroich of Horn said. “Even the tool life and part quality.
“Multi-axis, multi-spindle machine tools with Y-axis
capabilities are emerging to complete parts in one setup,”
Vanderink continued. “The use of robots on the shop floor
is increasing and is becoming a viable operation for small to
medium-sized shops now.”
According to Garud, Walter is also adjusting design. “The
need for higher volumes and reduced cycle times is always
weighing down on tool manufacturers,” he said. “Walter
recently introduced a new line of G4014 toolholders specif-
ically designed for gang tooling. One of the key features of
these holders is the side-access screw to clamp the insert
into the toolholder.
“The side-lock, or ‘smart lock’ as the technology is
called, allows the users to index the inserts while the tool is
The new Penta 17 has five cutting edges and allows for parting, still clamped onto the gang tooling of a Swiss machine,” he
grooving, side turning, back turning and threading. This new,
smaller design is primarily for the Swiss machining industry, and continued. “The side access to the indexing screws allows a
is a Penta line expansion, joining the larger Penta 24 and Penta 34 time reduction of up to 70 percent in insert indexing, saving
tools. (Provided by Iscar USA)
valuable time on high-volume Swiss machining operations.”
standard offering from most manufacturers is a considerable
jump in pressure from what it was just a few years ago. Cutting Geometry Essentials
High-pressure coolant offers benefits in chip breaking. Industry changes also create other considerations for
Coolant-through tools, with better and more focused coolant toolmakers and their customers. “Geometry always plays

58 Manufacturing Engineering | March 2021

a critical role in grooving operations,” Walter’s Garud Progress in various manufacturing technologies may play
said. “But parting-off operations typically tend to need a role in the future for parting and grooving, Iscar’s Vanderink
the inserts to go all the way to the center of the bar, said. “Additive manufacturing will be a big player from here
so cutting speeds are zero at the center, which means on out,” he said. “Already, new concepts are on the way
tougher grades are always going to be
better than the harder grades. Also,
chip-crimping is quite important. Not
only do the chips need to curl into
‘sixes and nines’ shapes, they also
need to be folded axially, so the chip
breakers need to be aggressive to fold
the chips.”
Added Vanderink of Iscar,
“Technically, center-height position of the
tool is critical. The process of a square
tool plunging into a round part is very
abusive. The centerline dynamic is not
fiction. It is real and essential for success
in these applications.”
He also said clamping is an issue.
“Using torque wrenches when clamping
inserts in all parting and grooving tools is
essential to maintain clamping force, tool Horn’s Y-axis part-off blade 960 system mounted to HSK adapter. (Provided by Horn USA)
integrity and finally part quality.”
Kollenbroich of Horn noted that managing centerline due to this technology. Additive manufacturing producing
is critical. “Centerline can be your biggest friend and your near-net shaped parts will change how removing material is
worst enemy. All manufacturers design their tools to work viewed. This concept alone will drive the innovation needed
on center. When a machine is off, even slightly, things to accommodate these types of components.”
become unpredictable. Customers typically experience Advancements in carbide substrates are “ever chang-
a drop in tool life, maybe poor surface finish or, worse ing and we are seeing new grades and coatings that
yet, catastrophic failure. It is critical to apply part-off and are making a meaningful impact in tool life,” he added.
grooving tools properly, and on center.” “Industry 4.0 is expanding into tooling more and more.
Tracking of tool life and wear is becoming a seamless part
The Trend to Greater Control of the manufacturing process.”
One question is what to expect in the next few years.
“I believe one thing we will see is machines equipped with
sensor monitoring technology watching slight changes in the FYI
tool and adjusting accordingly,” Kollenbroich said. “Some Horn USA Inc.
machine manufacturers already have things like this, but they 888-818-4676 / [Link]
are not accurate or sensitive enough yet. Incorporating this Iscar USA
sensor technology into the toolholder and tying directly into 817-258-3200 / [Link]
the machine control is a possibility.” Sandvik Coromant
Said Winter of Sandvik Coromant, “We will see machines 201-794-5000 / [Link]
turning in all directions and the requirement for part-off and Walter USA LLC
grooving tools is to do the same.” 800-945-5554 / [Link]

March 2021 | [Link] 59

SOFTWARE

Simulation Software
Meets the Need for Speed
The latest additions for CNC toolpath simulation adds speedier programs,
better accuracy and digital twin capabilities

PATRICK WAURZYNIAK
Contributing Editor

T
oolpath simulation software However, choices range from basic Manufacturers rely on digital twin
toolpath simulation to reduce the
gives manufacturers assur- to sophisticated, and it pays to know machine setup time by an average of
ance that their machine tools when to use the right simulation for 65 percent, giving them the confidence
to run the program and reduce the
will cut parts quickly and your individual needs. number of iterations during the test run.
(Provided by DP Technology)
accurately, which is particularly useful To the point, most CAD/CAM
when machining expensive materials systems feature some basic simulation
like titanium or Inconel. Today’s CAM capabilities using plug-in component
software offers users a growing modules that simply use cutter location
number of choices of how to prevent (CL) data. CAM users needing higher
costly machine tool collisions and other resolution simulations can look toward
metalcutting errors. third-party NC simulation programs,

60 Manufacturing Engineering | March 2021

such as CGTech’s VERICUT or Hexagon’s
NCSIMUL. These third-party applications
offer G-code simulation of all parameters
used in the cutting process, including
cutting tools, the machine tool and any
accessories used in machining compo-
nents, to help avoid costly mistakes.

Fast and Accurate Metalcutting

Today’s machine tool environments more
often require that manufacturers employ
digital twin simulation—visualizing the actual
machining process for optimal accuracy.
“A key trend in toolpath simulation is digital With the accuracy and performance improvements of simulation, programmers can
get near instantaneous feedback and simulation can be used to interactively create
twin simulation, which provides a precise each operation. (Provided by CAMWorks/HCL)
digital replica of the entire machining envi-
ronment and leverages the full knowledge of your machine’s Inc. is based in Scottsdale, Ariz.) “Many CAM systems
capacities, such as axis limits, turning option, or kinematic still simulate based on internal CL, or cutter location data,
chain, to maximize your productivity,”
said Chuck Mathews, executive vice
president, DP Technology Corp., the
Camarillo, Calif.-based developer of
ESPRIT CAM software. “Digital twin
simulation also drastically reduces
machine setup time for manufacturers.”
Another key trend is to incorporate
digital twin toolpath simulation early,
in the programming stage, rather
than only in the verification stage,
Mathews added. “With a complete
machine awareness and the help of AI
algorithms, modern CAM software can
optimize the toolpath with the shortest
cycle time (reduce air cutting, minimize
tool changes, axis rotations), and
produce clean, edit-free NC codes,”
he said. “This reduces the need to use
separate software to verify and optimize
the toolpath after programming.”
Accurate G-code simulation avoids
machine collisions and broken tools,
according to Marc Bissell, senior appli-
cations specialist for HCL Technologies
Ltd., the Noida, India-based developer
of CAMWorks software. (HCL America

March 2021 | [Link] 61

SOFTWARE

which can leave opportunities for errors in the final G-code on the machine lets them know that a successful simulation
program,” Bissell said. “In addition, CNC machines operate guarantees a safe and successful cut,” Mund added.
differently based on their configuration and parameter Other considerations are the ability to get specific
settings. Using CAMWorks Virtual Machine, the machine information about the machine and cut to potentially refine
simulation is based on the same G-code file that will run a machining process and the general speed and ease with
the physical machine and the virtual machine is configured which a user can test multiple setups and strategies, he said.
to behave exactly as the real machine. This helps ensure Integrating component modules into CAM systems
WYSIWYG (what you see is what you get).” isn’t always easy, Mund noted. “Incorporating specialized
components into CAM systems is a powerful way of bringing
Simulation for Speedy Precision together complementary software tools in a single package.
Key trends in toolpath simulation are simple—delivering It is a widely used technique across the CAM marketplace,”
richer data that is immediately useful and increases the Mund said. “While prevalent, it’s not as straightforward as
precision and productivity of the results. This is according to simply plugging in a component. Proper implementation
Ben Mund, senior market analyst for CNC Software Inc., the requires changes, refinements, and new features to fully
Tolland, Conn.-based developer of Mastercam software. complement the tools and tool motion being simulated.”
He also noted that, in addition to the integrated simulation
delivered with a CAM system, there are also completely
stand-alone simulation options unconnected to any CAM
system. Both these options carry strengths and weaknesses,
and it is good to evaluate both.

G-Code Simulations
The third-party applications offering true G-code simula-
tion and verification include VERICUT from CGTech, based
in Irvine, Calif., and Hexagon Manufacturing Intelligence’s
NCSIMUL, acquired from a French software developer.
“Toolpath simulation and, more accurately, G-code
verification, as performed by NCSIMUL, has historically
helped manufacturers validate their programs, check the
CNC machining process against any type of collision, and
Simulation in Mastercam shows a workpiece model being ensure that parts are produced right, the first time,” said
machined. (Provided by CNC Software)
Silvere Proisy, NCSIMUL U.S. general manager. “Our user
“Good toolpath simulation software will reliably track experience is articulated around those three steps, built into
and note potential gouges, collisions, axis overtravels and NCSIMUL verification since the beginning. Proving out CNC
more. Programmers can interrogate the tool motion itself to programs offline remains the predominant need for all users
see exactly where a move is and other important pieces of of toolpath simulation software and is even more crucial for
information,” Mund said. “Some simulation solutions also multi-axis machining.”
track material removal rates, warn of spikes, or track axis Developing greater ability to predict metalcutting issues
reversals. But in the end, all simulation software must let is a significant emerging trend, he added. “While feed rate
the programmer see the accuracy of the material remaining optimization when moving the spindle around parts or cutting
compared to the desired finished part. material is the most obvious solution, simulating spindle
“If a programmer can avoid running a setup piece or slowly torque limitations and cutting force applied to tools provides
stepping through the first run of a program at the machine, they better technical data about the cutting process for program-
save considerable time and money and boost their productivity. mers, even before parts head to real CNC machines,” Proisy
Having a reliable, accurate representation of the cut motion said. “Hexagon has addressed those optimization needs with

62 Manufacturing Engineering | March 2021

Optitool, and the physics of cutting with Optipower. We can • enhanced “learn” modes for optimization, and
even predict the areas of wear and tear on turning inserts.” more optimization strategies such as calculating
Similarly, the G-code verification and optimization capabil- feed rates and subdividing tool motions to achieve
ities of VERICUT achieve higher accuracy with visualizations. constant ideal chip thicknesses as much as possible,
“All roads lead to ‘optimization,’” said Gene Granata, while simultaneously ensuring maximum allowable
VERICUT product manager for CGTech. “Companies are tool deflection, cutting forces, and spindle power
searching for and learning which optimization products work demands are not exceeded.
best and deliver touted results. The
shortest optimized run time isn’t always
best—it’s more about ‘real’ constant
chip thickness and consistency of
machining conditions that provide the
best overall results, increased tool life
and extended CNC machine longevity.”
Using specialized NC toolpath opti-
mization software like VERICUT’s Force
optimization can address all of these
issues in real time or batch processing, on
new or existing NC programs, and des-
tined for any NC machine—which is key
for automating metalcutting productivity,
Granata noted. He said key elements Simulation with VERICUT Force Charts shows details of an optimized milling operation.
Feed rates have been automatically adjusted to maintain constant ideal chip thickness
include gathering data to make data- as much as possible, resulting in machining times being reduced as much as 30 to 70
driven decisions (instead of “guesses”); percent (as seen in horizontal bar graphs), while cutting forces are simultaneously kept at
safe levels for the cutting tool and CNC machine. (Provided by CGTech)
more accurate data helps companies
provide more competitive quotes in a world of shrinking profit New features in NCSIMUL include faster processing
margins; connecting to CNC machines is becoming more as well as intermediate stock management that optimally
popular, primarily for monitoring overall equipment efficiency restarts the simulation where the new G-code iteration
(OEE); and access to “good” machining data (not just “Big generates a different result, Proisy said. “This is a smart way
Data”) can enable programmers to make better decisions, to save hours of simulation when setting up a new program
improve machining methods, and achieve optimal machining with trial and errors.
results the first time out. “Doing so early in the manufacturing “Beyond the traditional feed rate and force optimization
process, at the NC programming and simulation levels, is capabilities, we are now addressing five-axis singularity
much more cost- and time-effective than on-machine prove- point issues by predicting the lines of code where the user
outs and testing,” he added. will have vibrations or surface quality issues,” Proisy con-
Additions to CGTech’s VERICUT 9.2 software include: tinued. “The simulation can rate the five-axis machinability
• improved speed with faster collision checking, turning from a cutting strategy and determine if the cutting feed
and mill-turn operations, and machining with complex rate is achievable; eventually the programmer will decide to
cutting tools such as those often distributed by cloud- reposition the part in the machine, if necessary. Before this
based tooling repositories; new development, five-axis quality analysis could not be
• new cutting data graphs that provide the means to done prior to cutting the part, so bad surface quality could
gather more key information about machining processes, only be observed after the fact. Cutting time analysis for
highlight tool overloads/safety concerns, and show five-axis machining is becoming very important for better
when cutters are underutilized or machining methods are prediction; it’s a key factor when deciding between the
inefficient; and multiple five-axis strategies available.”

March 2021 | [Link] 63

SOFTWARE

Simulations Optimize Nikola Motor’s Machining Processes

MACHINE TOOL SIMULATION has been a standard part of The result is faster creation and execution of toolpaths and processes
manufacturing for over a decade. The challenge remains that while on the machine tool, resulting in much more efficient part production.
simulation can tell if a collision existed or not, it cannot do much A recent example was a project where a fixture was too large
to help overcome the challenges. Traditionally, simulation has been for the machine tool. “I jogged the machine to see how far we could
a pass/fail test. The programmer or manufacturing engineer must move the table in the Y axis without having the fixture collide with
determine what toolpath adjustments are required to avoid the the machine and set soft limits,” said Mike Jacobs, CNC prototype
collision(s) and then repeat the test in simulation, often several times, machinist for Nikola. “I was then able to set the same soft limits in
until success is achieved. the simulation environment, and the hyperMILL Virtual Machine NC
Optimizer respected these limits when creat-
ing the NC program. Before using hyperMILL,
the simulation I saw on my computer was not
always what was happening at the machine,
so collisions were common and I had to waste
time running vectors—a time-consuming and
complicated process.”
Also, traditional postprocessing and sim-
ulation software does not recognize retraction
to a safety point for reapproach—the tool
leaves the clearance plane and “you are in
Nikola Motor Company used Open Mind’s hyperMILL simulation software to optimize its the dark again,” Jacobs added. “To solve this,
manufacturing operations. (Provided by Nikola Motor Company)
the hyperMILL Virtual Machine NC Optimizer
For Nikola Motor Company, using the hyperMILL Virtual Machine offers an incredibly productive job linking capability. For example, I have
NC Optimizer from Open Mind Technologies, simulation not only uncov- a part that has 200 separate jobs, so having the automatic, multi-axis
ers collision problems, but also takes into account the bigger picture to job linking capability within hyperMILL Virtual Machine NC Optimizer
help achieve the company’s manufacturing goals, noted Riley Gillman, is a huge benefit. The software keeps the tool close to the part from
technical operations manager for the Phoenix-based manufacturer of one frame to the next, without any extra instruction from me. Having
electric semi-trucks. “The hyperMILL simulation software understands reliable software to manage multi-axis movements from toolpath to
the kinematics and axis limitations of the machine tool, bringing a layer toolpath with the smallest amount of space and distance possible—all
of software intelligence to automatically offer solutions to any problems while collision-checking the entire part and fixture within the machine
we encounter. The software solves collision problems automatically, travel limits—is a very big deal. And we are getting all this functionality
as well as optimizes the machine movement in ways that were not with an excellent, user-friendly interface—just straightforward text and
possible with our previous software.” check boxes, which are easy to understand.”

What Users Look For Binary Spaces, based in Teltow, Germany, has developed
Machining is a complex process that must be simulated a new data format called GDML to support the definition of
rapidly and accurately, noted DP Technology’s Mathews. digital twins for machines, fixtures, and tooling, he noted.
“With ESPRIT, we have integrated SimNC from Binary “Through extensive collaboration between ESPRIT and the
Spaces as the simulation engine for our digital twin simu- machine tool OEM partners, the large GDML data library
lations for programming, simulation, and optimization,” he has been growing rapidly in the last few years to support the
said. “The simulation engine is only one piece of the puzzle; needs of our end users.”
what’s more important is the amount of correct data for the Toolpath simulation software is continually evolving to
various machine models on the market.” add higher assurance in order to consistently and reliably

64 Manufacturing Engineering | March 2021

anticipate a manufacturing process. “Using a ‘digital twin’ Plug-in toolpath components are important to the
concept to model the actual machine components and simulation systems provided by CAM vendors, he said,
controller performance, the computed toolpaths are simulated noting that Open Mind uses MachineWorks’ kernel for
to identify collision potential and to enable high productivity machine simulation. The UK-based MachineWorks plug-in kit
on the machine tools,” said Alan Levine, managing director, provides material removal (or addition) and collision check.
Open Mind Technologies USA Inc., Needham, Mass. “While “The CAM provider decides how to use these tool kits and
third-party simulation software products check toolpaths adds their own analysis capabilities, such as the hyperMILL
independently of the CAM engine,
current simulation systems from
CAM manufacturers can improve
the quality of the simulation by being
able to connect detailed program-
ming parameters in addition to the
basic information of part, stock,
cutter and toolpath. The availability of
the complete manufacturing context
avoids cumbersome and time-inten-
sive efforts for individual verification
of collision areas, and enables
automation without losing safety.”
In addition to traditional simu-
lation tasks, the hyperMILL Virtual An engine block is simulated in Hexagon’s NCSIMUL toolpath simulation software. The latest
Machine NC Optimizer provides update includes speed and feature improvements to enhance the user experience and improve
manufacturing quality. (Provided by Hexagon Manufacturing Intelligence.)
novel technology to manufacturers,
Levine noted. “Not only are toolpaths checked against the NC Optimizer,” Levine said. “The total simulation solution
part and machine models, but toolpaths can be optimized includes the standard material displays and collision notices
with respect to the machine tool kinematics and specific as well as advanced functionality from the hyperMILL Virtual
geometry elements, such as an asymmetric head or an Machining environment, including smooth linking, analysis of
offset head,” he said. “While most CAM systems calculate constrained linear or rotary axis ranges, selection of five-axis
with a view of the workpiece, tool and a fixture device, the machine variants and more.”
hyperMILL NC Optimizer calculates best toolpath solutions
while also considering the entire machining environment.”
With integration between the CAM software and simula- FYI
tion, the hyperMILL NC Optimizer can also access program CGTech
settings and use them to determine preferred toolpaths, 949-753-1050 / [Link]
Levine said. “For example, a programmer may want to CNC Software Inc.
change a hole depth without changing the CAD model, or 860-875-5006 / [Link]
drill a hole to be larger than the model. In these cases, there DP Technology Corp.
is a collision relative to the part model, but there is not a 800-627-8479 / [Link]
collision relative to the part model considered together with Hexagon Manufacturing Intelligence Division
the programming allowances. Traditionally, the simulation 617-401-2197 / [Link]
is checking if toolpaths from the CAM system produce a CAMWorks/HCL Technologies Ltd.
collision or not, providing a go, no-go result,” Levine added. 480-367-0132 / [Link]
“With the hyperMILL NC Optimizer, the simulation environ- Open Mind Technologies USA Inc.
ment is doing this and also improving the toolpath.” 888-516-1232 / [Link]

March 2021 | [Link] 65

COMPANY PROFILES

Absolute Machine Bluco Corp.

Tools Inc.
[Link] [Link]
luco’s goal for over 30 years has been to Make
A utomation has never been easier. Today man-
ufacturers seek guidance in determining how
automation can fit into their current production pro-
B it Better by creating modular fixturing solutions
backed by outstanding service & support. Our fixturing
cesses. Absolute Machine Tools can help. We team-up specialists have designed thousands of solutions for
with customers to determine where automation will hundreds of industries, to tackle the most complex
best fit and remain affordable. We help customers train situations imaginable. Visit [Link]/app-snaps to
their current workforce so they too can upskill and play explore three tough challenges, and three outstanding
a critical role to ensure their company continues to be results:
competitive and profitable. Absolute Machine Tools • The Big Parts Challenge: When your parts don’t
is a better choice than typical automation integrators fit on a standard table, the answer is a custom
because we understand people and CNC machine system with floor rails.
tools…we are Absolute! • The Multiple Size Challenge: Parts of varying
sizes can all be done with one 3D modular weld-
ing table with a custom fixture design template.
• The Aluminum challenge: Pulling and distortion
on long trusses can be a problem. So can moving
those pieces. But a manual positioner provides
the solution.

Absolute Machine Tools Inc. Bluco Corp.

7420 Industrial Parkway Drive 1510 Frontenac Road
Lorain, Ohio  44053 Naperville, IL 60563
800-852-7825 800-535-0135
info@[Link] sales@[Link]

66 Manufacturing Engineering | March 2021

 Capture 3D Inc. Carr Lane
Manufacturing Co.
[Link] [Link]

C apture 3D is the leading provider of innovative 3D

measurement solutions, helping companies
solve engineering challenges, prevent future issues,
C arr Lane Manufacturing is recognized as a world
leader for standard tooling components and
industrial parts used by virtually every industry around
save time, minimize costs, and improve their overall the globe.
time to market strategy. Since 1997, Capture 3D has Known primarily for jig and fixture tooling com-
advanced some of the most influential manufacturing ponents, Carr Lane Manufacturing offers more than
companies into the digital age. With technology that 100,000 industrial parts, including quick change tool-
cultivates digital engineering strategies, Capture 3D ing plates and accessories, hoist rings, toggle clamps,
brings rapid manufacturing, Digital Twin, and Quality handles, knobs, ball and spring plungers, threaded
4.0 concepts into reality. inserts, clamp straps, drill bushings, alignment pins,
With high-resolution 3D scanning technology, fixture bases, and power workholding devices.
intelligent inspection software, photogrammetry Carr Lane Manufacturing is proud to manufacture
solutions, and advanced automation and robotics, and sell American-made fixture components, with most
Capture 3D is driven to strengthen the future of prod- of our fixture fabrication completed at two American
uct development, quality control, and manufacturing. plants located in St. Louis, MO, and Austin, TX.
As an official GOM GmbH/ZEISS USA partner, Capture
3D combines vast industry expertise with robust
technology to change the way people think about and
experience measurement. Contact Capture 3D for a
demo today.

Capture 3D Inc. Carr Lane Manufacturing Co.

3207 S Shannon Street 4200 Carr Lane Court
Santa Ana, CA 92704 St. Louis, MO 63146
714-546-7278 314-647-6200
info@[Link] Sales Contact: [Link]@[Link]

March 2021 | [Link] 67

COMPANY PROFILES

CGTech Chevalier Machinery

Inc.
[Link] [Link]

H eadquartered in Irvine, California, CGTech

specializes in NC/CNC simulation, verification,
optimization, and analysis software for manufacturing.
E stablished in 1982, Chevalier Machinery Inc. is
a leading manufacturer of grinding, turning and
milling CNC machines for a variety of precision-based
Since 1988, CGTech’s product, VERICUT® software, industries. Assembly of machines is done in our ISO
has become the industry standard for simulating CNC 9001-certified, Taiwan-based facilities.
machining in order to detect errors, potential collisions, Chevalier’s network of qualified dealers delivers our
or areas of inefficiency. VERICUT enables users to products on time, at competitive pricing and always
eliminate the process of manually proving-out NC pro- backed by our legendary service. Providing superior
grams. It reduces scrap loss and rework. The program solutions in Aerospace, Automotive, Defense, Energy,
also optimizes NC programs in order to both save time Mold, Gas/Oil, Medical and Semiconductor.
and produce higher quality surface finish. VERICUT Chevalier’s user-friendly PC-based SMART iControl
simulates all types of CNC machine tools, including and iSurface Control make it easy to learn and operate,
those from leading manufacturers such as DMG/Mori using conversational graphic programs without an
Seiki, Mazak, Makino, Matsuura and Hermle. VERICUT engineering degree.
runs standalone, but can also be integrated with leading Our exclusive intelligent Machine Communications
CAM systems. CGTech also offers machine-indepen- System™ (iMCS), a comprehensive remote monitoring
dent off-line programming and simulation software for system, connects clients with MTConnect on Chevalier
CNC fiber-placement, tape-laying, auto-drilling, and machines, compiling performance data, remote machine
fastening machines. With offices worldwide, VERICUT monitoring, alarm history, maintenance, data analysis
software is used by companies of all sizes, universities/ and OEE. iMCS software is user friendly, IoT ready and
trade schools, and government agencies. designed for your analytic needs.

CGTech Chevalier Machinery Inc.

9000 Research Drive 9925 Tabor Place
Irvine, CA 92618 Santa Fe Springs, CA 90670
949-753-1050 562-903-1929
info@[Link] info@[Link]

6ʹ Manufacturing Engineering | March 2021

 DP Technology— Fagor Automation
ESPRIT CAM Corp.
[Link] [Link]

E SPRIT® is a high-performance CAM system for

CNC programming, optimization, and simulation —
supporting any class of CNC machine via one common
T he combination of decades of machine tool control
knowledge and the technological advancements of
the future.
user interface and workflow. Using a digital twin of the For 45 years, Fagor Automation has been a leading
CNC to simplify the programming process, ESPRIT single source provider for CNC systems and high
delivers edit-free G-code. Combined with ESPRIT’s accuracy linear and angular encoders. Known for our
ability to solve workflow challenges with individually flexibility of our production process, we offer optimized
tailored automation solutions, ESPRIT is the smart solutions for OEMs in a wide variety of markets includ-
manufacturing solution for any machining application. ing aerospace, automotive, energy, and more. Fagor
With world-class technical support, ESPRIT Automation is present in over 50 countries worldwide.
empowers you to get started quickly and keep your We currently fit one of the widest ranges of man-
shop running at top efficiency. ESPRIT is the only CAM ufacturing sectors with our CNC controls—such as
system you’ll ever need. milling, turning, laser, additive/hybrid, and miscella-
neous applications. Our control platform is known for
both its ease of use and its extensive list of powerful
features that we provide standard.
Our feedback products consist of enclosed linear
encoders, exposed linear encoders and angular/rotary
encoder products. Our products are built for the man-
ufacturing environment with an emphasis on durability
combined with accuracy and low interpolation error.

DP Technology—ESPRIT CAM Fagor Automation Corp

1150 Avenida Acaso 2250 Estes Avenue
Camarillo, CA 93012 Elk Grove Village, IL 60007
805-388-6000 847-981-1500
esprit@[Link] fagorusa@[Link]

March 2021 | [Link] 6͵

COMPANY PROFILES

Greenleaf Corp. HORN USA Inc.

[Link] [Link]

G reenleaf Corporation has been a leading supplier

of industrial cutting tools for 75 years, specializ-
ing in the manufacturing of high-performance tungsten
H orn USA, Inc. is a wholly-owned US subsidiary of
Horn S.A. Luxembourg, Europe’s leading supplier
of precision carbide metal cutting tools and a world
carbide and ceramic grade inserts and innovative leader in precision cutting tool technology. Horn USA
toolholding systems. Greenleaf is also a world leader serves North America with customized tooling solu-
in technical ceramic materials for medical, aerospace, tions and more than 27,000 standardized metal cutting
and electronic applications. Greenleaf sells and products. The pro-active and highly skilled workforce
distributes its products in more than 60 countries. provides tools to improve your processes and extend
Greenleaf’s corporate headquarters in Saegertown, tool life through increased accuracy and technical
PA and a facility in North Carolina are the mainstays expertise.
of pioneering breakthroughs in cutting tool technology In September 2020, Horn USA moved into an
and manufacturing. Award-winning customer service 110,000-ft 2 state of the art building, approximately
and technical support is also achieved through offices three times larger than the previous location. This new
in the United States, Europe, and China. facility allows for expanded production capabilities in
the US, greater support opportunities, and additional
room for growth. The centrally located manufacturing
facility, field applications engineers, and in-house
specialists are committed to providing professional
and focused attention to your manufacturing needs
and requirements.

Greenleaf Corp. HORN USA Inc.

18695 Greenleaf Drive, PO Box 1040 1870 General George Patton Drive
Saegertown, PA 16433 Franklin, TN 37067
800-458-1850 sales@[Link]
sales@[Link]

70 Manufacturing Engineering | March 2021

 Iscar USA Kennametal Inc.

[Link] [Link]

I scar’s new Logic3Cham, the next evolution in the

popular Sumocham family of self-clamped replace-
able carbide tipped drills boosting drilling productivity
W ith over 80 years as an industrial technology
leader, Kennametal Inc. delivers productivity
to customers through materials science, tooling and
up to 50%. The 3-flute design accomplishes this wear-resistant solutions. Customers across aerospace,
with advanced technologies producing smaller chips earthworks, energy, general engineering and transpor-
which help in chip evacuating which is usually a major tation turn to Kennametal to help them manufacture
limiting factor in successful drilling at high feed rates. with precision and efficiency. Every day approximately
The user-friendly system allows for quick change of 9,000 employees are helping customers in more
the drilling head on the machine with no setup time. than 60 countries stay competitive. Kennametal Inc.
Drill head diameter range is .472” – 1.020” in .004” generated nearly $1.9 billion in revenues in fiscal 2020.
increments. Metal Cutting is Kennametal’s largest business seg-
ment, dedicated to offering world-class metalworking
solutions and services. Our innovation helps solve our
customers’ biggest challenges so they can deliver the
products and services we rely on every day. Learn
more at [Link].

Iscar USA Kennametal Inc.

300 Westway Place 525 William Penn Place, Suite 3300
Arlington, TX 76018 Pittsburgh, PA, 15219
817-258-3200 800-446-7738
info@[Link]

March 2021 | [Link] 71

COMPANY PROFILES

Marubeni Citizen- Methods Machine

Cincom Inc. Tools Inc.
[Link] [Link]

M arubeni Citizen-Cincom (MCC), known for their

highly precise and versatile Citizen Swiss-type
and fixed-head lathes, continues to grow their product
S ince 1958, Methods Machine Tools, Inc. has been
North America’s foremost supplier of leading-edge
precision machine tool and automation solutions – providing
line to serve the manufacturing industry with new superior products, engineering, service, training, parts, and
technology, accessories and automation. LFV cutting integration. With over 300 employees and eight sales and
for chip control, ATC (automatic tool changer), laser technology centers, Methods has installed and services over
systems, bar loaders, parts handling systems and 40,000 machines throughout the United States, Canada
custom automation enhance the ability to make preci- and Mexico. Methods has built an excellent reputation in the
sion parts quickly and efficiently. Citizen machines are industry by partnering with machine builders and customers,
very diverse across all industries that require precision and providing strong application knowledge along with
and complex machined parts for aerospace, automo- outstanding service and support. We have many long term
tive, medical, electronics, and more. The capabilities partnerships including Nakamura-Tome, Fanuc, Yasda, OKK,
are endless. and Kiwa.
MCC is also proud to offer service, support and
spare parts that are readily available and just a phone
call away. Their competent, exclusive distributors, in
addition to MCC’s technicians, provide the best local
support by effectively serving the increasingly sophis-
ticated requirements of the small parts manufacturing
industry.

Marubeni Citizen-Cincom Inc. Methods Machine Tools Inc

40 Boroline Road 65 Union Avenue
Allendale, NJ 07401 Sudbury, MA 01776
201-818-0100 877-668-4262
sales@[Link] sales@[Link]

72 Manufacturing Engineering | March 2021

 NSK America Corp. Promess Inc.

[Link] [Link]

N SK America Corporation delivers electric and

pneumatic high-speed spindle solutions to
manufacturers in the western hemisphere. With less
P romess was formed in 1984 to provide the man-
ufacturing industry with in-process monitoring
systems, specializing in force and torque monitoring
than 1 micron TIR from the Nakanishi factory in Japan, applications. In 1989 Promess entered the motion
NSK America can adapt to your current process and control arena developing a fully electric, ball screw
equipment to ensure the proper application of micro assembly press with built in force monitoring. This was
drills and end mills. a first step in using process data measured in real time
Nakanishi tools can achieve spindle speeds up to to close the loop on motion control.
80,000 rpm for electric spindles and 160,000 rpm Promess continued to develop systems that utilize
for pneumatic spindles. Whether you are using mills, various sensors, adjusting the process in real time to
lathes, swiss-style lathes, robots or even making your produce good parts each and every cycle. Promess
own specialty purpose machine, NSK has a spindle delivers the complete system including the mechanics,
for your application. This year, NSK brings to market a control electronics, sensors, amplifiers and software.
fully tool changeable electric spindle that will allow for Promess also provides pre-project application engi-
100% lights out manufacturing. Along with spindles, neering assistance, installation support and training
NSK also has an assortment of electric and pneumatic services.
micro grinders as well as an ultrasonic polisher for Promess’ mission is to provide our customers with
deburring needs as well. All current products are in our innovative sensing and motion control solutions, taking
new 2021 catalog. full responsibility for the complete system, with the
ultimate goal of reducing risk for our customers, saving
both time and money.

NSK America Corp. Promess Inc.

1800 Global Parkway 11429 Grand River Road
Hoffman Estates, IL 60192 Brighton, MI 48116
800-585-4675 810-229-9334
info@[Link] promess@[Link]

March 2021 | [Link] 73

 COMPANY PROFILES

WALTER USA LLC

[Link]/us

W alter offers highly engineered precision cutting

tools for milling, drilling, turning, boring and
specialized tools helping customers improve process
reliability and increase productivity. The company’s
competence brands – Walter, Walter Titex, Walter
Prototyp, and Walter Multiply – give it a unique edge:
Engineering Kompetenz. This means that Walter
offers more than a range of precision tools, it provides
tailored advice and targeted service along the entire
process chain. This combination enables customers
to reap substantial benefits in terms of performance,
process reliability, and productivity.

WALTER USA LLC

N22 W23977 RidgeView Parkway West
Waukesha, WI 53188
800-945-5554
[Link]@[Link]

74 Manufacturing Engineering | March 2021

 PRODUCT PREVIEWS

Polishing and Finishing Compounds Level 2 protection balanced

The Farécla line of polishing compounds and surface with extreme dexterity for
finishing products includes the Profile Advanced Plus Liquid tasks calling for fine motor
Compound for a high level of cut and gloss, resulting in skills and tactile sensitivity.
clarity on painted surfaces and wood lacquers. It produces Its composite yarn includes
finer finishes a blend of high-strength
when used with a filament fibers for cut resis-
twisted wool pad. tance up-wound with nylon
The abrasive and spandex for ease of
technology use. It features an 18-gauge, high-performance polyethylene
removes sanding (HPPE) and glass-fiber shell, and a black polyurethane palm
marks to P1500. coating for abrasion protection and enhanced grip.
The Profile Select Brass Knuckle Safety Products
is a cutting compound for removing sanding marks to P800 770-674-8930 / [Link]
and finer. For finishing, the Profile Finish Liquid Compound
removes swirls and holograms. The Profile Polymer Wax Twin-Spindle Machining Center
delivers a high-gloss finish with excellent evenness and real The twin-spindle series DZ 22 machining center has a
transparency on dark colors, according to the manufacturer. spindle clearance of 600 mm. It is designed to machine
Norton | Saint-Gobain Abrasives
254-918-2313 / [Link]

Drill for Low-RPM Applications

The Nirox high-performance drill from the Sphinx brand
was developed for use at low cutting speeds when working
in unstable environments. The
drill is available in diameters
from 0.30 to 3.00 mm. The
geometry has a degressive helix
angle equal to 30 degrees at
the point, and is designed for
accurate and precise hole loca-
tion up to 9×D. According to
the company, a TiAlSiN-based
coating allows for enhanced
chip and coolant evacuation in
difficult-to-machine and adhesive materials such as titanium,
SATISFY YOUR NEED FOR SPEED WITH OUR
Inconel, stainless steel, hardened steel and CoCr alloys.
BIG Kaiser Precision Tooling Inc.
224-770-2999 / [Link]

PPE Glove
The SmartCut BKCR2403 smart glove is designed ORDER BY 6 PM FOR FAST SHIPPING – GUARANTEED
for jobs needing cut and abrasion resistance, while also
requiring a long-wearing grip, dexterity, and flexibility. The COMPLETE CATALOG
light-duty, cut-resistant glove offers ANSI Cut Resistance 1-800-295-5510 [Link]

March 2021 | [Link] 75

PRODUCT PREVIEWS

complex, large Air Conveyor

workpieces. The Type 303 Stainless Steel
The company 3 NPT Threaded Line Vac air
also offers a operated conveyor converts
4-axis variant ordinary pipe into a conveying
of the Series system for parts, scrap, trim
22. Featuring and other bulk materials. The
two work- chemical- and corrosion-resis-
piece-changing tant Line Vac operates at higher
table variants, temperatures and employs
the four-axis trunnion plate version handles 680 x 1,330 a larger inside diameter that aids in conveying bigger
mm diameters up to 600 kg; and the twin-spindle five-axis parts and larger volumes of material over long distances.
version handles two 599 x 340 mm diameters up to 150 Threaded Line Vac Conveyors utilize minimal amounts of
kg. The company says its machine platform uses a moving compressed air to generate an instant vacuum on one
gantry design, and the rigid machine bed and active compo- end, with high output flows on the other. The 3 NPT 303SS
nent cooling helps achieve the required workpiece precision. Threaded Line Vacs are CE compliant and meet OSHA
Chiron America pressure requirements.
704-587-9526 / [Link] Exair Corp.
800-903-9247 / [Link]

Video Measuring System

The NEXIV VMZ-S3020 is a
Scientific Cutting Tools
CNC video measuring system that

Solid Carbide Spotting Drills captures high-speed, real-time

measurement results. It has a 300
x 200 x 200 mm working volume.
Proprietary optical measuring,
image processing and analysis
technologies detect edge features
to determine the shape and dimen-
sion of components. It features
improved stage control technology,
image processing algorithms and high-resolution, linear
encoders that track stage position. Through-the-lens (TTL)
laser auto focus achieves repeatability better than 0.5 µm.
Laser scanning of 1,000 points/sec acquires the cross-sec-
tional shape of a surface to evaluate relative heights.
Nikon Metrology Inc.
A valuable first step in holemaking Process 810-220-4360 / [Link]
82º, 90º, and 100º Countersink & Chamfer

120º and 142º Spotting Drills Modular Angle Encoders

Designed With A 4 Facet Point & Constant Web The ERA 4000 angle encoder series consist of a steel
drum at various diameters with a 20 µm, 40 µm or 80
1.805.584.9495 1.800.383.2244 µm graduation on the OD, and a scanning unit that reads
Learn more at [Link] the graduation. Reference marks denote increments as

76 Manufacturing Engineering | March 2021

 CLASSIFIEDS

PRODUCTS/SERVICES

distance-coded or one per revolution.

The series features the company’s signal
processing (HSP) capability on the scan-
ning units. The scanning unit “learns” the
signal quality from the drum and adjusts
the LED intensity on the next signal
period. HSP operates in an analog way
and increases the speed capabilities of
the encoder system to 1 MHz scanning.
Heidenhain Corp.
847-603-4018 / [Link]
OIL MIST & SMOKE
IN YOUR SHOP?
Conveyor and Filtration Solutions [Link]
The EcoFilter Conveyor for use on turning and machining centers utilizes a Tel: 1-800-645-4174

two-stage metal chip removal and coolant filtration design. A hinged steel belt
conveyor removes large chips,
and a flow-through filtration cell
separates the remaining fines from
the coolant. Heavy-duty brushes
attached to the bottom of the belt
Reserve
wipe these fines from the surface
of the filter cell, where they flow to
Your Ad
the bottom of the conveyor via a
CleanCleat system. The EcoFilter Today!
reduces the number of chips that migrate to the coolant tank, which decreases the
frequency of tank cleanout and downtime for maintenance.
Jorgensen Conveyor and Filtration Solutions
262-242-3089 / [Link] TO PLACE:
Employment, service, new and used
equipment, rebuilding, parts & service,
scrap metal, agents, business listings,
PCD Tools for Machining Aluminum consultants and general admission.
PCD drills, reamers and end mills are
available for machining aluminum. In drilling and
CONTACT:
reaming operations, the tools perform at cutting Dave O’Neil
1000 Town Center
speeds of up to 900 m/min. Milling operations Suite 1910
perform at speeds of 6,000 m/min. With Southfield, MI 48075
Phone: 313-425-3260
through-the-tool coolant capabilities and an Email: doneil@[Link]
Email: advertising@[Link]
MQL-ready interface, the PCD round tools are RATES:
Line Ad. Per line $35 (minimum
designed for rough and finish machining. The 5 lines, 7 words per line avg.)
PCD end mill line features 6-50 mm tools, and No agency commission.
Display ad per inch:
cutting depths up to 50 mm. The PCD drill line 1x: $195 6x: $180 12x: $165
(maximum 2")
features 6-20 mm tools in 0.5 mm increments, Color available, please inquire.
up to 5×D. The PCD reaming portfolio offers No agency commission.
6-20 mm tools in 1-mm increments. Display Ad Units.
(Same as publications rates)
Kennametal Inc. Agency commission allowed
to recognized agencies.
724-539-8033 / [Link] Payment in advance on all listings.

March 2021 | [Link] 77

CEO ROUNDTABLE
EXECUTIVE PERSPECTIVE

An Insider Perspective on Manufacturing’s Future

WHAT IS THE FUTURE OF MANUFACTURING? that were already being contemplated. Those at
Recently, Ron Fritz, CEO of Tech Soft 3D, hosted the executive level are looking at the allocation
a roundtable discussion with four other industry of capital, right-sizing the workforce, and the real
executives to discuss the future of manufacturing, estate footprint. Where do I have factories, where
the impact of COVID-19, aspects of manufactur- do I have dependencies? That is playing out now.
ing that will change, and industry collaboration. Lobovsky:
The participants were: Companies are learning
Meghan West, CEO of CNC Software, a to be less present on
provider of CAD/CAM solutions; their manufacturing
Marc Lind, senior vice president of strategy for floors, even when
Aras, a provider of enterprise PLM software; they’re local. High-
Sam Golan, CEO of High QA, a provider of volume consumer
manufacturing quality management software; and goods figured that out
Max Lobovsky, CEO of Formlabs, a 3D printing a long time ago, but
technology developer and manufacturer. lower-volume industrial
Fritz: There’s goods are figuring out Max Lobovsky,
CEO of Formlabs
been a lot of that they can get by as
speculation that well. I don’t think manufacturing is coming back
the disruption to the U.S. or Europe in any large-scale fashion
that COVID-19 anytime soon.
caused to supply Fritz: Five or ten years from now, what
chains will prompt aspects of the manufacturing world will have
ME STAFF REPORT
companies to changed dramatically?
Ron Fritz, CEO of Tech Soft 3D
de-risk their supply West: I think trade shows are going to be one
chain and return more of their manufacturing to of those things. The idea of everybody spending
North America and Europe. To what degree do time and money to set up a booth for people to
you think that will happen? come and meet with you—that’s one of the things
Golan: This is about human psychology and that’s going to change. At my company, we’ve
behavior. As long as COVID-19 remains an issue, shifted to virtual, and that’s enabled us to reach a
people will temporarily manufacture parts closer to far larger audience.
home, but once the pandemic has passed, they The manufacturing industry in particular is
will revert back to what they used to do before. such a face-to-face industry. I think because it’s
West: Manufacturing is such a price-sensitive so small, everybody knows everybody, so it’s
industry—the profit margins are just so small. all about networking. Going to a trade show is
Regardless of the risk, manufacturers will always almost like a family reunion: You see the same
look for the lowest-cost option, whether that’s people there year after year after year, which
outsourcing to China or another country, or is a wonderful part of it. I think we’re going to
whether that’s bringing it inside. have to find a way to still make those connec-
Lind: We have already been seeing companies tions and strengthen those relationships in a
start to think about how their supply chain is con- different way.
structed, given the current geo-political tensions. Lobovsky: Since we’re a hardware com-
It seems the pandemic is accelerating decisions pany, the trade shows are quite important to

78 Manufacturing Engineering | March 2021

us because people need to see our products. In fact, West: In general, in the
because we don’t do much outside sales, it’s often the manufacturing industry, there’s a
only way people get to see our products. So, we’re trend towards more collaboration
looking forward to those types of in-person gatherings between different parties, which
continuing. In the meantime, though, we have other ways means a requirement for more
of demonstrating our capabilities to potential customers, information. The richer that data
including sending out sample parts. is, the easier it is for somebody to
Golan: The move towards take something, understand the
remote working during COVID-19 context behind it, and turn it into a
has showed a lot of companies Meghan West, reality. Without all of that informa-
CEO of CNC Software
that they don’t need as much tion, it’s so difficult to pass a part
office space. Factory floors are or anything on without someone having a lot of questions or
a different story, but corporate trying to better understand it.
headquarters are going to rethink Lind: To jump back to an earlier question: in 10 years, are
how much office space they we going to say ‘That inter-operability problem has changed
actually need. so much—nothing worked with anything else back then.’ Part
Lind: Data visibility will be one of the hitch between not just the
Sam Golan,
of the big changes. A lot of data collaboration component, but also
CEO of High QA
has been collected in factory the seamless flow of data from engi-
settings for years now, but not much has been done with it, neering to manufacturing to quality,
as far as managing operations. Instead, there’s still a lot of is that the tool’s not designed to
management by “walking around” and seeing what’s going have the data accessible, available,
on. It’s going to become self-evident that you need to have and compatible with other tools,
data feeds and KPIs. whether it’s the machines on the
Fritz: What trends do you see around information floor or the other tools downstream
sharing and collaboration among manufacturers and that people are using in the supply
Marc Lind, Senior Vice
suppliers? chain. And you just wind up with the President of Strategy
for Aras
Golan: Model-based definition is even more important requirement to redo work because of
now than it was before. Prior to the pandemic, OEMs were the incompatibilities. You need to be able to bring data together
likely to visit their suppliers regularly to make sure parts so that you can collaborate, not just within the four walls, but
were being manufactured correctly. Now, it’s more difficult to down through the supply chain and in remote settings.
travel, so it’s critical to get suppliers all the information they Golan: This is a great way of describing Quality 4.0 or
need to make the part correctly. And geometry, while vital, Industry 4.0, in which everything is connected. And it’s not
isn’t the only thing that matters. just about having data—it’s about having access to that
Lobovsky: Something that people don’t understand information when you need it, so that you can make the right
about drawings today is that their primary purpose isn’t decision at the right time.
to transmit the geometry information. It’s primarily a West: Everybody used to work in silos and was protective
human-readable overview of what’s important about the part of their data. But now, there has to be a focus on working
that’s being made, and it conveys all kinds of other infor- with partners and making sure that there’s compatibility with
mation besides the geometry. I would love to kill drawings; other processes in the manufacturing chain. It’s all about
people spend a ton of time making drawings, and our 3D the user’s experience. Everyone wants that ‘easy button.’
printers live in a world that’s free of drawings, so it’s possible. As vendors, we need to make the process more effective
But STEP or non-drawing systems need to account for the and more efficient. Every vendor should figure out how to
human-readable part of it, and you do need a document to improve their piece of that experience and make it seamless
go along with the geometry data. from start to finish.

March 2021 | [Link] 79

VIEWPOINTS
OPINION, ANALYSIS AND IDEAS

Dispelling Factory Automation Myth #1

AUTOMATING MACHINING OPERATIONS is at the simplest to do when there is a cell configuration
top of the list of goals for most manufacturers, already in place, for example with two or more
as needs and capital expenditure budgets allow. CNC machine tools and with all handling,
Most of us understand, perhaps all too well, the loading/unloading of parts, and programs
drivers of automation—the skilled workers gap, accomplished by an operator. If the machines
rising costs of materials, narrowing profit margins, are five years old or newer, they can usually
competitive pressures, greater production accommodate additional, intelligent functionality.
flexibility, and other familiar efficiency issues. If they are older than that, for instance 10 to 15
Of course there is the “coolness factor” of years old with PLCs, we generally do need to
factory automation, too, but even those sorts of upgrade the control system to a true CNC 32-bit
fun techno aspirations need to have a positive operating system.
financial outcome. We are businesspeople, after When the system is retrofitted with newer CNC
all. This past year, the COVID-19 pandemic controls, we can add automation. Further, as long
impacted the existing workforce; many employ- as the installation has that technology backbone,
ees were either out with the illness or out having a company can acquire a “smart” software
to quarantine from exposure. There were also interface to tie in dynamic (versus manual) part
many new pandemic protocols in place, such and program changes on the robot, automatic
as in-plant social distancing requirements. This scheduling priorities, and other intelligence.
alone pushed many parts producers to install
automation equipment, primarily robotics, sooner First Modular Step
than planned. For some companies, yes, this interim phase
DAVID SUICA
President
As an automation equipment and software just addresses current needs until a greater
Fastems LLC provider, the inquiries we receive often include investment can be made more aligned with the
the following statement: “I know I need to get long-term goal of a wholly connected shop. Yet
new CNC machine tools to do this.” The short rather than a dead end, it can be viewed as the
reply from us is, “No, you don’t.” Certainly there first modular step on the automation road as long
are caveats to that response, such as an under- as there is ample open computer architecture to
standing of the types and ages of the current be able to add to it as time goes on.
machine tools and the firm’s short and long-term On the other hand, it may be that this particular
automation goals. However, the overriding installation is indeed an independent, stand-
sentiment that an organization needs to invest in alone cell that can’t technologically become a
one or several brand-new CNC machine tools to connected part of the larger whole. Even so, it is
get an adequate, interim level of automation is the still a solution to address current needs, and we
prevailing myth we confront when speaking with do what we have to do to stay in business. But
manufacturers. the idea that you must purchase one or more
I am officially ousting that myth right now. brand new CNC machine tools to undertake this
I can cite many cases in which our company endeavor—whether it’s for a lone cell or the first
added robots or pallet automation to existing step on the longer automation road—is untrue.
equipment already in the factory, providing the Myth dispelled.
same level of return on investment and other For more information, email David Suica
benefits as new machine installations. This is at [Link]@[Link]

80 Manufacturing Engineering | March 2021

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March 2021 | [Link] 81

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