Manufacturing and Automation White Papers

The Russians hacked the grid and shut off the lights in Ukraine, the Israelis used a virus to over-rev and damage nuclear separation centrifuges in Iran, the Chinese—and your competitors—know all your trade secrets. Meanwhile, internet-enabled commercial devices are being hacked and used for nefarious purposes from spying through nanny-cams to empowering denial-of-service attacks. Today, concerns about cybersecurity are a major force damping the free flow of information we need to leverage the cloud and computing power to take advantage of the fourth Industrial Revolution—Industrie 4.0 and the Industrial Internet of Things (IIoT).

The white paper explores the results of kinematic validation simulation testing on the implant done by the Orthopaedic Innovation Centre. The testing reveals that utilizing additive manufacturing and key post-processing operations on this customized knee implant resulted in samples that exceeded expectations

As 3D printed powder-bed technologies such as SLS and MJF rise in popularity, their users stumble upon a common problem – post-processing. After excess powder is initially brushed away (as seen in the picture at left), the build tray is caked in unusable powder. Current methods of removal such as manual bead blasting and vibratory machines leave much to be desired with regards to their labor requirements, damage rates, and inconsistent results in removing powder from fine cavities.

The term “optimize process parameters for additive” is commonly used in the additive manufacturing (AM) world. But what does it really mean to optimize parameters for metal additive manufacturing? Bringing a 3D-printed part to market involves identifying the correct material source, characterizing the raw material, identifying the correct machine parameter window for deposition, developing the stress relief and heat treatment parameters, identifying the correct post finishing technique and, finally, determining the right NDE technique for inspection. All of this involves optimization to determine the ideal parameter sets based on functional part requirements.

In the next decade, Digital Manufacturing technologies will allow companies to connect physical assets and processes by a "digital thread" - unleashing a seamless flow of data that will link every phase of the product lifecycle.

In this ebook, we share how to combat surprises in your design change management more easily, efficiently, and precisely. Combine steps and maximize the time you spend designing your project, and minimize time spent on changes and updates to your designs.

Titanium is often used in aerospace and aircraft applications due to its strength and light weight, however it is known to be difficult to machine. Metal 3D printing continues to make headway as advancements in Selective Laser Melting technology allow for larger components to be built out of metal powder in a laser powder bed over a period of days, eliminating the need for conventional machine setup and tooling. The resulting build provided the customer with a part offering both cost and time savings while reducing weight.

The Emory University Future of IIoT Predictive Maintenance research study was designed to identify the gaps between the high-level strategic and business drivers of change and the reality of implementation. For this purpose, we interviewed Maintenance and Reliability professionals responsible for Predictive Maintenance in their organizations.

Learn how your throughput may be limited with traditional submersion support removal systems. This white paper will review why current “default” mechanical and chemical post-print methods for FDM are inadequate along with details of the revolutionary Volumetric Velocity Dispersion (VVD) automation technology. See how VVD utilizes different forms of mechanical energy to increase FDM support removal efficiency, reduce drying time, and mitigate the risk of damaged parts.

In SME’s second report of the series, we’ll dive into how to get started defining strategies and implementing solutions by identifying 7 essential critical technology elements (CTE) building blocks. The important topic of finding and training skilled workers is the subject of SME’s third and final Smart Manufacturing Report coming later this year.

MWES’ proprietary process of 3D Metal printing of exotic materials is demanded due to expensive manufacturing methods involving casting or machining out of stock material. Download our free Whitepaper to learn the Layer-by-Layer Process to Successful Additive Manufacturing!

As engineers, we are always challenged to bridge the gap between design and manufacturing in the most effective way. As manufacturers, you produce new parts from a prototype design, but also struggle to select the best process for long-term production. Download our Guide to Process Development where we share with you how to successfully launch a new product or optimize an existing process!

When upgrading your hardware platform to a newer and more powerful CPU with more, faster cores, you expect the application to run faster. More cores should reduce the average CPU load and therefore reduce delays. In many cases, however, the application does not run faster and the CPU load is almost the same as for the older CPU. With high-end CPUs, you may even see interferences that break determinism. Why does this happen, and what can you do about it?

A revolution in part feeding technology. To achieve flexibility in assembly machines, manufacturers are all faced with the same problem: feed more variants of parts within a single automated machine and reduce the time required to change production batch from product “A” to product “B”. The solution: using flexible part feeders with a powerful vision system and reduce implementation costs.

The Smart Manufacturing Report Series helps manufacturers consider, evaluate and execute strategies to become strong entities as the industry shifts to integrated and flexible advanced manufacturing technology and tools. Upcoming reports provide a roadmap for manufacturers who want to adopt these practices, outlining the right technologies and solutions, and how to recruit and train a “smart” workforce.

For over 30 years, Smart Products USA, Inc. has focused on the intricate details of how one-way check / pressure relief valves work in low pressure, low flow devices. Sharing this knowledge with existing and potential customers can save them time and money as they develop their current or future applications. As a resource, this white paper answers critical questions, such as: Will a certain step affect the device’s performance? Is there a part in the operation process that will be critical to the application?

An encoder is a sensing device that provides feedback from the physical world; that is, it converts motion to an electrical signal that can be read by some type of control device, such as a counter or PLC. The control device then uses that signal to control a conditional event, such as activating a print head to create a mark at a specific location, or positioning a joint correctly on an articulated robot limb.

As part of the Industry 4.0 area at the recent EMO 2017 trade show, HEIDENHAIN presented a system of production in which all work steps are networked—from the design to the deliverable component. The core components of the network showcased were the software solutions of Connected Machining. They provide TNC controls with access to all order-related data in the company network, so the specialist at the TNC control can become a director of the process chain. This details much of that system.

Many are unaware of the extent to which the theoretical field of computer vision has produced tangible benefits for manufacturing. Embodied in compact smart cameras as well as powerful, PC-connected camera systems, the brilliant work of academicians is being used daily to make industrial operations safer, steadier and more productive. The ability to automatically extract information from digital images opens many doors for manufacturers striving to cut costs, improve quality and streamline their processes overall. The primary uses of machine vision are inspection, gauging, and robot guidance. This white paper by Omron Microscan explores machine vision’s fundamental functions, benefits for industrial automation and real-world applications.

With the explosion in adoption of IIOT applications utilizing MQTT as the messaging protocol, it is critical to implement cyber security at the forefront of its enablement. As with any other computer network, an IIOT application is only as secure as the weakest link in the infrastructure. This white paper will discuss some of the best practices in implementing a secure MQTT infrastructure.

Learn about traditional methods vs. new technologies that intelligently leverage chemical solutions along with mechanical energy to achieve efficiencies in PolyJet post-printing. Discover pros and cons of common chemical-based solutions for 3D post-print support removal as well as considerations for implementing existing and new technology approaches in terms of safety and performance. This white paper includes case study data demonstrating advantages in cycle time, cycle efficiency, and operator attendance time for new “smart” applications of chemical treatment with mechanical energy

Learning What Causes Static Electricity Static electricity can be a major nuisance in manufacturing facilities. It can affect the finish/quality of the products being produced, impact the speed of the operation, and cause workers to experience uncomfortable shocks. But it doesn't have to be this way. There are steps that can be taken to eliminate or control static within a facility, and EXAIR can help. EXAIR's White Paper "Basics of Static Electricity" is designed to help readers learn about the causes of static electricity, the steps that can be taken to eliminate static, and the products available to help control it.

In the next decade, Digital Manufacturing technologies will allow companies to connect physical assets and processes by a "digital thread" - unleashing a seamless flow of data that will link every phase of the product lifestyle.

The need for real-time uncompressed video places a significant burden on networks. In industrial vision systems, glass-to-glass latency thresholds are in the order of 130 milliseconds (ms) or less. For image-guided surgery or military closed hatch driving applications, designers aim for end-to-end latency of 85 ms or less.

This white paper highlights the role of digital factory software for Industry 4.0. All-new ideas and concepts are required and new software tools for the digital factory are blazing the trail forward.

Learn how by Implementing Connectors and Power Bus Systems. Today’s manufacturers are making the switch from hardwiring to connectors in applications such as power distribution, machine connectivity, and motor control. Choosing connectors over hardwiring produces significant cost and time savings as well as increases automation system reliability. Read this white paper to learn about the design, integration and installation considerations to help you determine if a connector solution is right for your application.

How have Japan’s 4 most prominent SMT brands addressed the challenges of an ultra-competitive industry? Find out in Best Practices for Real-Time Machine Automation Performance in IoT & Industry 4.0.

Thanks to turn-key functionality for complete quality control and data security, Aegis’ FactoryLogix MES is ideally suited for highly-regulated industries. For K2 Energy, implementing the system has not only provided these benefits but also helped drive the company from a small business start-up to a leading supplier of energy storage systems.

Productivity and accuracy are important attributes in the competition for machine tools. Five-axis machining provides considerable potential for increasing productivity. In many cases it permits higher metal removal rates than 3-axis machining. Production times can be significantly shortened thanks to a reduction of time required for resetting, for example, or through multi-operation machining in one setup. In any case, with increasingly complex workpiece geometry, 5-axis machining is becoming an indispensable part of the machining process.

With proprietary and particularly user-friendly software tools for a generic input/output (IO) technology, Piab is taking their first step towards smart sensor and actuator communication.

Predictive maintenance is widely considered to be the obvious next step for any business with high-capital assets: harness machine learning to control rising equipment maintenance costs and pave the way for self maintenance through artificial intelligence (AI).

Manufacturers are optimistic about their industry and the U.S. economy but concerned about the ongoing struggle to find qualified workers, according to the 2017 Manufacturing Report from professional services firm Sikich LLP. In the firm’s third annual report on the manufacturing industry, nearly 80 percent of respondents said they are more optimistic about the U.S. economy compared to last year while 66 percent said the same about the manufacturing industry. And 69 percent expect headcount to increase. Even so, respondents identified addressing workforce challenges as a top priority for their companies, and nearly 60 percent pointed to a lack of qualified workers as a barrier to business growth.

Sensing technology is everywhere today. Sensors are used to detect human touch on a smart phone, ambient temperature in a room, and even in non-invasive blood glucose measurement for diabetes detection. This whitepaper addresses the most common types of presence sensors used in industrial motion control including their application, design criteria, integration requirements, associated costs, testing and maintenance.

Cable carriers are an ideal way to protect cables, hoses, and all other lines throughout movement on modern machinery, while protecting them from abrasion, tangling, and over bending. In this eBook, explore the technology behind modern cable carriers, material options, tech tips and tricks, and more.

This paper evaluates whether Robotics equities traded on Stock Markets worldwide are a good investment opportunity or not. Robotics seems to become more and more attractive for both institutional investors (who act rationally and prefer medium to long term investments) and individual investors (who are driven by irrational behaviour and prefer short term investments). To forecast if robotics is an investment opportunity that could inflate a new financial bubble in the oncoming years, this paper compares robotics equities with Internet equities and analyses what happened during the Dot-com Mania in the 1990s. Many similarities come out as well as several key enabling factors that confirm robotics is a major investment opportunity for the next decade.

Just like how the steam engine led an industrial revolution centuries ago, software and data are changing the way we manufacture today. In this white paper, learn how industry-leading companies are accelerating the product development cycle through the use of new technologies and data analytics.

Whether you’re new to the injection-molding process or a veteran of manufacturing, our comprehensive Designing for Moldability white paper is a quick reference guide to wall thicknesses, surface finishes, tolerances, materials, and other thermoplastic molding insights. It’s a thorough look at injection molding that might just provide a few tips to help you make better parts.

Our 3D printing white paper examines the various additive manufacturing technologies—SL, SLS, DMLS, FDM, PolyJet, and others—being used by today’s product designers and engineers to build prototypes and even functional, end-use parts.

Advanced air-driven vacuum technology allows automotive manufacturers to move towards smarter factories, and although energy-efficiency, reliability, productivity and safety may seem straight-forward, there are obstacles along the way. However, improvements made in press shops can act as a roadmap for the rest of the production in body shops, paint shops and assembly lines. In this white paper, we help you navigate the market of vacuum technology.

Selecting the right encoder for a unique application can be a daunting task for the design engineer. This whitepaper covers commonly asked questions when considering encoders for motion control applications. From basics such as mechanical configuration and absolute versus incremental to the differences in accuracy and resolution, "Encoder Basics for Motion Control Engineers" will shed some light on the encoder selection process.

Concentrated solar power (CSP) and concentrated photovoltaic (CPV) methodologies generate electricity by focusing a large amount of sunlight onto a much smaller area. To maximize efficiency, the sunlight needs to be accurately focused. Being off by even a single degree could result in a significant drop in efficiency, and the biggest impact to the cost of delivering solar energy is efficiency. As with most systems, the accuracy is limited by the accuracy of the sensors used in that system. There are a number of different types of sensors that can be used in these systems. This paper discusses why an absolute inclinometer is the most effective sensor solution and why the US Digital T7 is superior to other inclinometers available today.

Sensata Technologies new white paper helps manufacturers of HVAC and cooling systems design next generation solutions that can take advantage of “green” refrigerants that do not adversely impact the environment.

How the Industrial Internet of Things has led to the development of next-generation smart plastics with sensing capabilities built-in

Machine Vision is one of the driving forces of industrial automation. For a long time, it’s been primarily pushed forward by improvements made in 2D image sensing and, for some applications, 2D sensing is still an optimal tool to solve a problem. But the majority of challenges machine vision is facing today has a 3D character. From well-established metrology up to new applications in smart robotics, 3D sensors serve as a main source of data. Find out more in the freely-accessible white paper Parameters​ ​of​ ​3D​ ​sensing​ ​techniques​ ​in​ ​a​ ​nutshell, written by Photoneo CTO Tomáš Kovačovský.

“How Integrated Thermal Protection Technology Can Prevent Solid State Relay Failure in Industrial Systems” describes the future generation of SSR power protection for industrial refrigeration and manufacturing systems. Solid state relays provide robust solutions for electronic switching in load control applications and offer many performance, design and reliability advantages over electromechanical relays. Since the 1970s, these solid-state relays have been a proven electronic power switching solution for a variety of industrial and manufacturing applications, providing a longer lasting, more versatile, flexible and robust solution than electromechanical relays. However, this technology has now taken a giant leap forward with the development of new solid- state relay designs with integrated thermostats that prevent overheating, protecting component and system operation from potential damage or shut down. This product evolution will undoubtedly change the game in thermal protection for a wide range of industrial applications.

This White Paper discusses post-processing considerations for 3D printed advanced polymers, including FDM, SLA and Polyjet. Learn more about the current state of post-processing techniques for additive manufactured advanced polymers and innovations for optimizing the critical support removal step to enable full-scale production.

Industrial mass flow control is a crucial part of burner and combustion control in manufacturing applications. Precise mass flow control of the fuel-to-air ratio to the burner is essential to produce quality products for the manufacturing industry including glass, metals, and ceramics manufacturing. Download our Burner Control for Manufacturing Application Tech Note to learn how precise mass flow control of the fuel-to-air ratio helps produce quality products.

In beverage production process, precise mass flow control of Carbon Dioxide (C02) is a crucial part of creating high quality brews and beverages. It is pivotal that beverage manufacturers have the ability control the exact amount of carbon dioxide (CO2 ) being injected into their beverages during the bottling process. Mass flow controllers (MFCs) are used to regulate and control the amount of CO2 injected into the bottles during filling and capping to assure uniformity of the product. Download our Brewery/Beverage Process Application Tech Note to tread more about precision control of CO2 injection in beverage manufacturing.

This paper provides information about different types of recoaters and how they influence the quality of your 3D-printed parts. Knowing how to position your parts can make a huge difference. Consult our guidelines and learn more about metal 3D printing.

The Manufacturing Industry is facing many challenges today, from The Age of the Customer to the rise of Industry 4.0. A Configure-Price-Quote solution can help to solve some of those problems. Download the whitepaper to learn what a CPQ solution is, and the value proposition and benefits for manufacturers with complex configurations.