© Nanofabrica | https://www.nano-fabrica.com

Nanofabrica’s additive manufacturing (AM) platform, a micron-level resolution AM technology, operates cost-effectively and repeatably, making it an industrial production alternative to traditional manufacturing processes such as micro-molding. Micron resolution can be achieved on centimeter-sized parts, and thousands of parts and components can be made in a single build, making the technology appropriate for mass manufacturing.

One area where the technology has found a perfect fit is in the manufacture of various micro-optical parts and components. The ability to be able to produce complex, extremely flat, extremely small, and extremely lightweight optics today opens potential for product innovation in many industrial sectors. In addition, for a variety of reasons including green manufacturing considerations and the design freedom that working in plastic allows, plastic has become an increasingly popular material for micro-optic applications.

© Nanofabrica | https://www.nano-fabrica.com/

Because of this, micro-injection molding is the popular technology for micro-optics manufacturing, and until the launch of Nanofabrica’s AM technology. Use of injection molding for micro-optic manufacture, however, requires the optimization of design, mastering, tooling, and production steps, meaning a close interaction between supplier and product developer is vital. The ability for Nanofabrica’s technology to overcome complexity issues and to eliminate the need for tooling is key, and the technology is therefore used for an array of applications such as the manufacture of jigs and fixtures for optical alignment, optical connectors for optical fibers, fiber optic ferrules and other small related elements, and optical elements such as lenses and prisms.

“Currently, most precision optical assemblies are undertaken using precision robotics. With Nanofabrica’s micro AM technology, which is characterized by micron resolution printing capabilities, customers can additively manufacture a jig that allows for precise positioning of optical parts. Currently we have customers using our micro AM platform to make optical connectors and fibers, lenses and prisms, and illumination optics. With continual development of surface finish, we expect to be able to print imaging optics in the very near future,” says Jon Donner, CEO of Nanofabrica.

Manufacturers requiring micron and sub-micron level accuracy and resolution have an AM platform available and can benefit from the advantages of AM since it’s agnostic to part complexity and unique geometries are possible. The Nanofabrica technology becomes an enabling technology, allowing the manufacture of parts and features previously impossible.

Today, innovation in medical applications is largely driving the micro-optic sector, and is constantly increasing the demand for smaller, higher quality, and more versatile micro-optics. In the medical device sector, micro-optic development is working for developments in compact sensors and illumination methods to further refine devices such as endoscopes and various invasive camera applications. Nanofabrica’s technology is pushing the boundaries, opening up the manufacture of parts and components previously seen as impossible using traditional manufacturing processes.

“Additive manufacturing has many innate advantages as a production tool, among which are the fact that it allows designers to think out of the box when it comes to apparent design restrictions, and of course multiple design iterations can be made speedily to stimulate the creation of innovative end products. But until the launch of Nanofabrica’s micro AM production technology, the requirements from the micro optics sector in terms of ultra-precision and repeatable resolution and surface finish were impossible to achieve through the use of 3D printing. Using Nanofabrica’s micro AM platform, OEMs can now in a single process create micro-optical polymer-based products with complexity and features such as freeform surfaces that would either be impossible using conventional manufacturing technologies, or be prohibitive in terms of time and cost,” Donner says.

© Platinum Tooling | http://platinumtooling.com

Live tooling, as the name implies, is specifically driven by the CNC control and the turret of various spindle and powered sub-spindle configurations on CNC lathes to perform various operations while the workpiece remains in orientation to the main spindle. These devices, whether BMT or VDI, are also called driven tools, as opposed to the static tools used during turning operations and are usually customized for the particular machine tool builder’s turret assembly.

Most often, live tooling is offered in standard straight and 90º configurations with a wide variety of tool output clamping systems, including collet chuck, arbor, Weldon, Capto, whistle notch, hydraulic, HSK, CAT, ABS, and a variety of custom or proprietary systems developed by the many suppliers to the industry.

© Platinum Tooling | http://platinumtooling.com

As your jobs change or volume increases or you encounter specific challenges in machining very large parts with deep pockets or very small intricate parts, for example, and the need arises for new machinery, a common error is made by accepting the standard tooling packages provided by the builder. This is not a criticism of the standard packages from builders, but you need a set of parameters to consider when evaluating the tooling and tool holding devices to use; you need to do as much evaluation of your process when determining the proper tooling to be used as you did when you evaluated the various machines available for purchase. 

This examination can range from the simple (external vs. internal coolant) to the sublime (adjustable or extended tooling configurations) to the truly exotic.

Tool life is the product of cutting intensity, materials processed, machine stability and, of course, piece parts produced. Two seemingly identical job shops can have vastly different tooling needs because one is medical and one is automotive, or one specializes in the one-offs and low-volume work, while the other has a greater occurrence of longer run jobs. The totality of your operation determines the best tooling for the machines being purchased. 

© Platinum Tooling | http://platinumtooling.com

Bearing construction and the resulting spindle concentricity drive the life of any tool and you might find that just a 10% to 15% greater investment in a better design can yield both longer lasting cutters and consistently superior finish on your products. Of course, the stability and rigidity of the machine tool base are also critical factors, especially on large or deep pocket workpieces, where the distance from the tool base to the cutter tip is greater. Bevel and spur gears that are hardened, ground, and lapped in sets are best for smooth transition and minimal runout. Roller bearings are consistently superior to spindle bearings in live tooling applications, so look for a combination system to get the highest precision possible. Also look for an internal vs. external collet nut, so the tool seats more deeply in the tool, as superior rigidity will result. 

Likewise, coolant high pressure might be desirable. Look for 2,000psi in 90º and 1,000psi minimum in straight tools. 

© Platinum Tooling | http://platinumtooling.com

You need to ask another question, namely, is the turret RPM sufficient to handle the work to be done? It’s possible a speed increaser on the tool would be helpful. 

Would it be beneficial to move secondary operations to your lathe? Gear hobbing can be accomplished or producing squares or flats through use of polygon machining. 

Standard live tooling most often is best suited to production work, where the finish, tolerances, and cutter life are critical, while quick-change systems may be better suited to the shop producing families of products and other instances where the tool presetting offline is a key factor in keeping the shop at maximum productivity.

© Platinum Tooling | http://platinumtooling.com

This opens the discussion of long-term flexibility and it’s the most often overlooked consideration in buying live tooling. What work do you have in the shop, what work will be coming in, and the overall economies of a changeable adapter system on your tooling may be considerations not often made when the focus is centered on the machine being purchased. Dedicated tools for large families of product may be desirable but consider a changeable adapter system and talk to your supplier before making that determination. Likewise, if the future work you’re bidding involves more families of product, think ahead when buying the initial tooling on the machine. 

If standard ER tooling is suitable for the work, there are many good suppliers but do consider the construction aspects noted above. For a quick-change or changeable adapter system, there are fewer suppliers in the market, so seek them out and be sure they can supply the product styles you need for all your lathe brands. Adjustable angle head systems can be costly but very worthwhile, owing to the stability and rigidity of their construction, when producing families of parts with only slight differences in the dimensions. 

Now, the exotic example…it evidences the value of having test runs done on alternative tool styles.

One company was doing a cross-milling application on an AL6063 sheave, using an ER40 output tool on a Eurotech lathe, running 10ipm at 4,000rpm. They were making three passes, with a cycle time of 262 seconds and getting a chatter finish on 20,000 pieces per year. The annual cost of the machining was over $130,000. By using an improved adapter tool design with ER32AX output and the same parameters, they were able to produce the part in a single pass with a smooth finish and cycle time of just 172 seconds. Over the course of the year, this turned into a savings of $45,000, 20x the cost of the tool. The bottom line is the bottom line, as the accountants tell us. 

In the end, you may not need a +135º/-30 universal adjustable tool or a multi-spindle live holder or even a quick-change adapter system but do consider all the options. Talk to your machine builder and several tool suppliers, plus the most important people in this equation, your shop personnel, as their input is invaluable.

Preben Hansen, president of Platinum Tooling Technologies Inc., Prospect Heights, IL, can be reached at 847.749.0633 or phansen@platinumtooling.com.

St. Paul, Minnesota – Matsuura Machinery USA Inc. officials have hired Shannon Collett as the company’s Matsuura LUMEX Administrator.

“With the surge in demand for Matsuura’s Lumex hybrid additive manufacturing technology, we continue add to our knowledgeable and educated team of professionals. Shannon has extensive experience in inventory control, accounting, finance and customer relations areas. Her proficiency will help us more efficiently manage our Additive Manufacturing Center Operations, maintain accurate accounting of our material usage, and manage our inventory of Consumable Tooling,” said Tom Houle, director, Matsuura Lumex, NA, Matsuura Machinery USA Inc.

© Matsuura

The Matsuura Lumex Series combines selective laser sintering (SLS) along with high speed milling (HSM) commonly called hybrid AM. The series, manufactured for more than 10 years, is now offered in North America with sales and technical support provided by Matsuura Machinery USA.

Matsuura’s combination of technology platforms enables production of parts and component geometries in a method never imagined possible. These machines manufacture highly complex integrated parts and molds in shapes and configurations that were once impossible using traditional milling methods.

“Additive Manufacturing is being described as the manufacturing platform of the future. Specifically, the hybrid version of metal AM is the newest innovation and provides some direct benefit that customers can see clearly. For Matsuura, because we are built on a machine tool platform – casting, boxed ways, etc. customers are seeing how they can benefit from this rigid robust system on a manufacturing floor and not simply in an experimental lab.

“This is contributing to the movement of AM from an experimental based technology housed in a controlled laboratory environment and only accessible to the scientists to one where AM is an integral component of any machining line or supplier. This change is driving AM and hybrid AM technology excitement,” Houle explains.

Cassandra Yanke has been promoted to logistics and project manager, maintaining responsibility for ensuring the availability of Matsuura machinery for the U.S. market. She will continue to optimize the Matsuura supply chain by closely managing the logistics process.

“At Matsuura USA, great customer service is our utmost priority. Cassie’s promotion to Logistics and Project Manager will continue to preserve Matsuura’s critical delivery process as she is a master of multi-tasking,” says Brad Baker, VP finance & administration for Matsuura Machinery USA, Inc.

Yanke will facilitate the exchange of Matsuura machine orders from the initial sale to customer delivery, closely aligning with Matsuura’s sales and technical departments and serving as the liaison between Matsuura shipping and receiving vendors.

Yanke recently celebrated 5 years of service with Matsuura USA, where she previously served as logistics manager and contract administrator.

The National Institute for Metalworking Skills (NIMS), in partnership with Festo Didactic, will establish industry-recognized skills standards and credentials for jobs related to Industry 4.0. With the significant trend in digitalization of manufacturing through technology advancements such as Industrial Internet of Things (IIoT), training in these skills is needed. With NIMS’ emphasis on manufacturing skills training, credentialing, and standards, plus Festo’s complete Industry 4.0 learning Factories, courseware, and eLearning integration, the two organizations are well poised to provide the training programs for Industry 4.0.

Montez King, executive director of NIMS, says, “This is an exciting development for manufacturers and educators as it directly addresses both the data-driven revolution happening in manufacturing today and the skills gap. There are so many interdependent functions and abilities surrounding Industry 4.0 that this effort will help to bring clarity to the proficiencies required, train people extremely well, and validate their expertise.”

The emergence of Industry 4.0 is new territory for most in manufacturing. As such, among the first tasks to be accomplished is to conduct research to discover and verify exactly what those competencies must be. Then, the training protocols and credentials will be created.

“We are hopeful to have the standards identified and the training program in place by the end of 2019,” King says.

Thomas Lichtenberger, CEO of Festo Didactic says, “As the production line become ‘smarter’ – collecting data to change processes and create efficiencies – workers and students will be expected to adapt in the same way.  Bringing NIMS, Festo, and other industry partners together, we look forward to a collaboration that leads to world class industry standards and learning systems programs.” 

During the development of the new Industry 4.0 skills standards, NIMS will ascertain the credentials in its existing programs that support the various Industry 4.0 functions and target new credentials for development. The training outcome is to provide employees in or entering a manufacturing workplace with an understanding of Industry 4.0 concepts and impart certifiable skills as companies increasingly adopt automation and data gathering and management functions in their manufacturing operations.

Massachusetts Governor welcomes Festo, 12 other firms at annual MassEcon Event

Festo technologists are developing fluid handling systems for increasing the speed, accuracy of automated screening, sequencing laboratory equipment.

© FESTO

Governor Charlie Baker recently recognized 13 companies, including Festo, for locating or growing businesses in Massachusetts at the 11th annual MassEcon Corporate Welcome Reception.

The companies recognized created 500-plus new jobs, expanded business space by more than 130,000ft² located in multiple regions of the state, and are involved in life sciences, manufacturing, technology, beverage, printing, and health care. Among the 13 were such well-recognized names as Aetna, Gelato, Humana, and Servier Pharmaceuticals. This was the fifth year that Baker welcomed companies at MassEcon’s event, which has been held for past 11 years. MassEcon champions Massachusetts as one of the world’s best places to start, grow, and locate a business. 

Festo dedicated a Technology Engineering Center (TEC) in Billerica in 2018. This TEC is the company’s first engineering center in the United States devoted to the life sciences. Being located in greater Boston gives personnel proximity to such research institutions as MIT, Harvard, and Brown. The region also hosts many laboratory equipment manufacturers. The team at TEC pioneers the development of new high speed, high accuracy fluid handling products based on pneumatic principles. The center works with individual customers on automated motion and fluid handling solutions that bring laboratory equipment to market faster and with less cost.

“Establishing this center for LifeTech research and development in greater Boston was the right thing to do in terms of talent pool, proximity to customers, and being a great place to live and work,” notes Craig Correia, director, Process Industries, NAFTA. “It was an honor to be recognized by the governor at the annual MassEcon welcome reception.”

“As I listened to the companies that were being welcomed, I could tell many of them are here because of the rich and diverse community … that we have,” Gov. Baker says. “Our success as a Commonwealth has been this ability to retain the … vitality of local communities while we continue to attract these terrific businesses.”