Advanced Manufacturing Now

John Graham, senior product marketing manager for Ansys Spaceclaim, Ansys Inc., talks with Manufacturing Engineering Senior Editor Patrick Waurzyniak about how 3D modeling software can help manufacturers streamline designs and boost manufacturing productivity. With today's 3D modeling software, manufacturers are able to efficiently repair incomplete models, reverse engineer files, and incorporate powerful computer-aided engineering (CAE) software into manufacturers' toolbox to more efficiently create manufacturing processes.

Jeannine Kunz, vice president of Tooling U-SME, details how awareness of AM's capabilities is clearly on the rise: Some big manufacturers are focusing on what AM means to their human capital, and AM is often being incorporated into existing roles. Kunz also discusses how Tooling U-SME can help customers increase their use of additive technologies while the world waits for standards. Her division at SME leverages the knowledge of SME members to help companies work through challenges, including "make or buy decisions," she notes. And--the pièce de résistance--she previews the "first-and-only additive certification," at a fundamentals level: SME is set to announce it next month at RAPID +TCT (www.rapid3devent.com) in Pittsburgh.

Randolph Bradley, Technical Fellow in Supply Chain Management at Boeing, explains the Center for Excellence in Logistics and Distribution's reason for being, and Boeing's involvement with the industry-academia partnership. Among what is covered: energy use in the supply chain; demand forecasting using Bayes' Rule (also used to crack Germany's Enigma code during WWII), and insights gained from MHI's US Roadmap for Material Handling and Logistics.

Joe Lampinen, Senior Director, Global Practice Consultant for Engineering, Business, & Professional Services at Kelly Services, explores how manufacturers today must meet the challenge of engaging younger workers just entering the profession. These workers have the expectation that they will change employers ten times or more during their careers. Employers must be able to upskill and engage all of their workers and choose the right option from the many available for bringing in outside workers, including temporary workers, independent contractors, outsourcing, and consulting firms.

What's up with AM machines this year? At the Aerodef conference, SLM Solutions' Winthrop Sheldon takes on this and several other market-trend questions. "You're seeing more multi-laser systems. You're seeing generally more open systems (in terms of parameter control and material use). And you're also seeing larger format systems. So there are quite a few new trends that I feel SLM was instrumental in bringing to market. Now the question is can we maintain our position with these technologies—now that more of our competitors have, let's say, multi-laser systems."

Dimitrije Milovich, president and CEO of Radius Engineering Inc. (Salt Lake City), discusses the role small manufacturers play in aerospace. His company has fewer than 40 employees but has established a niche in aerospace. Milovich was at SME's AeroDef Manufacturing Show in Fort Worth, TX, where he received the 2017 J.H. "Jud" Hall Composites Manufacturing Award. He spoke with Senior Editor Bill Koenig about how small companies play an important role in aerospace manufacturing. Milovich also discusses advances in composites and what they mean for aerospace.

EnvisionTEC CEO Al Siblani explains why the SLCOM 1, a machine that does selective lamination composite object manufacturing and is in beta testing, is an important development in 3D printing: "There's absolutely no limitation in terms of geometry in terms of what kinds of composite parts you can build—unless it's a closed volume. Besides any closed volume, the SLCOM 1 allows you to additively manufacture parts that are 24 inches wide, 30 inches long and 24 inches deep. So what really makes the SLCOM an interesting product is its ability to print very large parts that could be used in some luxury automobiles as finished goods. It could also be used in a production capacity in aerospace companies." In part because of automation, SLCOM 1 promises to reduce to two or three days a manual manufacturing process that now takes about 13 days: making one GE90 engine blade in composites.

Zane Michael, director of thermal business development for Yaskawa America/Motoman Robotics Division, explains why the biggest challenge for welding manufacturers today is the shortage of welders. He notes that fabricators can apply robotic welding technology with a high degree of success by first using simple systems, and explains why human welders still play a major role in robotic welding by analyzing and managing the performance of robotic welding units.

At the Aerodef conference in Texas, Conrad Leiva, VP for product strategy and alliance at iBASEt and chair of the smart manufacturing working group at MESA, says companies should first evaluate their business model today to get ready for a smart manufacturing future. Next, they should look at their IT infrastructure. And don't forget to address digital handoffs between systems. "We're coming from a culture of silos and moving to a culture of collaboration--across our departments internally and into the supply chain."

For starters, NASA's HUNCH program brings projects, mentors, expertise and schools. SME's PRIME initiative brings mentors, equipment and a scholarship component. "It's kind of a big deal that those things mesh so well," says Blake Ratcliff, program manager of NASA HUNCH.