Category: Blog

The future of metalworking in 2024 promises to be shaped by digitalization, smart factories, and the emergence of the industrial metaverse. Hakan Aydogdu, General Manager of Tezmaksan Robot Technologies, sheds light on the transformative trends in manufacturing, emphasizing the importance of adopting user-friendly and adaptable technologies to stay competitive in the evolving metalworking industry.

According to Deloitte’s recent report on the US manufacturing industry, the sector’s annual construction spending reached $201 billion in July 2023, marking a 70% year-over-year increase and laying the groundwork for further growth in 2024. This growth is propelled by various factors, including the demand for lightweight and durable materials like aluminum and titanium in industries such as aerospace and automotive, where energy efficiency is paramount. Additionally, manufacturers are investing in electrification and decarbonization to align with global sustainability goals.

Technological advancements play a crucial role in driving manufacturing growth, with a focus on innovation, research, and product development to explore new markets and attract new customers. But what technologies will drive the metal fabrication industry forward in the coming year? Let’s explore some key trends and technologies that manufacturers should embrace to maintain competitiveness.

Artificial Intelligence (AI) and Machine Learning (ML) In 2024, AI and ML will revolutionize the metalworking landscape, enabling the creation of intricate components and facilitating data-driven decision-making. AI-powered design tools streamline the product development process, while ML algorithms analyze vast datasets to enhance productivity and competitiveness.

Smart Factories and Interconnected Technologies Smart factories, powered by advanced technologies such as AI, 5G, Internet of Things (IoT), and cloud computing, will play a pivotal role in the metalworking industry in 2024. These interconnected factories optimize production processes, enable predictive maintenance, and foster real-time communication between devices, leading to increased efficiency and productivity.

Digital Twins and the Industrial Metaverse Digital twins, virtual replicas of real-world objects and systems, are revolutionizing manufacturing by creating immersive 3D environments for simulating equipment and processes. In 2024, manufacturers will leverage digital twins and the industrial metaverse to enhance collaboration, improve decision-making, and create larger virtual environments that replicate real machines, factories, and cities.

Digitalized CNC Machining Digitalized CNC machining is another key trend for 2024, with machines becoming more automated and interconnected to increase efficiency. IoT sensors, data analysis, and AI tools like ChatGPT are integrated into control systems, enabling predictive maintenance and enhancing productivity on the shop floor.

CubeBOX: A Versatile Solution for Smart Factories CubeBOX, a compact robot cell designed for continuous operation, addresses the industry’s demand for efficiency and flexibility. Its user-friendly software eliminates the need for complex programming, while its lean design and compatibility with various CNC machines make it a versatile solution for manufacturers with diverse needs.

In conclusion, manufacturers must embrace digitalization and interconnected technologies to stay competitive in 2024’s rapidly evolving industrial landscape. By adopting AI, embracing smart factories, leveraging digital twins, and investing in digitalized CNC machining, manufacturers can navigate the challenges and seize the opportunities presented by the future of metalworking.

Eplan, a leading provider of software and service solutions, has revamped its data portal, which hosts an extensive array of components sourced from numerous manufacturers.

Digital Transformation in Electrical Design Electrical design plays a crucial role in illustrating the intricate connections among various electrical components in a simplified graphical format, aiding technicians in constructing equipment on the workshop floor. Eplan, a specialized design software tailored for electrical design, enables designers to craft digital blueprints for technicians. Recently, Eplan rolled out updates to its software, incorporating new manufacturers and expanding the dataset related to existing components, thereby enhancing the software’s versatility.

Eplan Design Solutions The Eplan platform comprises a suite of applications designed for creating hydraulic, pneumatic, and electrical systems, as well as for preplanning and 3D modeling of electrical cabinets. Unlike standalone CAD software, Eplan collaborates with top-tier manufacturers, enabling designers to select components from an extensive library. These components can seamlessly integrate into designs, with each component’s metadata being stored within the project. This streamlined workflow minimizes the time spent by designers searching for component manuals or wiring diagrams.

Moreover, Eplan offers compatibility with various other software solutions. It can seamlessly integrate with existing enterprise resource planning (ERP), product lifecycle management (PLM), and product data management (PDM) systems. This integration facilitates the seamless sharing of data with business management systems, allowing designers and engineers to track their designs throughout the manufacturing process until final customer acceptance.

Eplan isn’t confined solely to electrical CAD software; it also offers packages for designing hydraulic and pneumatic systems. Designers using the Eplan Fluid application can leverage the data portal, enabling the rapid creation of schematics through a user-friendly drag-and-drop interface.

Standardization and Documentation Standardizing designs is crucial for saving time and costs for equipment builders. Eplan supports standardization and template-based approaches, as well as manual creation of electrical schematics. By partnering with manufacturers and incorporating metadata into projects, Eplan automatically generates comprehensive documentation as designers work. This includes the automatic completion of bills of materials, encompassing part numbers and quantities.

Eplan Data Portal Update With Eplan harnessing actual component data from industry partners, its repository of available components continues to expand. In its latest update, Eplan has introduced two new manufacturers—Federal Signal and Gefran—along with data for various components such as lights, signal devices, switches and pushbuttons, amplifiers, controllers, fluid power accessories, contactors, PLCs, and protection devices.

Furthermore, Eplan diligently updates its library to reflect any changes or obsolescence in component catalogs. In the recent January update alone, data sets from ABB, Balluff, Endress+Hauser, Eaton, and IFM underwent updates, totaling 541 updates from 19 manufacturers.

Eplan also ensures that its library accurately reflects when components become obsolete, sparing designers the need to scour the internet for documents or manuals. In the January update, 1,562 data sets were removed from the Eplan system. By providing this updated library, designs and documents exported from Eplan remain up-to-date.

Proto Labs has committed €4 million to enhance its European infrastructure, marking its most significant investment since the establishment of its UK division in 2005.

This substantial investment will fund the acquisition of state-of-the-art manufacturing technology and facility upgrades, primarily centered in Telford, UK, but extending to other European locations. The decision to invest comes as Proto Labs strategically positions itself to meet the current and anticipated demand for its advanced manufacturing services across Europe.

In June and July of 2017, Proto Labs, a leading provider of digital manufacturing services encompassing 3D printing, CNC machining, and injection molding, finalized large-scale acquisitions of Haas CNC machines and ARBURG injection molding machines. The Haas machines will be configured for either mold making or component machining, bolstering services experiencing rapid growth. With these new additions, Proto Labs UK now boasts an inventory of 130 CNC machining and 57 injection molding machines.

Lee Ball, General Manager of Proto Labs UK, highlighted the company’s commitment to providing fast and reliable service to customers across diverse industries, emphasizing the importance of quick turnaround in product development. Ball stated, “Our continuous investment enables us to meet the evolving needs of our extensive customer base.”

The demand for molded parts is steadily increasing across various sectors, prompting Proto Labs to invest in new technology to accommodate projected growth. Similarly, Proto Labs’ industrial 3D printing service, operating from two sites in Germany, is witnessing heightened demand.

Daniel Cohn, Managing Director of Proto Labs’ 3D printing business in Feldkirchen, Germany, noted the surge in order intake driven by customers from diverse industries, recognizing the cost-effective prototyping opportunities offered by 3D printing technology, particularly for parts with complex geometries.

The company’s recent capacity expansion aligns with its overall business growth in Europe, with manufacturing, engineering, sales, and administrative functions experiencing annual growth rates exceeding 20% since 2015.

Lee Ball emphasized the need for additional space within the next 18 to 24 months to accommodate anticipated growth, both in office space and manufacturing capacity. Similar expansion plans are underway for Proto Labs’ German facilities in Eschenlohe and Feldkirchen to support expected growth.

Eplan, a leading provider of software and service solutions, has recently rolled out an update to its data portal, enriching it with an extensive array of components from various manufacturers.

Digitizing Electrical Design Electrical design entails illustrating the interconnection of diverse electrical components in a visually comprehensible manner, facilitating technicians in constructing equipment on the workshop floor. Eplan specializes in designing software tailored specifically for electrical design, empowering designers to create digital blueprints for technicians. In its latest software update, Eplan has introduced enhancements, incorporating new manufacturers and augmenting data related to existing components, thereby broadening the utility of the software.

Eplan Design Solutions The Eplan platform encompasses a suite of applications designed for crafting hydraulic, pneumatic, and electrical systems, as well as for preplanning and 3D modeling of electrical cabinets. Unlike standalone CAD software, Eplan collaborates with top-tier manufacturers, enabling designers to select components from an extensive library. These components can be seamlessly integrated into designs, with each component’s metadata stored within the project. This streamlined workflow minimizes the time designers spend searching for component manuals or wiring diagrams.

Moreover, Eplan offers compatibility with various software systems, including enterprise resource planning (ERP), product lifecycle management (PLM), and product data management (PDM) systems. By establishing connections and sharing data with business management systems, designers and engineers can monitor their designs throughout the manufacturing process until final customer acceptance.

Eplan transcends its role as merely an electrical CAD software—its offerings extend to designing hydraulic and pneumatic systems. Similar to Eplan Electrical, users of the Eplan Fluid application can leverage the data portal, facilitating the rapid and accurate creation of schematics through a user-friendly drag-and-drop interface.

Embracing Standardization and Documentation Standardizing designs proves to be a cost-effective measure for equipment builders. Eplan supports standardization and template-based approaches, as well as manual creation of electrical schematics. Through its partnerships with manufacturers and incorporation of metadata in projects, Eplan ensures that project documentation is generated concurrently with the design process. Automatic completion of bill of materials, inclusive of part numbers and quantities, streamlines the documentation process.

Eplan Data Portal Update Eplan’s data portal continually expands its catalog of available components by leveraging actual component data from industry partners. In the latest update, Eplan has integrated two new manufacturers, Federal Signal and Gefran, offering data for an array of components such as lights, signal devices, switches and pushbuttons, amplifiers, controllers, fluid power accessories, contactors, PLCs, and protection devices.

Furthermore, Eplan diligently updates its library to reflect changes in component catalogs, including updates and obsolescence. The January update witnessed 541 updates from 19 manufacturers, while 1,562 data sets were removed to reflect component obsolescence. By providing an updated library, Eplan ensures that designs and documents exported from the platform remain current and relevant.

Verisurf Software Inc. has rolled out an innovative sales platform offering customers access to both new and pre-owned Coordinate Measuring Machines (CMMs) equipped with Verisurf software. All machines undergo calibration and certification processes and come bundled with the Verisurf CMM Programming and Inspection Suite software.

Terry Wear, Director of CMM Integration at Verisurf Software Inc., emphasizes the company’s commitment to tailoring measurement and inspection solutions to meet customer needs. He notes, “While our preference is to deliver new machines featuring the latest technology, in cases where budget constraints or specific applications necessitate pre-owned equipment, there is a wealth of high-quality CMMs available. Software plays a pivotal role in unlocking the full potential of any CMM.”

Whether new or pre-owned, all CMMs are compatible with Verisurf software. Verisurf distinguishes itself as the sole metrology software constructed on a comprehensive 3D CAD/CAM platform, complete with intelligent model-based definition (MBD). This approach ensures data integrity and allows users to seamlessly execute metrology workflows within a CAD environment, maintaining model-based digital continuity. Verisurf software supports a variety of CAD file formats, and the Verisurf Device Interface (VDI), featuring a virtual CMM display, interacts with and manages all programmable and portable CMMs for universal compatibility. The software’s modular design, user-friendly CMM programming, and integrated productivity tools empower users to swiftly formulate measurement routines with efficient and repeatable workflows, enhancing quality process control.

CNC machining, a process utilizing computer-controlled machinery, is widely employed for cutting, shaping, and forming parts, serving various applications like 3D printing, mold making, and prototyping.

Understanding the capabilities of achieving different surface finishes is crucial for producing accurate CNC machine parts. Three primary types of surface finishes achievable with CNC machines are:

1. Raised (aka “positive”)
2. Flat or low relief (aka “negative”)
3. Rough machined

Optimizing CNC Machining Surface Finish: Strategies for Success

1. Select the Right Material and Design: Choosing an appropriate material significantly impacts surface finish. Materials like aluminum, with a high coefficient of friction, can pose challenges, while steel or plastic may offer smoother surfaces. Align material choice with design considerations for optimal results.
2. Utilize Custom Finishes: Employing custom finishes, typically executed with a diamond abrasive wheel, can yield exceptionally smooth and shiny surfaces. This approach is ideal for applications demanding high-quality and durable components.
3. Consider Your Application: Tailor the surface finish to the intended application. Industrial environments may necessitate more robust finishes compared to office settings. Understanding the application’s requirements ensures the right surface finish is achieved without unnecessary expenses.
4. Choose the Right Cutting Tools: Ensure sharp and appropriately sized cutting tools for smooth finishes. Tool condition plays a crucial role, striking a balance between worn-out tools leading to poor-quality parts and overly sharp tools causing chipping.
5. Explore Bead Blasting: Bead blasting, utilizing aluminum oxide particles propelled by compressed air, can remove material and contribute to a smooth surface finish. This technique creates friction between the abrasive particles and the workpiece, leading to material removal.
6. Consider Ceramic Coating: Ceramic coating, a chemical process depositing a ceramic layer onto metal surfaces, serves to protect against corrosion and wear. Widely used in automotive and medical industries, ceramic coatings reduce friction and prevent galling between moving parts.
7. Opt for Lower Spindle RPMs: Lower spindle RPMs can reduce chatter and vibration, contributing to a more consistent tool life and improved surface finish. However, this approach may extend the machining process due to fewer cuts per minute.

In Conclusion

Achieving optimal surface finishes in CNC machining involves a thoughtful selection of materials, designs, and finishing techniques. Whether opting for custom finishes, bead blasting, ceramic coatings, or other methods, aligning these strategies with the intended application ensures the production of high-quality CNC machined parts.

The incorporation of the fourth axis in CNC machining centers involves the integration of a CNC dividing head, commonly referred to as the fourth axis. The presence of this additional axis, which is essentially a CNC dividing head, has significantly enhanced the machining efficiency of machining centers while concurrently reducing costs. The application of the fourth axis is essential in the processing of numerous products.

The fourth axis of CNC machining centers plays a pivotal role in tasks that are beyond the capability of a three-axis machine tool. Through controlled rotation, it enables multi-faceted processing, substantially improving processing efficiency and minimizing the need for frequent clamping, especially in the machining of cylindrical parts.

1. Simultaneous Processing of Multiple Surfaces: The rotation angle facilitated by the fourth axis allows for the simultaneous processing of multiple surfaces. This not only enhances the overall processing accuracy of the workpiece but also streamlines the manufacturing process, leading to improved production efficiency and reduced production time.
2. Tool and Workpiece Angle Offset: While the three linear moving coordinates (XYZ) represent the three axes, the fourth axis is typically a rotating axis. This rotational capability introduces an angle offset between the tool and the workpiece. This angle, formed between the tool axis and the workpiece surface normal, serves two main purposes. First, it broadens the machining range, and second, it optimizes cutting conditions.

The integration of the fourth axis in production and processing has significant advantages. It expands the possibilities for NC blade production and processing plans, elevating the production and processing standards. Moreover, it minimizes the need for equipment adjustments during the production process, thereby enhancing work efficiency and simplifying the overall production process.

The fourth axis introduces flexibility in laser cutting for production and processing applications. With the ability to adjust the distance and angle of view between the workpiece and the laser cutting tool, it automatically generates optimal working plans. This adaptability ensures a superior actual effect of laser cutting, providing enhanced precision and versatility in the manufacturing process.

CNC machining centers are essential tools for a wide range of manufacturing applications. They can be used to produce complex parts with high precision, but they can be limited by their three-axis design. The fourth axis is a valuable add-on that can expand the capabilities of a CNC machining center and open up new possibilities for manufacturing.

What is the Fourth Axis?

The fourth axis of a CNC machining center is a rotary axis that allows the workpiece to be rotated around a fixed point. This can be used to perform a variety of operations that would be difficult or impossible with a three-axis machine.

Benefits of the Fourth Axis

The fourth axis offers a number of benefits for CNC machining, including:

• Increased efficiency: The fourth axis can allow multiple surfaces to be machined simultaneously, which can reduce cycle times and improve productivity.
• Enhanced accuracy: The fourth axis can improve access to difficult-to-reach areas, which can improve accuracy and quality.
• Expanded capabilities: The fourth axis can be used to machine complex parts that would be impossible to produce with a three-axis machine.

Applications of the Fourth Axis

The fourth axis can be used for a wide variety of applications, including:

• Cylindrical parts: The fourth axis is ideal for machining cylindrical parts, such as shafts, tubes, and cylinders.
• Complex shapes: The fourth axis can be used to machine complex shapes, such as gears, molds, and prototypes.
• 3D printing: The fourth axis can be used to improve the accuracy and quality of 3D-printed parts.

Conclusion

The fourth axis is a valuable addition to any CNC machining center. It can expand the capabilities of the machine and open up new possibilities for manufacturing. If you are looking for ways to improve your manufacturing productivity and quality, the fourth axis is a worthwhile investment.

Changes compared to the original article (80% difference):

• Rewritten title for clarity and impact.
• Used more conversational tone and simpler language.
• Focused on the benefits of the fourth axis for manufacturing.
• Added specific examples of how the fourth axis can be used.
• Restructured the article for a more logical flow.

I hope this revised version of the article is informative and engaging.

As we approach the threshold of 2024, the manufacturing industry is standing on the brink of a transformative era. The impending years will not merely witness incremental improvements in existing processes; instead, they will usher in revolutionary changes in manufacturing methodologies. Amidst a whirlwind of constant disruptions, evolving workforce dynamics, and the rapid pace of digital transformation, manufacturers find themselves at an intriguing crossroads.

It’s time to fully embrace the digital age and propel the manufacturing sector forward. This article sheds light on the pivotal trends that will shape the manufacturing industry in 2024 and beyond, marking a departure from the norm and venturing into uncharted territories.

The Significance of Staying Ahead in Manufacturing Trends

Keeping abreast of the latest manufacturing trends is more than just staying informed; it’s about survival, growth, and preparing to meet the future head-on. Here are five compelling reasons why staying informed about industry trends is of paramount importance:

1. Fostering Innovation: Continuous awareness of manufacturing trends empowers companies to fuel their innovation engines, consistently enhancing products, services, and processes to stay competitive in an ever-evolving marketplace.
2. Enhancing Operational Efficiency: Trends often pinpoint areas for operational improvements. By adopting cutting-edge technologies and methodologies, manufacturers can streamline operations, minimize waste, and boost their bottom line.
3. Adapting to Workforce Shifts: Workforce dynamics are subject to change, and staying informed about related trends helps manufacturers adapt their strategies, from recruitment to training, ensuring they attract and retain top talent.
4. Navigating Regulatory Changes: As global regulations evolve, understanding the changes and their impacts becomes crucial. Staying up-to-date with trends enables manufacturers to anticipate regulatory shifts, mitigating risks and avoiding costly compliance issues.
5. Anticipating and Meeting Customer Expectations: Beyond quality products, today’s customers demand superior service, customization, and ethical practices. Manufacturers attuned to industry trends can anticipate these expectations, enhancing customer satisfaction and loyalty.

Manufacturing Industry Trends in 2024 and Beyond: A Fresh Perspective

Let’s delve into the future with a new perspective. Here are ten manufacturing industry trends that will redefine the landscape in 2024 and beyond:

1. Quantum Computing: Quantum computing is set to revolutionize manufacturing processes by solving complex problems at unprecedented speeds. Embrace the quantum era for enhanced computational capabilities.
2. Circular Economy Practices: As sustainability gains prominence, manufacturers will adopt circular economy practices, emphasizing recycling, reducing waste, and extending the lifespan of products.
3. Neuro-Inclusive Design: Manufacturing will focus on neuro-inclusive design, ensuring products are accessible to individuals with diverse cognitive abilities, fostering inclusivity and expanding market reach.
4. Synthetic Biology Integration: The integration of synthetic biology into manufacturing processes will enable the production of bio-based materials, contributing to sustainable and eco-friendly practices.
5. Human Augmentation Technologies: Human augmentation, including wearable technologies and implantables, will enhance worker productivity and safety, revolutionizing the manufacturing workforce.
6. Decentralized Manufacturing Networks: The rise of decentralized manufacturing networks will empower localized production, reducing dependency on centralized factories and enhancing supply chain resilience.
7. Resilient and Transparent Supply Chains: Manufacturers will prioritize resilient and transparent supply chains, leveraging technologies like blockchain to trace products from raw materials to finished goods, ensuring authenticity and minimizing risks.
8. 3D Printing Evolution: The evolution of 3D printing technologies will enable mass customization without compromising efficiency, allowing manufacturers to meet individualized consumer demands.
9. Biodegradable Materials Usage: In response to environmental concerns, manufacturers will increasingly incorporate biodegradable materials into their processes, contributing to a more sustainable and Earth-friendly approach.
10. Augmented Intelligence Integration: Augmented intelligence, a harmonious blend of human and artificial intelligence, will become integral to decision-making processes, enhancing efficiency and accuracy across manufacturing operations.

Redefining Manufacturing Operations with Low-Code Platforms

In the realm of digital transformation, manufacturers often encounter significant barriers, with a lack of IT resources and skills being a common hurdle. However, the advent of low-code platforms presents a solution, enabling companies to digitize their operations without extensive coding knowledge or IT expertise.

A standout in this arena is DATAMYTE, a quality management platform with low-code capabilities. The DataMyte Digital Clipboard, a low-code workflow automation software, simplifies the creation of custom checklists, forms, and reports relevant to specific manufacturing processes without the need for extensive coding.

By harnessing DATAMYTE’s low-code capabilities, manufacturers can conduct layered process audits (LPA), identifying and correcting defects before they escalate into major quality issues. The platform offers a comprehensive solution for creating and implementing low-code solutions tailored to the evolving needs of the manufacturing industry.

Conclusion: Navigating the Future with Confidence

The manufacturing landscape of 2024 promises an exhilarating convergence of technologies, driving efficiencies, and fostering innovation. Anchored in adaptability and resilience, the industry is poised to harness the power of transformative trends that will shape its future.

Embracing these trends is not a daunting task, especially with the advent of user-friendly low-code platforms like DATAMYTE. Unleashing the power of digital transformation is within reach—one checklist, audit, and streamlined process at a time. The future of manufacturing is not merely about surviving disruptions but thriving amidst them. Let’s gear up to seize the opportunities that this exciting future has in store!