Category: Blog

Laser cutting is a nuanced process, involving the precise engraving and cutting of various materials like metal, wood, plastic, and acrylic using a focused beam of light. The key to successful laser cutting lies in sophisticated software that guides and controls the laser beam. Selecting the right engraving or cutting software is crucial, akin to choosing the appropriate laser engraving or cutting machine.

Various software programs cater to laser cutters, ranging from those designed for beginners and hobbyists to general-purpose software with laser cutting applications. Here, we present a list of the best laser engraving and cutting software for 2023, suitable for both industrial use and individual enthusiasts.

Free Options

1. LaserGRBL
   • Key Features: Ideal for beginners, it offers a jogging feature for manual laser head positioning, an override function for real-time adjustments, and raster image import for diverse graphic options.
   • Platform: Windows
   • Note: Not available for macOS in recent versions.
2. Inkscape
   • Key Features: Open-source vector graphic software supporting SVG, PDF, JPG, GIF, and PNG. Available on Mac, Windows, and Linux.
   • Note: A versatile tool more geared toward general vector graphics than laser cutting.
3. SolveSpace
   • Key Features: Simple user interface with minimal input but a steep learning curve. Extremely resource-friendly, taking up less than 10 MB, and exports directly to SVG.
   • Note: Free software suitable for laser-cutting design needs.
4. LaserWeb4
   • Key Features: Community-supported free laser cutter program with unique features like materials and price calculators.
   • Note: Excellent choice for hobbyists and beginners.
5. CorelDRAW
   • Key Features: A popular vector graphics program with an intuitive interface and support for various formats. Paid software with advanced features.
   • Note: Ideal for custom illustrations and design professionals.

Paid Options

1. LightBurn
   • Key Features: Monthly subscription justified by design and layout features, advanced operations tools, and direct communication with laser cutter control units.
   • Note: Offers compatibility with most controllers.
2. DraftSight
   • Key Features: Professional-grade design software with features like JPG file conversion, importing multiple files into a single project, and rendering projects in various output files.
   • Note: Relatively high-priced but suitable for professional designers.
3. TurboCAD Designer
   • Key Features: Powerful design tool for 2D designs, exporting vector files in various formats. Overkill tool for cleaning up vector drawings and a PDF Insert/Underlay tool for efficient laser cutting.
   • Note: Available for both Windows and Mac OS.

In conclusion, whether you opt for a free or paid option, choosing the right laser engraving software is crucial for mastering the intricacies of raster and vector files and confidently designing laser engravings. With the diverse options available, users can find the perfect software to complement their laser cutting machines, making the learning curve worthwhile.

Medical tools, instruments, and paraphernalia are evolving rapidly, with new tech innovations enhancing patient care and overall well-being. Such items can be found in various settings, from operating rooms to therapy facilities and from rural health centers to home first aid kits.

Though these medical items differ in purpose, they exhibit several universal characteristics:

• Foremost, their construction should ensure the utmost safety, including the materials from which they are crafted.
• They should function consistently, maintaining specific standards for repetitive and predictable outcomes.
• Many are tailored to fit particular needs, especially related to the human body’s unique intricacies.
• It’s vital that new inventions transition smoothly from concept to market launch after thorough testing and validation.

CNC (Computer Numerical Control) manufacturing has emerged as a perfect solution, addressing these needs effectively.

Modern Innovations in CNC Production

The ongoing evolution in CNC tooling technology is a response to market needs. As designs become more intricate, the demand for heightened precision grows, pushing the boundaries of tool design possibilities.

Manufacturers continuously strive to enhance equipment performance. Their goals include managing vibrations, boosting machine velocity, curtailing upkeep expenses, and delivering adaptable machining setups capable of multifaceted tasks in a single operation.

There are three cutting-edge technical advancements aiding in these pursuits:

1. Magnetic Linear Drives: Traditional multi-axis CNC devices maneuver along several independent pathways, usually via a linear screw drive mechanism. These methods often suffer from friction, wear, and limited speed and accuracy. However, magnetic linear drives operate similarly to Maglev trains. Magnetic forces lift the carriage from its track and also propel its movement, minimizing friction, wear, and the need for maintenance. This approach achieves superior speed and precision.

2. Oil-Cushioned Guides: To reduce friction, another ingenious technique involves oil-cushioned guides. These guides use an oil film, consistently pumped, to minimize friction and vibration, ensuring remarkable finished product quality.

3. Thermal Regulation: During high-performance machining, heat accumulation can challenge precision due to material expansion. To counteract this, advanced cooling mechanisms are employed, and adept manufacturers can anticipate and adjust for such thermal expansions.

Given its attributes, CNC machining stands unmatched in reliability, accuracy, affordability, adaptability, and scalability. Let’s delve into how CNC production particularly benefits medical device development in pivotal aspects.

Swift Prototyping: Prototypes are foundational for all new inventions. With CNC, once a design is greenlit, actual parts can materialize within a day. This swift turnaround accelerates crucial prototype evaluations.

Accuracy and Consistency: Advanced CNC equipment can replicate designs with microscopic variances, ensuring unmatched precision. Previously, such accuracy was reserved for expert machinists in controlled conditions, but now digital innovations have made perfection commonplace.

Flexible Production: Unlike other manufacturing techniques that necessitate costly and time-consuming molds or casts, CNC doesn’t mandate such investments. This flexibility ensures cost-effective production, even in limited quantities.

Material Versatility: CNC machinery is adaptable, processing varied raw materials with minor adjustments. This allows designers and medical professionals significant flexibility in material selection.

Regulatory Compliances: Essential certifications, such as ISO 13485, guarantee that manufacturers uphold stringent quality standards throughout the production process. It’s essential to emphasize that regulatory clearances, like FDA approvals, lie with the product’s designer or owner, not the manufacturer.

Diverse Applications: CNC’s adaptability allows it to cater to numerous customized medical product fabrications, from surgical tools to testing equipment components. However, for large-scale plastic components, injection molding is more appropriate.

The intricate world of modern-day manufacturing often poses the task of discerning the workings of various machinery and techniques. Recognizing the disparities between CNC milling and CNC turning is instrumental for machinists, ensuring optimal utilization of resources. During the design phase, it provides CAD and CAM professionals the clarity to design components that favor one specific machine, optimizing the production workflow.

Milling and turning, while somewhat similar, employ unique strategies to shape materials. They are both methods that subtract material. Their utility spans from petite to vast components and a diverse range of materials. Their distinctions, however, guide their application suitability.

This discourse delves into the rudiments of CNC turning and CNC milling, their utilities, and their primary variances.

CNC Milling – A Closer Look What’s CNC Milling About? Through bespoke, predominantly digital design aids, CNC milling deploys an array of spinning cutters to carve material off a piece. What emerges is a tailored component, steered by a G-code CNC schema, replicable for uniform product batches.

The Scope of CNC Milling in Production: CNC milling caters to both mammoth and modest production scales. From robust industrial arenas to nimble workshops or even sophisticated labs, milling is versatile. While they cater to a plethora of materials, certain mills have specific areas of expertise, such as metal versus wood applications.

Uniqueness of CNC Milling: Primarily, milling apparatus anchors the material on a platform. The machine’s layout might allow this platform to traverse along the X, Y, or Z trajectories, with the material itself being static. The milling tools, usually aligned horizontally or vertically, revolve to carve out the material.

Such machines can perforate the material or retrace their paths over it, simulating a grinding mechanism.

CNC Turning – A Deeper Dive What Exactly is CNC Turning? Turning is articulated by clasping material bars in a mechanism, spinning them, and introducing a cutter to shape it. CNC turning integrates digital command sequences for this shaping process.

Modern Manufacturing & CNC Turning: CNC turning stands out when crafting irregular or cylindrical components. It’s also adept at operations that maintain the original structure – like boring or threading. It’s a method behind crafting components ranging from substantial rods to specific screws.

Distinct Features of CNC Turning: In essence, turning apparatus, like a CNC lathe, spin the component whilst the cutter remains stationary. This dynamic renders possibilities that would be challenging for conventional milling machines. The tools are distinctly mounted, providing stability due to the rotation between the principal and secondary ends. Such stability allows for diverse cutting techniques and finishes.

Although turning centers can accommodate active cutters, these are more typically seen on milling machines.

Contrasting CNC Milling and CNC Turning: CNC milling employs revolving cutters and linear movement to carve the material’s face. In contrast, CNC turning offers precision in carving holes and configurations with exact dimensions.

Turning, in layman terms, mirrors traditional lathe operations but spins the main unit instead. The machinery’s movement is pivotal, typically powered by a motor, allowing full-circle operation without interruptions.

Both methodologies are governed by CNC commands, defining every move in the production sequence, ensuring precision. This precision and automation imply minimal manual intervention, reserving human input for oversight and loading tasks.

Choosing Between CNC Milling and Turning: When sculpting a piece, CNC milling shines for tasks like surface alterations and designs demanding symmetry or angles. Depending on the orientation of the cutting tool, mills can be horizontal or vertical, each with distinct attributes. A sturdy vertical mill can tackle diverse tasks with finesse. In contrast, horizontal mills, or the robust vertical variants, are tailored for extensive production cycles, evident in almost every contemporary production house.

CNC turning, conversely, is the go-to for prototype designs or lesser volume outputs. It thrives when dealing with irregular or cylindrical designs and can scale up for bulk production of specific items, like fasteners.

In essence, while both machines are the linchpins of CNC production, they differ in their core operation. Turning machines spin the component, whereas milling devices rotate around the cutting instrument. Mastery over either, or both, enables machinists to deliver components with unparalleled precision.

CNC equipment is a cornerstone in numerous production and manufacturing workflows. These devices have the prowess to undertake intricate operations with unparalleled precision, rendering them indispensable to many sectors. Yet, as with any technological apparatus, CNC devices necessitate periodic upkeep to guarantee optimal performance. This article sheds light on the significance of consistent maintenance of CNC equipment and its implications for the machine’s durability and productivity.

Consistent upkeep of CNC equipment mitigates the risks of expensive malfunctions and operational halts. Through timely maintenance, potential glitches can be pinpointed and rectified before escalating into substantial challenges. In the bigger picture, proactive measures tend to be more economical than reactive solutions, as the latter might involve costly repairs or replacements. Moreover, such timely care can prolong your CNC equipment’s lifespan, maximizing the value derived from your capital expenditure.

The fidelity and precision of your equipment can also be enhanced with periodic maintenance. As devices function over time, certain components might deteriorate or accumulate dirt, compromising their efficiency. By ensuring machines are consistently in prime condition, the quality and precision of the outputs can be fortified. This precision is paramount for sectors demanding stringent specifications, like aviation or biomedicine.

Another salient advantage of maintenance is bolstering the safety of CNC equipment. Aging equipment can manifest signs of wear and tear, escalating the probability of mishaps and related hazards. A steadfast maintenance routine safeguards against these risks, ensuring machines remain safe for use. Furthermore, adhering to routine checks can ascertain compliance with safety norms, safeguarding you from potential legal repercussions.

Elevating the productivity of your CNC equipment is yet another benefit of maintenance. Ensuring that devices are always in top-notch condition can amplify output rates and diminish operational interruptions. It’s also worth noting that maintenance can bolster the machine’s energy efficiency, translating to more sustainable operations and slashed energy expenses.

It’s pivotal, when embarking on CNC equipment maintenance, to abide by the stipulations set by the machine’s manufacturer. This ensures the machine receives the right care, using apt components and methods. Furthermore, meticulous record-keeping of all maintenance activities can serve as a valuable reference to monitor equipment health and preempt significant issues.

To wrap up, the consistent upkeep of CNC equipment is cardinal to ensure the machine’s operational longevity and peak performance. By championing maintenance, businesses can avert expensive halts, elevate output precision, ensure operational safety, and enhance machine efficiency. Adhering to the manufacturer’s advice and meticulous record-keeping further refines the process. Embracing these strategies ensures CNC equipment continues to offer substantial value for its cost.

Pioneering the future of industrial technology, Mitsubishi Electric is once again making headlines with its latest advancements in the automation domain. The company recently showcased an array of innovative robots and controllers, further solidifying its esteemed position in this industry.

Mitsubishi Electric, known by its stock symbol MIELY, has unveiled an array of new automation technologies. Among these, the spotlight is on a state-of-the-art bin-picking robot, which offers distinctive features, as well as a servo amplifier aimed at amplifying safety measures and consolidating safety inputs from various points.

Next-Gen 3D Bin-Picking Solution Scheduled for a grand reveal at the PACK Expo in Las Vegas this September 2023, the new 3D bin-picking robot from Mitsubishi Electric promises to be a game-changer. This advanced robot boasts the ability to cohesively work alongside two of its counterparts in confined spaces, effectively dodging collisions and charting movement strategies. This accomplishment is the synergy of Mitsubishi Electric’s robotic precision, Realtime Robotics’ groundbreaking collision evasion software, and SICK’s superior machine vision technology.

This robotic trio will showcase their capabilities in a setup that uses machine vision to identify key components, interactivity between the robots, and then processes this information for intricate picking and packaging tasks.

The idea is simple: if a single robot can optimize speed and efficiency, three can multiply those results. But this is only feasible when they operate seamlessly without any hiccups or collisions during their designated tasks.

Introducing MELSERVO J5 Servo Amplifiers At its core, the MELSERVO J5 is built to unify several safety instruments. This includes emergency buttons, light barriers, sensor beams, production line emergency cords, and more. Their primary function is to halt systems in potential danger scenarios. Leveraging the FailSafe over EtherCAT (FSoE) protocol, these amplifiers consolidate devices, relaying alerts about hazardous situations, and manage servo motors to guarantee a secure state. The standout feature of FSoE is its ability to transmit vital safety information alongside routine data signals, prioritizing the safety data and ensuring duplication as required. The unique aspect is the distinct transmission of data through the same medium, guaranteeing swift and dependable reactions.

For those unfamiliar with servo amplifiers, their function might be a tad deceptive. These devices are designed to quickly dissipate energy from moving components, thus halting various machines. For instance, think of a conveyor system transporting minerals from deep underground to an elevator. Should a miner accidentally land on this conveyor, they could engage one of the emergency cords. This would then trigger a system where all the motion energy – from the belt, the individual, and the minerals – is rapidly transformed into heat, halting everything. The essence of servo “amplifiers” is to utilize the minor control input and an additional power source to achieve this rapid halt.

Mitsubishi’s Leap Forward in Automation Always at the forefront of automation gear, these latest offerings by Mitsubishi Electric further emphasize their commitment to technological evolution. The new 3D robot is set to revolutionize operations by making picking and packaging more streamlined and secure. In parallel, the MELSEVO J5 offers industries a rapid solution for integrating foolproof safety mechanisms, ensuring consistent reliability in automated environments.

In hands-on production, it’s noticeable that identical compact CNC machinery, when operated by varying personnel over similar durations, results in significantly different output efficiencies. The performance potential of many CNC lathes isn’t entirely harnessed. To maximize the machine’s production capability, it’s essential to account for all factors impacting the machine’s efficiency.

To bolster the productivity of CNC lathes, it’s crucial to deeply examine the components being processed by the lathe, gaining clarity on specifications like material, design intricacies, tolerance criteria, surface finish expectations, and any requisite heat treatments. Armed with this understanding, one can then select an optimal milling methodology and a streamlined processing path.

A single component can be manufactured following several distinct processes. Different methods can lead to varied efficiencies, costs, and precision levels. Hence, while guaranteeing component quality, efforts should be made to elevate production efficiency, curtail costs, and establish a logical machining method.

When machining a part using a bespoke CNC lathe, the positioning and setting of the component should aim to harmonize design specifics, procedural data, and computational programming metrics. This synchronization ensures that the machinery’s processing efficacy is fully exploited. It’s advisable to reduce clamping repetitions and, post a singular position and clamping action, process all intended surfaces. This minimizes the need for manual tweaks in the processing sequence due to placeholder adjustments.

Cutting parameters encompass spindle rotation speed, cutting depth, and feed velocity. When deciding on cutting amounts, for preliminary roughing operations, the focus should be on enhancing output. Here, choosing a more significant cutting depth and faster feed might be beneficial. However, for semi-finished and final processes, ensuring machining quality should be paramount while also factoring in efficiency and cost. During non-material cutting phases, the tool’s feed rate should be increased. Precise values can be derived from the machine’s user guide, cutting volume references, and hands-on experience.

While using a cordless drill may suffice for small DIY projects, there will come a time when you need the precision and accuracy of a drill press for tasks that require specific hole depths and distances. To ensure excellent results in your next project, it’s essential to select the right drill press with the necessary features. This buyer’s guide aims to assist you in finding the ideal drill press for your needs, whether you’re working with metal or wood.

Understanding Drill Presses: A drill press is similar to a handheld drill, featuring a drill chuck to hold various drill bits. However, the similarities end there, as drill presses are not operated by hand. Instead, the drill press consists of a motor, chuck assembly, speed control handle, and feed handle mounted on a sturdy support column and base. An adjustable worktable, often accompanied by a vise, moves along the column.

Types of Drill Presses: There are two main types of drill presses: benchtop and floor models.

Benchtop Drill Press: As the name implies, the benchtop drill press is designed to fit conveniently on a workbench, making it suitable for smaller projects and compact workshops. These drill presses typically have an 8- to 12-inch swing, which is the distance from the center of the drill chuck to the edge of the support column, multiplied by two. They can drill holes up to 2 to 3-3/8 inches deep, making them ideal for garage setups.

Floor Drill Press: Floor drill presses, on the other hand, are standalone machines that are securely fastened to the shop floor. They offer more power for heavy-duty tasks and larger workpieces, usually featuring a 13- to 20-inch swing and the ability to drill holes 3 to 6 inches deep.

Common Uses for a Drill Press: While drilling holes is the primary function of a drill press, there are several other applications where it excels:

1. Drilling holes to a specific depth using a depth stop.
2. Drilling angled holes by tilting the head or table if the drill press has those features.
3. Reaming precise-diameter holes.
4. Creating threaded holes with a tap.
5. Countersinking holes for flat-headed screws or deburring hole edges.
6. Counterboring to accommodate socket head cap screws.
7. Cutting square or rectangular holes in wood using a mortising bit.
8. Sanding materials using a sanding drum that fits into the drill chuck.

Important Features to Consider: When choosing a drill press, there are several key features to look for:

1. Sufficient Horsepower: Aim for a drill press with at least 1/2 horsepower unless you regularly drill large holes in tough metals. More power may be necessary for heavy-duty applications.
2. Swing Size: Determine the swing size you require based on the distance from the center of the chuck to the column. Consider larger swings if you’ll be drilling holes more than six inches from the edge of your workpieces.
3. Depth Stop: A depth stop is crucial for consistent drilling when multiple holes need to be drilled to the same depth.
4. Stroke Distance: More stroke distance allows for working with longer drill bits and thicker materials, enhancing the versatility of the drill press.
5. Digital Readout: A drill press with a digital readout displays the running speed and can provide precise depth measurements.
6. Chuck Capacity: Ensure the drill chuck has a large enough capacity to accommodate the size of drill bits you intend to use.
7. Adjustable Worktable: Look for a high-quality worktable that can be adjusted vertically and sometimes swiveled to accommodate various workpiece sizes and hole depths.
8. Warranty: Check for a solid warranty to ensure the longevity of your drill press. Some manufacturers offer warranties that include additional features like laser guide alignment systems.

Common Drill Press Accessories: To enhance your drill press capabilities, consider these common accessories:

1. Heavy-Duty Worktable: Especially useful for benchtop drill presses, a sturdy worktable provides a reliable surface for attaching your drill press.
2. Drill Press Vise: A vise is essential for securely holding smaller parts during drilling.
3. Mortising Chisels: These chisels are used for cutting square and other-shaped holes.
4. LED Work Light: Built-in lights improve visibility and reduce shadows during drilling.
5. Sanding Drums: Attachable sanding drums expand the drill press’s functionality to include sanding tasks.
6. Laser Guide: A laser guide with crosshair lines on the workpiece helps achieve precise drilling accuracy.

Cost of Drill Presses: Drill press prices vary based on features and accessories. Smaller benchtop models can start as low as $40 to $50, while larger drill presses with advanced features can reach prices of $10,000 or more. Generally, the price reflects the quality and capabilities of the drill press.

Benefits of Owning a Drill Press: Investing in a drill press provides several advantages:

1. Increased Control and Power: Drill presses offer greater control and power compared to handheld drills, resulting in faster and more accurate drilling.
2. Versatility: With the ability to handle larger drill bits and work with harder materials, drill presses are more versatile for various applications.
3. Durability: A quality drill press will outlast a handheld drill while consistently delivering high performance.

Conclusion: A drill press is a valuable tool that offers precise drilling and increased efficiency. It is an essential addition to any machine shop or workshop, whether you’re a professional or a hobbyist. By considering the necessary features and accessories, you can select the perfect drill press for your needs and ensure successful project outcomes.

Metal additive manufacturing (AM) has brought about a revolutionary change in the manufacturing industry by enabling the production of intricate and complex parts in a faster and more cost-effective manner. However, post-processing these parts is crucial but can introduce time and financial constraints that offset the benefits of AM. One of the critical steps in post-processing metal AM parts is support removal, which poses a significant challenge. While supports are necessary for maintaining part fidelity during the manufacturing process, they must be removed to achieve the desired final product with the intended shape, features, and tolerances.

Although manual support removal is still prevalent in many metal AM applications, this article explores the transition to automated support removal (and finishing) solutions and examines the advantages and disadvantages of using Computer Numerical Control (CNC) systems compared to the versatility and reliability of robots.

TO SUPPORT OR NOT TO SUPPORT? THAT IS THE QUESTION

There is an ongoing debate that the support removal challenge in AM will eventually be resolved through support-free printing. This ultimate goal would allow for complete design freedom and optimized resource efficiency, where raw materials and energy are solely utilized for the final part rather than supports.

Unfortunately, the AM industry has not reached that point yet. While designs are being optimized to minimize the need for supports, they remain a necessity for the foreseeable future. Reducing the material and energy used for supports is generally beneficial, but it can also compromise design freedom and impact the functionality of the end-use part. For instance, parts requiring filled cavities or overhangs may face challenges in achieving lightweight designs. Generative designs may also face unnecessary constraints to accommodate reduced supports.

Moreover, a focus on support reduction can affect process efficiency. For example, building long parts may require specific orientations, occupying more space on the build plate. Stacked builds may become impractical due to interconnected support structures.

In summary, while efforts should always be made to minimize supports, they currently remain essential for most complex AM applications.

MANUAL POST-PROCESSING

Surprisingly, manual support removal remains the preferred method for the majority of AM users today. Skilled technicians employ various traditional hand tools, including Dremels, to remove supports. This method has been tried and tested, requiring problem-solving skills and creativity. It is well-suited for high-mix, low-volume production environments.

However, manual support removal is time-consuming, labor-intensive, and messy, often involving toxic dust that necessitates personal protective equipment (PPE) or shielded environments. There are common issues such as the risk of powder ignition and explosion, as well as repetitive strain injuries. Additionally, manual removal lacks accuracy and repeatability, as quality control problems arise due to variations between individuals and shifts. Furthermore, scaling up manual support removal becomes challenging when the demand for AM parts significantly increases.

AUTOMATION, AUTOMATION, AUTOMATION

Some progress has been made in automating the post-processing of metal AM parts. One common approach involves the use of CNC milling machines, a proven technology widely used in various manufacturing applications, including hybrid AM. CNC machines offer undeniable accuracy and repeatability. However, just because a solution is common and successful in certain areas does not always make it the best choice.

CNC can be effective when dealing with parts that require tight tolerances and when flatness, circularity, concentricity, or dimensions need to be within a few microns. It is also suitable for support removal in large batch builds with simple geometries that can be easily fixtured in a few orientations. Furthermore, CNC can be a good fit for prints where a CNC EDM (Electrical Discharge Machining) takes care of most supports during platform removal.

However, CNC machines are not well-suited for thin-walled components, space-saving stacked builds, lattice structures, or breakaway supports. CNC programmers also struggle with generatively-designed organic shapes with compound curves.

This highlights the argument against using CNC for support removal in the AM ecosystem.

One of the key advantages of AM is the design flexibility that enables users to iterate, customize, and upgrade components from one batch to the next. Companies utilizing AM for production purposes rarely invest in rigid industrial automation as any design iteration would require new CNC trajectories and come at a high cost. The design flexibility of AM should extend throughout the entire manufacturing process chain.

This issue is similarly encountered in tooling and fixturing. High-precision fixtures suitable for rigid industrial automation do not make sense unless committing to a long-term design.

Additionally, batch-to-batch variability poses a challenge. Even with perfect fixtures and tool paths, relying solely on a perfectly predictable support surface directly from the printer may not be ideal. AM supports are designed to deflect, ensuring that AM parts remain stable. The thin connections between supports and components minimize surface witnesses and facilitate the easy removal of scaffolding. Material composition may even vary between batches, resulting in different behaviors and appearances of supports.

ROBOTS TO THE RESCUE

Automation in AM requires adaptability, especially for support and witness removal. This challenge has been addressed through sophisticated software and artificial intelligence systems that generate tool paths and robot motions without the need for an entire systems-engineering team. This allows for quick iteration and automation of small batches.

Instead of high-precision fixtures, 3D scanning can be utilized to locate parts. This means that plastic fixtures can be quickly produced using desktop FDM printers without concerns about accuracy or design changes. Force sensors can be employed to sense the surface and adjust the machining process accordingly, spending more time on high spots until the final shape is achieved or achieving a consistent finish through polishing.

One significant advantage is that robots can employ various tools for support removal and finishing. If the suitable tools for the materials or types of supports used are already known, these exact tools can be attached to a robot, providing greater confidence in the automation process. Adding a new custom tool to a robot is similar to adding a new type of endmill to a CNC machine and does not require costly involvement from a system integrator.

Rivelin Robotics, a specialist in metal AM post-processing, already offers products that demonstrate these capabilities. The company specializes in developing and installing robots designed specifically for a wide range of AM post-processing applications. Rivelin Robotics’ advanced robotic solutions excel in reliable and accurate support removal.

Compared to traditional CNC machines, Rivelin Robotics’ robots offer several advantages such as improved speed, accuracy, and repeatability for support removal and finishing processes. They are highly flexible and can be easily adapted to different applications and processes.

Safety is a significant focus in the design of Rivelin Robotics’ robots, featuring protective casings and safety features that reduce the risk of accidents and injuries. Moreover, their power and coolant requirements are significantly lower than those of CNC machines, leading to increased resource efficiency, energy efficiency, and waste reduction.

In summary, robots are emerging as a superior solution compared to CNC machines for automating support removal from metal AM parts due to their speed, efficiency, flexibility, accuracy, repeatability, safety, cost-effectiveness, and sustainability. Integrating robots into the process not only improves the quality of the finished product but also ensures a safer, more sustainable, and cost-effective end-to-end manufacturing process.

Rotzinger, a leading provider of automated cosmetic and packaging equipment, has successfully integrated CoreTigo’s state-of-the-art wireless IO-Link technology into their packaging machines. This innovative solution enables dynamic changeovers, minimizes cable infrastructure, and significantly reduces downtime.

Driven by a customer request for a food packaging machine that could handle high throughput and accommodate various products, Rotzinger recognized the need for advanced technology. They turned to CoreTigo, a renowned supplier of industrial communications, to explore their wireless IO-Link technology, which promised to deliver the required I/O capabilities without the hassle of bulky cables and enable rapid tooling changeovers.

IO-Link Technology Unleashed IO-Link represents a cutting-edge industrial protocol that leverages Ethernet/IP or ProfiNet to transmit status or control information from discrete inputs, discrete outputs, or IO-Link devices. A key advantage of IO-Link is its ability to enable devices to transmit diagnostic data and accept configurations via industrial protocols.

The Power of IO-Link Wireless CoreTigo’s impressive portfolio includes a range of wireless IO-Link devices meticulously designed for industrial applications. These wireless products encompass control and monitoring systems, as well as sensors and actuators. Among their offerings, the TigoMaster product line stands out by providing wireless IO-Link master functionality, which can be seamlessly integrated into virtually any industrial device. Additionally, the TigoHub i4, a multiport I/O hub, wirelessly connects to IO-Link masters and supports up to four IO-Link devices.

Moreover, CoreTigo offers IO-Link bridges, clever devices that can transform traditional wired IO-Link devices into wireless counterparts. Equipped with an internal antenna and two M12 connectors, these bridges enable wireless IO-Link technology to connect wirelessly with the device.

Like conventional IO-Link masters and hubs, the Tigo product line offers great flexibility as it can be combined and configured in various ways to enhance overall I/O capability.

Flexible Packaging Equipment Revolutionized Flexibility is a crucial aspect of automated equipment, as manufacturers constantly strive to make their machines as adaptable as possible. Interchangeable tooling is one method employed to increase flexibility, but the time required for equipment changeovers often results in lost production time.

To tackle this challenge, Rotzinger has successfully implemented wireless IO-Link technology in their packaging machines. By utilizing grippers mounted on a servo-driven conveyor, the need for cables is eliminated. CoreTigo’s TigoBridge actuators enable wireless control, allowing the machine to package single or double product packages without any equipment downtime. The shuttles can be easily batched into their respective configurations, ensuring seamless production.

Retrofitting Equipment for Enhanced Performance As an alternative to purchasing new equipment, retrofitting existing machinery is gaining popularity, particularly when integrating data collection into established production lines. However, older equipment often lacks the necessary signals or sensors to gather machine efficiency data effectively. By leveraging wireless IO-Link technology, the impact on existing equipment is reduced, eliminating the need for signal cables or complex interfacing with the existing PLC.

Enter the TigoGateway, an IO-Link master capable of utilizing popular IIoT protocols for edge computing applications. Employing wireless IO-Link technology empowers machine builders to expand and upgrade existing equipment or facilitate the integration of flexible machinery with reduced changeover requirements.

The landscape of manufacturing has evolved significantly from the days of basic cutting tools. Nowadays, customers expect top-notch tools made from high-quality materials, with minimal margin for error. The focus has shifted towards achieving an end-to-end process that encompasses everything from sourcing the best materials to delivering an exceptional customer experience. This transformation heavily relies on interconnected machines and devices. As the expectations for cutting tools continue to evolve, the types of CNC machines employed can make or break a company’s position in the competitive toolmaking industry.

In the future, smart factories will require both software and hardware solutions. You might have come across everyday objects like toasters that can detect when we’re running out of bread or devices that anticipate our need for servicing before we even realize it. These are the exciting applications of the Internet of Things (IoT). However, the advantages of IoT are not limited to these consumer-oriented examples; they can significantly benefit manufacturing facilities as well. IoT enables factories to predict when a machine requires servicing, monitor its performance, and detect low stock levels. In fact, factories can even integrate IoT-connected devices like a USB-connected sandwich press in the lunchroom, bringing convenience to the workplace.

This is where software plays a crucial role. Smart factories seeking the benefits of IoT must prioritize connectivity. Machines must have access to software that connects them to an internal network, enabling seamless interaction across the entire system. In some cases, it may even be beneficial to connect these machines to larger networks that leverage customer and supplier information, resulting in streamlined processes.

Software also brings other impactful benefits. For instance, our latest product introduced advanced features to cutting tools, allowing for more intricate cutting tool geometries. Different industries have varying requirements; for example, aerospace and power generation utilize both hard and soft materials, necessitating different cutter geometries for machining. Through software, we have incorporated new geometries to manufacture specialized cutters tailored to these specific processes.

Moreover, having the right software is crucial for enabling different types of CNC machines to communicate with one another. In the past, machines utilizing different protocols or from different manufacturers often struggled to interact with internal systems within the factory. By implementing software on these machines, they can transmit data to a central location, where it can be distributed in a format understandable by every machine and person involved.

Interestingly, a significant portion of the machines currently in use (approximately 95%) are ten years old or less. This presents an advantage to your factory as these machines can often be upgraded with the latest software and compatible accessories for automation. Retrofits offer an opportunity to avoid wholesale machine replacements. Instead, updating machines one by one allows for uninterrupted factory operations with minimal downtime and cost, ensuring a seamless customer engagement experience.

Functionality in CNC machines is constantly improving and expanding. While CNC machines are not akin to phones that can fit in your pocket or fold up, they continue to evolve. Machines of the same size as those installed fifteen years ago now offer enhanced capabilities. For instance, CNC milling machines have progressed from four-axis to six-axis and have incorporated spiralling into their repertoire. As machines improve, so do their cutting processes and productivity, delivering faster, more precise, and easier-to-monitor operations.

It’s important to approach the transition one step at a time. Upgrade or replace machines strategically to achieve quick wins and swiftly enhance your factory’s capabilities in a cost-effective manner.

Closed-loop manufacturing is on the horizon, whether you embrace it or not. When upgrading or replacing your CNC machines, it’s essential to consider the business advantages you aim to achieve. In the realm of smart factories, competition revolves not only around range and precision but also specialization, customer experience, and time to market. CNC machines that facilitate build-to-order processes enable reduced