Tooling costs to make plastic bumpers and fascia can be reduced by a factor of five using a thermoformable sheet, which for the first time can now be laser welded. Fittings can be welded that allow attachment to cars. “In the past, it was impossible to fasten components to the thermoformed sheet in a cost-effective way,” comments Thilo Stier, innovation manager for A. Schulman, a plastic compounder based in Akron, OH. The main reason is that the visible surface of the sheet would show sink marks on the cosmetic surface.The solution is use of a black laser-absorbing layer to concentrate the heat zone on the area that is being welded. A fitting can be welded in two to three seconds, Stier says.
The new technology could put Invasion five-layer extruded thermoformable sheet on a fast track. Schulman introduced its Invision sheet product in 2006 and formed A. Schulman Invision, Inc., a wholly owned subsidiary. Schulman is building a new Invision plant in Findlay, OH. Sheet can be extruded in thicknesses ranging from 0.4 mm to 12 mm. Properties include good impact strength, UV stability and Class A surface, according to Stier.
A new service lets engineers and orthopedic surgeons design and 3D print highly accurate, patient-specific, orthopedic medical implants made of metal -- without owning a 3D printer. Using free, downloadable software, users can import ASCII and binary .STL files, design the implant, and send an encrypted design file to a third-party manufacturer.
A recent report sponsored by the American Chemistry Council (ACC) focuses on emerging gasification technologies for converting waste into energy and fuel on a large scale and saving it from the landfill. Some of that waste includes non-recycled plastic.
Capping a 30-year quest, GE Aviation has broken ground on the first high-volume factory for producing commercial jet engine components from ceramic matrix composites. The plant will produce high-pressure turbine shrouds for the LEAP Turbofan engine.
Seismic shifts in 3D printing materials include an optimization method that reduces the material needed to print an object by 85 percent, research designed to create new, stronger materials, and a new ASTM standard for their mechanical properties.
A recent study finds that 3D printing is both cheaper and greener than traditional factory-based mass manufacturing and distribution. At least, it's true for making consumer plastic products on open-source, low-cost RepRap printers.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This discussion will examine what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.