Direct digital manufacturing is making fast strides for low-volume applications requiring complex detail, but some significant issues remain. Design engineers require process verification, particularly for high-end parts. For example, the widespread adaption of closed-loop process controls about a dozen years ago provided verification that required process parameters in the injection molding process were being maintained. Direct digital manufacturing systems were originally developed by companies in the rapid prototyping business, where such requirements were not necessary. Parts were simply required for form and fit, and not so much for functional testing. There is often considerable process variation in the new additive fabrication systems being developed for manufacturing directly from digital files. Improvements will come, however, and the new systems are certainly worth a look in several situations, particularly those where there are constant design change orders.
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.