Everywhere I explored at Rapid 2009, it was apparent there is a battle under way in materials technology in the fast-emerging rapid manufacturing industry. Some suppliers have “real” materials. Others are stiff and tough. Some are clear. Design engineers can be excused if they can’t keep it straight. You virtually need to keep a daily scorecard. And no matter what you pick, you are probably making some type of tradeoff. There may be some sacrifice in surface finish or accuracy in a laser sintering process. But you get real world metals and plastics that are actually used in functional applications. The range of materials’ qualities you can get with stereolithography systems is impressive. They are increasingly stiff and tough, and will be getting better in terms of thermal properties. Both systems offer the opportunity to create intricate internal shapes, though. And that’s something that’s expensive and difficult to achieve in the injection molding process.
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.