A publication of REVIEW/OUTLOOK

AdvancedManufacturing.org | December 2018

MANUFACTURING IN

2050
Solid U.S. Economic
Momentum Poised
to Cool in 2019
Cyber Secure
Manufacturing is
Smart Manufacturing
Testing the Metal:
New Ways to Check
Work Materials
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CONTENTS
DECEMBER 2018 VOL. 161, NO. 7
SHOP SOLUTIONS
22     will be empowered to rapidly innovate like never before.
Robotic Welding Speeds Up
Manufacturing of Mobile
Road Safety Devices
Founded to improve safety
for road workers and travelers
alike, Safety Technologies Inc.
developed automated fagger
assistance signs—welded
fabrications with their own
self-contained power and
solar power units. As a small
business, robotic welding
technologies helped the
company improve productivity,
boost quality and increase
production of the signs and
the substructures of the trailer
decks that support them.
26     As metals and other materials get more complex, knowing what
CNC Turns ‘Feel’ Into High-
Precision Carbide Grinding
Glenn Bridgman, president of
Bridge Tool & Die, describes
the difference between his
shop’s manual grinders and
its newest state-of-the-art
CNC ID/OD grinder as “feel vs.
facts.” Bridgman believes that
manual grinding is a personal
operation, yet he sees today’s
advanced CNC grinding
technology as a way to turn
that expert feel into cold hard
facts and numbers.
Join SME
sme.org/join
UTLOOK
A publication of
REVIEW/O
Cover: Manufacturing is becoming
smarter and more digitally connected.
AdvancedManufacturin
g.org | December
2018
As we look to what 2019 and beyond
will hold for the industry, automation,
the Industrial Internet of Things and
digital visualization are poised to
boost productivity, improve quality
and empower a new generation of
manufacturers. The future is bright for
manufacturing and this issue provides
a snapshot of what is to come.
FEATURES
30  Outlook: Solid U.S. Economic
Momentum Poised to Cool in 2019
OXFORD ECONOMICS
U.S. economic growth is expected to continue in 2019, while
outlooks for the aerospace and defense, automotive, energy
and medical industries vary.
37  Manufacturing in 2050:
The World Turned Upside Down?
ED SINKORA, CONTRIBUTING EDITOR
Powerful trends will push manufacturing close to complete
automation by 2050, while the people still working in the industry
44  Cyber Secure Manufacturing
Is Smart Manufacturing
JIM LORINCZ, CONTRIBUTING EDITOR
Large corporations have IT departments with considerable
resources. SMMs need all the help they can get to guard
against and ward off cyber-attacks.
50  Testing the Metal
BRUCE MOREY, CONTRIBUTING EDITOR
you are getting from your supplier, or what you have in stock,
is more important than ever.
CONTENTS CONNECT &
ADENGAGE
INDEX
PLAN–DO–NETWORK–LEARN
DEPARTMENTS
JANUARY
4  Up Front
ALAN ROOKS, EDITOR IN CHIEF MD&M Expo West Feature Articles in this issue:
Celebrating the People of Manufacturing Anaheim, CA, Feb. 5-7 • Five-Axis Machine Tools

6  Advanced Manufacturing Now

mdmwest.mddionline.com • Aluminum Machining
• Custom Cutting Tools
ILENE WOLFF, CONTRIBUTING EDITOR
• Workholding
ISS Takes Manufacturing to New Heights

8  Advanced Manufacturing Now

RAMONA SCHINDLER, BUSINESS DEVELOPMENT MANAGER, FEBRUARY
SIEMENS INDUSTRY INC.

Digitalization At Every Step For Machine Tool Builders HOUSTEX Feature Articles in this issue:
Houston, Texas, Feb. 26-28 • Energy Parts Manufacturing
10  Advanced Manufacturing Now houstexonline.com • Horizontal Machining Centers
TIM AYDT, INDEXABLE MILLING PRODUCT MANAGER, SECO TOOLS LLC • Swiss-Style Machine Tools
Helical Cutters Go Deep and Long in Tough Materials • Walk-Up Metrology

12  SME Speaks

HITOMI YAMAGUCHI GREENSLET, DR. ENG., MARCH
FSME, 2018-19 PRESIDENT, NORTH AMERICAN
MANUFACTURING RESEARCH INSTITUTION OF SME Industrial Supply Association Feature Articles in this issue:
How One Research Conference Still Inspires Me Houston, April 6-9 • Manufacturing Automation
and Robotics
16  News Desk www.isapartners.org
• Job Shop Automation
COMPILED BY THE SME EDITORIAL STAFF Automate Show
• CNC Machine Controls
GE, Once Manufacturing’s Bright Light, Dims Chicago, April 8-11
• Indexable Tooling

57  Product Previews

www.automateshow.com

APRIL
61  Classifieds
61  Ad Index
AeroDef Manufacturing Feature Articles in this issue:
Long Beach, CA, April 29-May 2 • Machining Aerospace Parts

62  Workforce Pipeline www.aerodefevent.com • Alternative Manufacturing

of Aerospace Parts
TIMOTHY J. BLONSKY,
ADVANCED MANUFACTURING COORDINATOR, • Vision Systems
CAPITAL WORKFORCE PARTNERS • PLM Software
CWP Targets Training, Development and • Laser Special Section
Marketing to Help Build Connecticut’s
Manufacturing Workforce

64  Viewpoints Although reasonable efforts are taken to ensure the accuracy of its published material, SME is
not responsible for statements published in this magazine. Readers are advised that SME shall
not be liable to any person or company for losses or damages incurred as a result of accepting
JASON ANDERSEN, VICE PRESIDENT, any invitation or offer contained in any advertisement published in Manufacturing Engineering®.
BUSINESS LINE MANAGEMENT, Copyright © 2018 by SME. Photocopy information: Users registered with the Copyright Clearance
Center, 21 Congress St., Salem, MA 01970, can purchase copies at $2.00 each referring to serial
STRATUS TECHNOLOGIES fee code 0361-0853/88/$2.00. All other photocopying without the permission of SME is prohibited.
Reprint information: For tearsheets, reprints, and bulk orders, write Cheryl Matulonis, cmatulonis@
Securing the Edge of the Network sme.org. Available on microfilm/microfiche from University Microfilms International, 300 N. Zeeb
Rd., Ann Arbor, MI 48106. Canada Post Publication Mail Sales Agreement No. 1436813

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December 2018 | AdvancedManufacturing.org 3

UP FRONT
A LETTER FROM THE EDITOR
1000 Town Center
Suite 1910
Southfield, MI 48075

Editorial Staff
Editor in Chief

Celebrating the People of Manufacturing Alan Rooks

847-239-0070
arooks@sme.org
Editor in Chief
Smart Manufacturing
WE TEND TO THINK OF the man- owner of four companies he started, Brett Brune
313-425-3253
ufacturing industry as an abstract including Burns Machinery Inc. bbrune@sme.org
concept, describing it in terms of (Minden, NV), a successful job shop. Senior Editor
trends, growth rates and output. Two Rather than retire from manufacturing, Bill Koenig
313-425-3058
of our features in this issue, including Burns has found himself working bkoenig@sme.org
the cover story, do exactly that. And with a community halfway around the Contributing Editors
that’s a good thing! But, at its core, world, in Kenya. After his family took in Geoff Giordano
geoffgio@verizon.net
manufacturing is a large collection a college exchange student from there,
James A. Lorincz
of people, all using the tools, ideas Burns and a group of people from his jameslorincz42@icloud.com
and other resources at their disposal church helped that student complete a Bruce Morey
to do their jobs each day. Of course, master’s program at Boston University. brucemorey.editor@gmail.com

this is not exactly news to anyone in Greg and his church group visited the Ilene Wolff
ilenewolff.sme@gmail.com
the industry, but many people make student’s village in Kenya, which led
Managing Editor
extraordinary contributions to manu- to the creation of Bridge Ministries, Candace Roulo
313-425-3033
facturing and those contributions can which helps fund the village schools croulo@sme.org
help to improve our society. and develop clean water supplies for Associate Editor
For example, Raye Montague, the village. Chris Mahar
313-425-3160
who passed away in October, made cmahar@sme.org
extraordinary achievements in Helping the Disabled Business Staff
engineering and manufacturing while Then there is Joseph Mollendorf, Vice President
SME Media
breaking through formidable barriers. a professor at the University at Dave O’Neil
ALAN ROOKS 313-425-3260
Editor in Chief
After facing racism and sexism in her Buffalo’s Department of Mechanical
doneil@sme.org
youth, and being denied entry to a and Aerospace Engineering who, in Audience Manager
college engineering program because 1990, was a part of a group awarded Mary Venianakis
905-755-0783
she was black, Montague became an a grant from the National Science mvenianakis@sme.org
engineer and the first female program Foundation to develop projects to help Digital Product Manager
manager of ships in the U.S. Navy, the disabled. Since then, he has been Tim Simpson
313-425-3040
according to an obituary in the New mentoring young people to create new tsimpson@sme.org
York Times. devices to assist the disabled; along Address Changes
Cheryl Matulonis
Her signal achievement was the way, his students have manufac- 313-425-3264
developing the first computer program tured nearly 600 devices to help people cmatulonis@sme.org

used to design ships, and then using
it to design a Navy ship in less than 19
hours (a process that previously took
a month). For this achievement, she
received the Navy’s Meritorious Civilian
Service Award in 1972, and the Navy
began using her system to design all of
its ships and submarines.
Also, consider the story of Greg
Burns, a mechanical engineer and
with disabilities live better lives. Creative Staff
Senior Graphic Designer
The last two stories come from Barry Sloan
an inspiring online series pub- 313-425-3195
bsloan@sme.org
lished by SME called “Humans of
Graphic Designer
Manufacturing.” I encourage you to Cheryl Addington
check out this series (sme.org/humans) 313-425-3348
cvoglesong@sme.org
and sign up for the newsletter that
delivers new stories to your inbox. It will
make you proud of the industry that is,
in many cases, your life’s work.

4 Manufacturing Engineering | December 2018

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ADVANCED MANUFACTURING NOW
INNOVATION IN MANUFACTURING PROCESSES
ISS Takes Manufacturing to New Heights
FOR A GLIMPSE OF advanced manufacturing
that’s out of this world, look 240 miles up in the
sky to the International Space Station (ISS).
Two entities are taking steps to form an
interstellar economy with the ISS as an orbiting
manufacturing hub—the Center for Advancement
of Science in Space in Melbourne,
FL, (managers of the ISS U.S.
National Laboratory) and Made In
Space, a Moffett Field, CA, firm.
“NASA and other government
agencies have done research for
decades showing that the micrograv-
ity of space can enhance different
products and, in some cases, enable
products to exist,” said Andrew
Rush, president and CEO of Made
Allevi’s bioprinter extruder
In Space. His company is involved
head, which is destined
with several projects on the ISS, for the International
Space Station.
including a 3D printer retrofitted
with the ZeroG, a bioprinter extruder head from
ILENE WOLFF
Contributing Editor
Allevi (Philadelphia), which makes bioprinters and
bio-inks. Its extruder head fits on the Advanced
Manufacturing Facility, a Made In Space 3D
printer installed on the ISS in 2016. The AMF was
designed for this type of collaboration.
“Allevi’s effort is a good example of leveraging
the upgradable and modular aspect of the AMF,”
said Rush. “We’re taking their technology and
adapting it for manufacturing in space.” He offered
an example of how microgravity can potentially aid
bioprinting: in normal gravity, 3D-printed vascular
tissue collapses in on itself before it has a chance
to cure. But in micro-gravity, the tissue has a
chance to cure without flattening.
Ricky Solorzano, CEO of Allevi, added that
vascularizing bioprinted tissue will require more
work. “From an engineering perspective and
a manufacturing perspective, we’re not that
sophisticated in being able to integrate blood
vessels into gels to make thick tissues.”
6 Manufacturing Engineering | December 2018
Another Made In Space project is a pilot factory
on the ISS with a mini-draw tower to spin ZBLAN
glass fiber for optical cable. Theoretically, ZBLAN
fiber is up to 100 times better than the silicon cable
that’s currently used. But when ZBLAN is manu-
factured on earth, it forms microcrystals that cause
signal attenuation over long dis-
tances. What’s encouraging to Made
In Space is that NASA did preliminary
research showing that manufac-
turing ZBLAN fiber in microgravity
suppresses the micro-crystallization,
greatly reducing the attenuation.
Finally, Made In Space’s Archinaut,
its earth-based manufacturing facility
that simulates the temperature swings
and pressure of low-earth orbit, is
in a two-year development program
with Northrop Grumman Corp. (Falls
Church, VA) and Oceaneering Space
Systems (Houston) to demonstrate the capability
for manufacturing and assembling large and
complex systems in a space-like environment. The
goal is to move the manufacturing and assembly
of these systems into space, so they don’t have
to endure the ferocious forces they would face, if
already built, during a rocket launch.
“We’re able to design and build our satellites
for the operational environment they’re used in
rather than simply to survive the delivery method
of the rocket,” said Rush, adding that a rocket’s
liftoff can subject it and its payload to 3-9 Gs as
well as extreme shock and vibration.
CASIS, tasked with promoting and brokering
research on the ISS, is, among other projects,
working with Delta Faucet (Indianapolis) to send
an experiment to the ISS to study how water
flows through an oscillating chip in a low-flow
shower head, according to published reports.
It may not be long before we see products with
a “Made in Space” label!
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ADVANCED MANUFACTURING NOW
INNOVATION IN MANUFACTURING PROCESSES
Digitalization At Every Step For Machine Tool Builders
TODAYÕS MACHINE TOOL BUILDER has read
many articles and papers about the emerging
concept of digitalization. Here are three ways
OEM engineering and management teams can
view this technology and its impact as it shapes
the production and sales process of the future:
1. Seeing digitalization as a viable means of build-
ing a more effective, reliable and predictable
machine from the outset of the design phase;
2. Realizing that digitalization adds definable value,
as it allows the machine tool builder better ways
to present value propositions to customers;
3. Utilizing digitalization, builders can fashion new
business models for the use of machine tools,
as digitalization demonstrates to customers
what they can do with the data. It also allows
the builder to better position the machine’s
value to customers to sell more services,
optimize machine uptime and track the perfor-
mance of equipment in the field, all of which
lead to improving the customer experience with
RAMONA
SCHINDLER
machine tools.
Business
Development
Manager, Siemens
Advantages During Design
Industry Inc. Having a visual model of a CNC machine for
ramona.schindler@
siemens.com
commissioning alone makes the investment in
digitalization worthwhile to builders. With the data
and design concept in hand, you can use digi-
talization tools, such as a mechatronics concept
designer, which brings the physics of the world
to your computer screen, so you can test the
PLC, test the NC, run the motion control or load
protocols (including full machine kinematics) and
conduct overall system component integration, all
prior to the first step of the build.
The available digitalization tools provide
accurate hardware in the loop emulation, transi-
tioning from CAD to CAM to mechatronic concept
designer, then finally to the virtual machine con-
troller. Since the model mirrors the real hardware
in operation under power, simulations of machine
8 Manufacturing Engineering | December 2018
motion and feedback are more precise than they
would be with a pure simulation.
Specific customer challenges can be
addressed at this stage and the results for the
machine tool builder are faster resolution of design
issues and less time to market with its machine.
Improved Customer Experience
The digital twin further integrates virtual and
actual machine commissioning and production
monitoring so the machine tool builder can
fashion new models, presenting their machines
with enhanced, augmented reality monitoring,
customizable apps for data prioritization and
particularly improved requirements and production
data evaluation scenarios. This data exchange
concept represents a richer value proposition for
the machine tool and creates a closer touchpoint
between builder and customer.
New business models are also created by the
machine tool builder’s ability to help its customers
utilize digitalization tools to improve their produc-
tion. The virtual twin, based upon the virtual NC
kernel (VNCK), allows various production, material
handling and full motion control scenarios to be
sampled in the design stage by the customer,
while virtual training for programmers, operators
and maintenance personnel is also possible.
As machine tool builders become more
capable of tracking the data on their CNC
machines in the field, a dual benefit results for the
end customer. Improvement in machine uptime is
made possible as the resolution of issues on the
machine becomes a more streamlined process,
plus current and rapidly emerging edge technol-
ogy can add more precise analysis of the machine
and the production process at the end customer.
Digital twins are emerging as viable tools in
the design and marketing of many CNC machine
tools today, a trend that will continue to grow in
the future.
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ADVANCED MANUFACTURING NOW
INNOVATION IN MANUFACTURING PROCESSES
Helical Cutters Go Deep and Long in Tough Materials
WHEN IT COMES TO ACHIEVING high materi-
al-removal rates in even the toughest materials,
it’s hard to beat helical cutters. With the correct
insert grades and cutting data, these cutters can
achieve far greater depths of cut than non-helical
milling tools without sacrificing reach or the ability
to hold tolerance. This means higher rates of
metal removal at speeds that reduce the time the
inserts spend in-cut, simultaneously minimizing
cycle times and maximizing tool life.
For demanding industries like automotive and
aerospace, custom helical cutters can transform
processes for even the most difficult applica-
tions. In materials ranging from heat-resistant
superalloys to aluminum, helical cutters can
easily outpace non-helical designs and custom
versions of the tools can be shaped to perfectly
fit the required application. However, demanding
industries often have equally demanding sched-
ules, and while custom tool manufacturers strive
to meet customers’ needs as quickly as possible,
TIM AYDT
Indexable Milling
the turnaround time for a custom product can be
Product Manager, prohibitive when there are parts to cut.
Seco Tools LLC
www.secotools.com
Despite that disadvantage, there are a myriad
of reasons to choose helical cutters. In one
example from the aerospace industry, a custom
helical cutter used for machining landing gear
torque links paid for itself within months. Made
from Ti5553, a heat-treated titanium alloy,
the part was previously
machined using a high-
feed milling strategy
that required 84 passes.
With a custom helical
solution, that number was
reduced to only four passes with
a 1.25" depth of cut.
Given the massive reduction in the
number of passes, one might expect a
slower process. However, the helical cutter
provided six times the tool life of the high-feed mill
10 Manufacturing Engineering | December 2018
and a 40% increase in metal removal rate. The
end result was a cycle time reduction of 60%,
which, over the course of a year of machining,
created more than $40,000 in savings.
Aerospace manufacturers have duplicated
these results across their industry. Another
manufacturer utilized custom helical tooling for
producing landing gear truck beams, the critical
component that links the axles and holds the
brake rods. When compared to the previous
solution the company used, the custom helical
solution provided 40% increases in speed and
metal removal rate. Furthermore, insert wear
was much more predictable thanks to process
improvements, extending tool life by three times
over the previous solution.
This increase in tool life also has significant
downstream effects. The time spent indexing
inserts or stopping machining for mid-process
tool changes obviously drops when tools last
longer. This frees a machine’s operator to work on
something more productive and reduces machine
downtime. Likewise, tooling manufacturers can
also offer replaceable end caps with custom
helical cutters, which make it simple to replace the
front rows of a cutter far more cost-effectively than
the alternative: buying a completely new cutter or
having the broken cutter repaired.
Seco’s semi-standard range of indexable
helical cutters all include replaceable
end caps for longer cutter life.
 These exceptional results are due in part to
insert grade selection—the correct grade
ensures the highest possible feed per tooth,
a major factor in metal removal rate. F40M,
a titanium aluminum nitride (TiAlN) coating,
is perfect for inserts cutting parts such as
torque links, while T350M, a titanium carbonitride
(TiCN) coating, is ideal for parts like the truck beams in
the last example.
Grades for Challenging Cuts
Recently, Seco has produced several grades designed
for the challenging cutting conditions created by titanium
and high-temperature alloys like Ti5553. One newer grade,
MS2050, features a niobium nitride (NbN) coating that
significantly increases lubricity. Meanwhile, the exceptionally
tough MS2500 can reach higher speeds than other grades
due to an aluminum oxide (Al2O3) top layer produced
via chemical vapor deposition (CVD), which makes for a
wear-resistant grade.
While insert selection plays a critical part in process
optimization, the custom helical cutters themselves played
a starring role in the examples from the aerospace industry.
Conversely, automotive manufacturers rarely need to reach
the tolerance levels required in aerospace. Instead, they
rely on the cutting geometries of helical mills to reduce
cycle times in high-volume applications. With long effective
cutting edges paired with aggressive insert geometries and
placement, these cutters can even outperform competitors
with helical interpolation, ramping and other advanced milling
techniques in addition to standard operations.
Semi-Standard Program
For many manufacturers, these advantages mean little
due to time considerations; regardless of industry, few
shops can afford the time their tooling suppliers need to
quote, design, produce and deliver a custom tool. Luckily,
Seco has a solution: a semi-standard helical cutter program
that streamlines the process by eliminating numerous
time-consuming steps. The result is an average reduction in
turnaround time of 50%, from over 60 days to as few as 30.
Seco’s helical cutters can achieve
high feed rates, large depths of
cut and aggressive metal removal,
according to the company.
The creation of a turnkey helical cutter solution revolves
around semi-standardization. Standard tooling, like any
line of standardized products, rarely works perfectly for
any given application, but experience has shown what
types of tools manufacturers use most often. An optimized
process naturally requires optimized tooling, and custom
products have traditionally been the only way to achieve
these benefits.
The semi-standard helical cutter program succeeds in
finding the happy medium between these types of tools.
Seco’s program draws on the company’s history of creating
custom products to identify a range of helical cutter solutions
that its customers most often request. Rather than quote
and design each product individually, the program allows
manufacturers to receive an instant price quote on well-un-
derstood designs, a major factor in reducing lead time.
By starting from a semi-standard design, the rest of
the process is much easier to optimize as well. Custom
products often require significant time spent on design and
subsequent approval, both of which can be accomplished
faster when the bulk of the design work has already been
completed. Likewise, semi-standard designs make it easier
to create optimal cutting programs, allowing for faster
production of helical cutters.
Naturally, a semi-standardized line of products cannot
serve as a substitute for a fully custom cutter. Your tooling
manufacturer should be able to meet these needs with
dedicated custom products and process optimization teams,
which are capable of engineering complete solutions for
complex applications. These services require more time, but
these teams can take a deep dive into a process and design
a tool around it. For the majority of metalcutting operations,
however, a semi-standard helical cutter will be all a shop
needs to positively impact its bottom line—all in less than half
the time it took before.
December 2018 | AdvancedManufacturing.org 11
 SME SPEAKS
GUEST EDITORIAL

How One Research Conference Still Inspires Me

MY FIRST PARTICIPATION in SME’s North American Twenty-four years have passed since I first
Manufacturing Research Conference (NAMRC) was stepped into this community. As the style of
in 1994 at NAMRC-XXII, hosted by Northwestern human life evolves, manufacturing technology
University (Evanston, IL). I presented my work, must constantly advance to respond and
“Development of a New Type of Magnetic Finishing improve the quality of our lives. Not only engi-
Tool for Internal Finishing of Tubes Using Rotating neers and researchers but also today’s educators
Magnetic Field,” in the Machining Innovation 1 and students must be flexible enough to respond
session at 10:30 a.m. on May 25, 1994. to these changes. How should manufacturing
At the time, I was a graduate student in Japan, education respond to these modifications within
and it was my first experience giving a
presentation in the U.S. I was excited
about the opportunity, but nervous
about presenting my work at such a
prestigious conference. To calm myself,
I repeatedly practiced my presentation
in my mind until I spoke. I had no energy
after finishing, and I do not recall how
I managed the rest of the day. What
I still remember are some vigorous
and constructive discussions and the
welcoming atmosphere.
HITOMI
YAMAGUCHI
According to the conference
GREENSLET, DR. program, 61 papers were presented at
ENG., FSME
2018-19 President
NAMRC-XXII in eight technical sessions
North American spread over two and a half days. In
Manufacturing
Research Institution
contrast, more than twice as many
Hitomi Greenslet, pictured with 2018 SME President Thomas Kurfess,
of SME (NAMRI/SME) papers were presented at NAMRC
PhD, FSME, PE, was elected to the 2016 Class of SME Fellows.
SME Member Since
1997
46 in 2018. This small conference in
1994 might have facilitated the opportunity for the existing educational system? This is the
worldwide professors, researchers and engineers real challenge our manufacturing community
to network and discuss manufacturing research is facing. I believe my senior colleagues have
and education. I could sense their passion for always discussed this challenge and responded
manufacturing even in casual conversation. to such changes in the past.
As a graduate student, participating in Likewise, NAMRC has maintained the
NAMRC-XXII was an eye-opening experience and same tradition and responded accordingly.
has been an outstanding memory throughout my NAMRC’s size, including the number of papers
professional career. By the end of the conference, presented as well as participants, has grown
I knew that NAMRC was one of the events I over the years, which influences the conference
wanted to participate in repeatedly. This boosted organization. The NAMRC proceedings are now
my motivation to write high-quality papers on open access, and NAMRC has adapted to the
topics related to manufacturing. changes over time by introducing new topics

12 Manufacturing Engineering | December 2018

SME SPEAKS

such as additive manufacturing, smart manufacturing,
cyber-physical systems, industrial application and manu-
facturing education.
Twenty-four years ago, I could not imagine that manu-
facturing education would be one of the topics discussed
at NAMRC. However, I now feel the need to emphasize the
importance of that topic and promote a better manufacturing
education for the next generation, not only as the president
of NAMRI/SME but also as a professor and member of the
manufacturing community. Although the style of technology
transfer has, perhaps, changed over the years, I can still
sense the passion for manufacturing among the attendees.
Right before I graduated from university, my supervisor,
Dr. Shinmura, advised me to set lifetime goals so I would not
simply drift along, driven only by life after graduation. I made
two goals that I still strive to meet every day. One is to be a
good researcher/engineer, and the other is to pass whatever
I learned from my seniors to the next generation. These
Even so, I have always been in the manufacturing commu-
nity, and I am still working toward the lifetime goals I set
years ago. I host students (from both K-12 and university) in
my laboratory every summer and have hosted events where
professionals can share their experiences with engineering
education and career development; however, my mission is
only partially complete.
If I had not participated in NAMRC-XXII back in 1994,
I am not sure if I would be where I am now. I would like to
thank everyone who supported my participation in NAMRC-
XXII 24 years ago and those who inspired me during the
conference. One day, I hope to be like the people who
inspired me.
NAMRC 47 (sme.org/namrc), June 10-14, 2019, will be
hosted by the Penn State Behrend School of Engineering
(Erie, PA). I look forward to meeting you there.
[1] Weinmann, K.J., 1998, “Twenty-Five Years of NAMRC and Beyond – A Brief History and Outlook,”
Transactions of NAMRI/SME, Vol. XXVI, pp. 11-15.

goals are a way to sincerely thank the countless people who

taught me various things, ranging from technical knowledge
to philosophical matters. Without their support, I could not
stand where I am today. Therefore, promotion of manufactur-
ing education naturally comes to mind.
I have faced several turning points throughout my
professional life, such as changing jobs, moving from one
place to another and so on. For instance, I took an internship
in Switzerland; I have worked in Japan and the U.S.; and I
have worked in academia, national labs and private industry.
Midwest Chapter Roundtable Conference
On Oct. 5 and 6, 12 SME chapters met at the Midwest
Chapter Roundtable Conference held in Ames, IA. The
conference agenda consisted of four modules: leadership,
chapter operations, engagement, recruitment and retention.
The leadership panelists were made up of industry and
SME volunteer leadership: Matt Edwards, Pella Windows
(Pella, IA); Duane Dierschow, Emerson Flow Controls
(Marshalltown, IA); Wayne Frost, LSME, CMfgE, 2015 SME

2018 SME OFFICERS INTERNATIONAL DIRECTORS

Edye S. Buchanan, CMfgT
INTERIM EXECUTIVE DIRECTOR & CEO
Sandra L. Bouckley, FSME, P.Eng.
AND DIRECTORS BriskHeat
CONTACT SME
Winston F. Erevelles, PhD sme.org / leadership@sme.org
PRESIDENT St. Mary’s University (800) 733-4763 / (313) 425-3000
Thomas R. Kurfess, PhD, FSME, PE
Georgia Institute of Technology Matthew L. Hilgendorf, CMfgT, EIT
Atkore International
PRESIDENT-ELECT 2018 SME EDUCATION
Mark L. Michalski Vincent W. Howell Sr., FSME, CMfgE
Corning Inc. (retired) FOUNDATION BOARD
VICE PRESIDENT
Susan M. Smyth, PhD, FSME Dean S. Phillips OF DIRECTORS
General Motors (retired) Link Systems
PRESIDENT
TREASURER Ralph L. Resnick, FSME
Kathy Burnham
Michael D. Packer, FSME National Center for Defense Manufacturing
Padilla
Lockheed Martin Aeronautics Co. & Machining and America Makes
VICE-PRESIDENT/SECRETARY
SECRETARY James W. Schlusemann
Susan E. Shimoyama
Dianne Chong, PhD, FSME Prosperia International
Rockwell Automation (retired)
The Boeing Co. (retired) Rebecca R. Taylor
The National Center for Manufacturing Sciences

14 Manufacturing Engineering | December 2018

president; and James Schlusemann, 2018-19 international
director, SME Board of Directors. Discussions were
centered around:
• Collaborative leadership;
• Working with four generations of the workforce;
• Workforce adaptation of automation and artificial
intelligence; and
• A genuine leader: expectations, commitment,
integrity, listening and more.
Presenters included Krishna Vuppala and Rob Drumm,
Waterloo Chapter 186 officers; Joe Vanstrom, faculty advisor
for SME’s Iowa State University S132 student chapter; and
Kyle Riegel, 2018-19 SME Member Council representative.
During the Midwest Chapter Roundtable Conference, attendees
toured Iowa State’s Industrial and Manufacturing Systems
Engineering Department, which focuses its research on operations
research and analytics; advanced manufacturing; human factors and
ergonomics; and systems engineering and engineering management.
In addition, SME member Kurt Carlson, a technician and
instructor at Chippewa Valley Technical College (Eau Claire, WI),
was also presented with his 2018 SME Award of Merit during
the conference. A keynote speaker provided a presentation on
3D printing with examples of industry adaptation and changes
to production processes. The conference included laboratory
machinery tours at Iowa State and concluded with a profes-
sional and student chapter summit.
Manufacturing Innovation Summit
Draws Over 375 Attendees
SME’s Nashville Chapter 43 held its second-annual
Nissan Manufacturing Innovation Summit Oct. 10-11 at the
Tennessee College of Applied Technologies (Smyrna, TN).
Thomas Kurfess, 2018 SME president, was on hand to
kick-off the event with his keynote: “Innovation Implementation
into a Manufacturing Environment—Thinking/Looking Outside
the Box.” The summit had more than 62 tabletop booths, 24
breakout sessions and over 375 attendees. It was designed
to provide Nissan and other manufacturers exposure to new
and innovative ideas for improving quality and lowering costs.
Chapter 43 handled registration of the booths, attendees
and other logistical issues for Nissan. Two SME student
chapters—Middle Tennessee State University S239 and
Tennessee Technology University S215—were represented as
well with S239 providing bags for the event. Chapter 43 uses
the proceeds of this event to fund its scholarship program and
other activities for the chapter.

TREASURER/CHAIR OF FINANCE John Miller Melissa T. Dochter

Peter F. Mackie Siemens PLM Software Schneider Electric
Wells Fargo Advisors
Mark Stratton Louis C. Dorworth
DIRECTORS SME (retired) Abaris Training Resources, Inc.
Ray Betz
Brian Ruestow, LSME Ronald A. Gill, HSME, CMfgE
Arconic
Norton Pulpstones, Inc. Gill Enterprises
Thomas G. Bridge, PhD, LSME, CMfgE
Pamela Ruschau, Esq. Karl R. Haapala, PhD
Western Illinois University (retired)
Leydig, Voit & Mayer, Ltd. Oregon State University`
Wayne F. Frost, LSME, CMfgE
Lonnie Love, PhD, FSME
Deere & Co. (retired)
Oak Ridge National Laboratory
Joe Kann 2018 SME John Kovalchuck, LSME, CMfgE
Cobble Creek Solutions
Gwendolyn Malone
MEMBER COUNCIL Macomb Community College
Kyle Riegel
GM Global ME Program Integration – Ergonomics CHAIR United Equipment Accessories
Irving Pressley McPhail, EdD Jason B. Jones, PhD
Hybrid Manufacturing Technologies Cary J. Rosenberg, CMfgE
National Action Council for
Watts Water Technologies, Inc.
Minorities in Engineering, Inc. REPRESENTATIVES
Vesna Cota Brock T. Strunk
Karla E. Middlebrooks
Tyco Electronics Canada ULC Epic Aircraft
Excellence in Action

December 2018 | AdvancedManufacturing.org 15


GE, Once Manufacturing’s Bright Light, Dims
G
eneral Electric Co.
(Boston) is an industrial
giant that traces its lineage
back to Thomas Edison.
GE’s prospects, however, are dimming.
The company changed CEOs in
October, dumping John Flannery after
a little more than a year on the job.
The company also announced plans to
write down the value of its troubled GE
Power unit by about $23 billion.
The power unit makes turbines for
power plants. GE said in its sec-
ond-quarter earnings report the unit’s
orders of $7.4 billion were down 26%
and its revenue slid 19%.
Flannery last year succeeded Jeff
Immelt, who had been in the shadow
of Jack Welch, his predecessor.
Welch had been an early celebrity
CEO. He popularized concepts such
as Six Sigma. He also implemented
a ruthless corporate culture, where
the bottom 20% of employees were
targeted to be forced out.
GE changed CEOs because its
stock price continues to lag. Under
Immelt, GE divested financial assets
and its NBC unit to concentrate on
being a more-focused industrial com-
pany. Flannery got the nod to make
GE more efficient and profitable.
H. Lawrence Culp
took over as GE’s
CEO in October.
16 Manufacturing Engineering | December 2018
TRENDS AND IDEAS IN MANUFACTURING
Flannery announced in June the
company would concentrate on avia-
tion, power and renewable energy.
Nevertheless, GE’s board decided
Flannery wasn’t getting the job done,
so it tapped director H. Lawrence
Culp Jr., 55. Culp is a former CEO
of industrial company Danaher
Corp. and joined GE’s board last
year. He got credit for revamping
Danaher into more of a science and
technology concern. GE’s board is
counting on Culp to perform another
transformation.
Moody’s Investors Service said in
October it was reviewing GE’s debt
for a possible downgrade. Moody’s
long-term rating is A2, the sixth-high-
est rating. The power unit was one
reason for the review.
The “prospects of the continuing
deterioration in its Power business…
is likely to persist for some time,”
Moody’s said in a statement. “The
change in GE’s CEO and chairman
was an additional consideration for
the review.” Culp also will be chair-
man in addition to CEO.
The company’s image has been
dimming for a while. Earlier this year,
there was a symbol of that. The Dow
Jones Industrial Average removed
NEWS DESK
GE, replacing it with Walgreens
Boots Alliance, the drug store chain.
One sector that will be watching
Culp closely is the additive manu-
facturing industry. GE has invested
heavily in 3D printing. It has adopted
additive manufacturing in aviation.
Companies such as GE and HP
Inc. are supposed to accelerate the
use of the technology in manufac-
turing. So there’s plenty of interest
among 3D printing players.
ÐSenior Editor Bill Koenig
Growing Partnership
Between Boeing and Haimer
Haimer GmbH (Igenhausen,
Germany) is continuing to develop its
partnership with the aerospace giant
Boeing. The Boeing Co. operates a
center of excellence and main produc-
tion plant for heavy metal machining
in Portland, OR, and has taken steps
to expand its strategic partnership
with Haimer by sponsoring a joint
membership for the two companies at
the Oregon Manufacturing Innovation
Center Research and Development
(OMIC R&D; Scappoose, OR).
The Boeing/Haimer partnership
dates back more than 10 years to
when Haimer’s Safe-Lock pull-out
protection system began to be used
at the Portland facility. Haimer, with its
U.S. operation located in Villa Park,
IL, develops toolholding, shrinking,
balancing and presetting solutions.
With a total now of 17 manufacturing
industry partners and three Oregon
public universities, OMIC R&D is
focused on developing advanced
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metals manufacturing technologies
through collaborative R&D.
Haimer Safe-Lock is Boeing
Portland’s standard for roughing
in its milling operations. Haimer
implemented an open licensing policy
where other cutting tool manufacturers
offer this technology as a standard
solution that is widely used in Boeing
machining operations. Boeing has also
received an IP, patent and trademark
license from Haimer to be able to
quickly respond to its machining
needs for this technology.
William Gerry,
program manager,
global technology
for Boeing Research
and Technology
(left) and Andreas
Haimer, president,
Haimer Group, at the
official membership
inauguration of Haimer
at the OMIC.
Prior to implementing Safe-Lock in
their production, Boeing faced the con-
stant challenge of preventing the cutting
tool from pull-out. Over the last 10 years,
since implementing Safe-Lock, Boeing
reports that it has not experienced a
single tool pullout incident.
William Gerry, global technology
program manager for Boeing
Research and Technology, said:
“Boeing is very carefully vetting and
inviting members to partner up and
contribute to OMIC R&D. We are
delighted about the new member-
ship of Haimer, who we know as a
high-quality toolholding, shrinking,
18 Manufacturing Engineering | December 2018
balancing and presetting technologies
company that Boeing has relied on
exclusively for this service. Haimer can
support OMIC R&D and its members
with state of the art technology and
industry 4.0 connectivity solutions.”
OMIC R&D is the fifteenth such
research center established with
Boeing leadership worldwide, and
the first Boeing has sponsored in the
U.S. Its mission is to bring together
manufacturing companies and higher
education in an innovation environ-
ment where “outside-in” applied
research with faculty and university
students solves real problems for
advanced manufacturers while train-
ing the next generation of engineers
and technologists.
Andreas Haimer, president of the
Haimer Group, said: “We are proud
and happy to be closely associated
with Boeing as a leading aircraft
manufacturer and one of our biggest
global customers. The investment
and membership at OMIC R&D is a
clear commitment to the commu-
nity, our customers and the entire
manufacturing industry in Oregon,
the Pacific Northwest and American
manufacturing. OMIC R&D is an
ideal platform to share these kinds of
best practices making American and
Oregon manufacturers more compet-
itive. Apart from Boeing Portland we
also heavily support the leading U.S.
Boeing facilities with our system tech-
nologies in Auburn, Seattle, Everett,
Helena, St. Louis and Fredrickson.”
Coordinated with OMIC R&D’s
applied research projects will be
hands-on “earn and learn” appren-
ticeship programs at the PCC OMIC
Training Center, led by Portland
Community College, and located in
a nearby facility that PCC is building.
While the Training Center construction
is underway, PCC has a temporary
delivery site at Scappoose High School.
Brendt Holden, president of
Haimer USA, said: “We have been
delighted to support various produc-
tion facilities in the Northwest over
the past 15 years with state of the
art shrinking and balancing machines
that have helped reduce operating
costs and increase productivity.
Lately we have been involved with
multiple presetting projects in the
Northwest which can reduce set
up time and increase significantly
the efficiency of the operation while
implementing Industry 4.0 technology
by tool management capabilities. We
are happy to share our equipment
and knowledge in the OMIC.”
Prima Industrie Introduces
Prima Additive Brand at
Innovation Day Event
Prima Industrie, a manufac-
turer of laser systems for industrial
applications, sheet metal processing
machinery, and industrial electronics
and laser technologies, hosted its first

Innovation Day event at its headquar-
ters and Tech Center in Collegno,
Turin, Italy, on Oct. 3. More than 160
guests from 20 different countries,
composed of customers and
prospects, universities and research
centers, and international media
representatives, attended the event.
The new Prima Additive division,
dedicated to the design, production
and marketing of turnkey solutions for
metal powder bed fusion (PBF) and
direct metal deposition (DMD) technol-
ogies, as well as application support
and global service, was introduced.
The new division will be made up of
managers and engineers located in a
new facility next to the Prima Industrie
headquarters. The building is currently
under construction and the investment
for the facility is near $7 million.
The new brand “reinforces the
pioneering spirit and the legacy of
innovation of our group,” said Prima
Industrie Group President Gianfranco
Carbonato. “Back in the 1970s, we
followed our vision and we entered
the market of laser machines for
industrial applications that was just
at its beginning, and it was a winning
choice. Today we are witnessing the
development of these new applications
of laser to metalworking and their
disruptive potential. It is a fascinating
new manufacturing paradigm, and we
are ready to help our customers seize
these business opportunities.”
The mission of the new Prima
Additive Division is continuous innova-
tion in laser for material processing and
its main commitment is to advance the
industry by reducing barriers to entry in
additive manufacturing.
Prima Additive is the third division
of the Prima Industrie Group, which
includes Prima Power (laser and
sheet metal working machinery) and
Prima Electro (laser sources and
industrial electronics).
Besides the addition of Prima
Additive, other recent R&D develop-
ments in the Prima Power Machinery
Division were related to Laser Next
2141 and a new 2D laser machine
concept, designed for larger size
applications. Also, the Prima Electro
December 2018
Prima Additive logo is showcased
at Prima Additive event.
Division focused on an expansion of its
CF Fiber laser family.
ÐManaging Editor Candace Roulo
Industries Still Struggle
With Automation, Report Says
Various industries are still struggling
with automation despite long-standing
efforts, consultant McKinsey & Co.
said in a report.
“Organizations in every region and
industry are automating at least some
business processes,” New York-based
McKinsey said. However, it added that
“only a slight majority have succeeded
at meeting their targets.”
The report is based on a survey of
more than 1,300 people from different
regions and industries. The survey was
conducted online in January.
“Although automation has become
commonplace, the results indicate
that success is by no means assured,”
McKinsey said.
Manufacturing has entered the
Industry 4.0 era, in which “connected”
machines provide data to operators.
Industry 4.0 is being used to track
parts and finished products more
closely and to ensure maintenance is
performed on time to keep operations
running. That’s on top of traditional
automation, such as robots.
The McKinsey report says auto-
mation efforts tend to work best on a
decentralized basis.
“Respondents at successful
organizations are more likely than their
peers to say their functions or business
| AdvancedManufacturing.org 19
NEWS DESK
units are accountable for delivering
automation efforts, with or without
support from a central team,” said the
report. “Conversely, respondents at
less successful organizations are more
than twice as likely…to say a central
team is solely responsible for automa-
tion delivery across the organization.”
What’s more, respondents to the
survey also said successful automation
“relies on the early engagement” of
information technology departments.
“First, these organizations’ IT teams
are more likely to have automated their
own processes…Organizations that
are struggling to implement automation
successfully would do well to elevate
the role of IT.”
The report urges companies that are
“just launching automation programs”
to make “automation a strategic priority
from the outset. Ways to put this in
action would include defining clear
strategic objectives from automation.”
McKinsey describes automation as
“a global phenomenon.” It said 57% of
all respondents “say their organizations
are at least piloting the automation of
processes in one or more business
units or functions.”
ÐSenior Editor Bill Koenig
Linear Friction Welder Delivered
to LIFT Facility in Detroit
Manufacturing Technology Inc.
(MTI) has shipped North America’s
first linear friction welder capable of
full-sized part development to the
Lightweight Innovations for Tomorrow
(LIFT) facility in Detroit where it will
contribute to lightweighting research in
the automotive and aerospace sectors.
Weighing 122,000 pounds (61
metric tons)—roughly the same weight
as a Boeing 737—the LF35-75 has
20 Manufacturing Engineering | December 2018
the largest tooling envelope of any
linear friction welder in the world,
allowing for the production of the
largest full-scale parts
available, according
to MTI. It will bring the
same linear friction welding technology
used in aerospace to achieve light-
weighting blisks and Integrally Bladed
Rotors (IBR) to aircraft engines and
the automotive industry.
“This is the only machine of its kind
in the world, and we are extremely
excited about the possibilities this
machine brings moving forward,” MTI
President and CEO Dan Adams said
in a statement. “Our North American
customers in the aerospace, automo-
tive, defense, rail and mining industries
have been looking for a machine that is
capable of full-scale parts.”
“Deploying a machine such as this
linear friction welder will increase our
lightweighting research and devel-
opment exponentially,” Nigel Francis,
LIFT’s CEO and executive director, said
in the statement.
Renishaw, Altair Announce
3D Printing Collaborations
Renishaw, a manufacturer of metal
additive manufacturing (AM) systems,
has joined with Altair, a provider of
engineering software, for a series of
projects aimed at bringing AM into
serial end use production.
“Altair is a world leader in
simulation-driven design,” Stephen
Anderson, AM business development
manager for Renishaw, said in a
statement. “Research combining their
software with our latest systems will
give them practical insights that will
lead to innovative improvements in
their products.”
David Coates, senior program
manager at Altair, said: “Working
closely with Renishaw benefits the
development and application of our
software to optimize designs for
functionality as well as for printability,
accuracy and suitability for its des-
ignated purpose. This collaboration
helps ensure AM part development,
print cycles and scrap rates are
minimized for our customers.”
Allis Roller Joins World Class
Manufacturing Program
Machined parts manufacturer Allis
Roller (Franklin, WI) is embarking on
the World Class Manufacturing (WCM)
integrative system for business and
operational optimization.
WCM is said to be one of the
most exclusive and highly respected
programs for lean manufacturing in the
world. With multinational customers
such as John Deere and CNH,
adopting WCM strategies is part of
Allis Roller’s larger goal of striving for
continuous improvement and a leaner,
more efficient manufacturing model.
Recent hire John Gil brings
extensive experience in manufactur-
ing quality control and operational
improvement. He is spearheading the
WCM push at Allis Roller. Gil currently
has a Green Belt certification in Lean
Six Sigma and is working towards his
Black Belt certification.
“We’re excited for the opportunity
to make our operation smarter, faster
and more cost-effective over time,”
Gil said in a statement. “World Class
Manufacturing is a unique and highly
selective program. We know it will
help us improve on the already solid
foundation we’ve built here at Allis
Roller.”
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Renishaw Inc 1001 Wesemann Drive West Dundee, IL, 60118
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SHOP SOLUTIONS
W
SAFETY TECHNOLOGIES INC. e have all encountered
delays in traffic due to
road work being done.
Robotic Welding In the northern climates
to fix potholes left over from winter; and
Speeds Up everywhere where repair and maintenance
Manufacturing and even major re-engineering of roads,
highways and bridges are required.
of Mobile Road Recognizing that these work zones are
potentially hazardous to workers and trav-
Safety Devices elers alike, Chuck Fanslow founded Safety
Technologies Inc. (Red Wing, MN) in 1994
to manufacture the AutoFlagger automated
flagger assistance signs for work zone traffic
control, according to his son, Jared Fanslow,
who is in charge of product development.
“We are a small business so we
know how important any improvement
in productivity can be. For example, our
automated flagger assistance signs and
the trailers that deliver them to work zones
depend on welding to provide sturdy con-
struction that can weather the most rugged
outdoor environments that are potentially
dangerous to construction road crews and
the traveling public,” Jared said. “So when
we needed a way to increase productivity,
improve product quality and free up time
to develop other products, we looked into
automating our welding processes,” he said.
AutoFlagger traffic control assistance
devices are welded fabrications with
their own self-contained power and solar
power units. The basic components of the
AutoFlagger system include a solar cell, a
trailer with an adjustable hitch that can be
combined for a single tow, a tool box with
control panel, and an adjustable mast that
can be raised up three more feet at the
job site.

Introduction To Robotic Welding

Available in two models, the
AutoFlagger 76-X with stop sign and
the AutoFlagger 54 with traffic signal,
the devices had been fabricated with
manual welding. “We looked at robotic
welding at a FABTECH trade show as
a way to increase our production of the
AutoFlaggers as well as the substructures
of the trailer decks that supported them.”
Working with its welding equipment
supplier, Fronius, Safety Technologies Chuck Fanslow (left), founder of Safety Technologies, and his son Jared (right),
chose the IRB 1660ID robot from ABB Robotics to automate welding of the
updated to a welding system that would AutoFlagger automated flagger assistance signs for work zone traffic control.
SHOP SOLUTIONS
work with whatever robotic arm the company selected. “All you have
to do is get the right interface for it,” said Jared. The company chose
the IRB 1660ID robot from ABB Robotics after meeting with ABB
representatives at the trade show. “We sent the welding system to
ABB so that they could test everything right in their factory. When we
got the whole process back we knew that it would work.”
The IRB 1660ID compact robot is designed for arc welding
and machine tending, according to ABB. The robot’s integrated
DressPack makes it easy to program and simulate predictable
cable movements. In addition, the ABB says that the more com-
pact footprint and minimized cable movement reduce maintenance
cost by as much as 50% due to reduced wear and tear on the
cables. The IRB1660ID’s compact, hollow wrist with Integrated
DressPack is well-suited for applications requiring work in tight
spaces such as arc welding and machine tending. The IRB 1660ID
can handle payloads up to 6 kg and has a reach of 1.55 m.
Big Drop in Welding Times
Safety Technologies has one welding cell. “With the robot
automation, I can do 90% of the welding with the robot, reducing
time from three hours welding manually to 40 minutes,” said
Jared. “I make special fixturing with a jig table with some jigs
taking 20 minutes and others as much as a whole weekend.”
Programming of the robot is easy, according to Jared. The
company has 40 different programs for its three different prod-
ucts, the two AutoFlaggers and the axle router which comprises
ten different components. There are 30 different components
that go into the trailers. At FABTECH, ABB demonstrated how
the joystick works and how using the FlexPendant enables
24 Manufacturing Engineering | December 2018
With the IRB 1660ID robot, Safety Technologies does 90% of
the welding in its one cell, reducing time from three hours
welding manually to 40 minutes. Programming the robot
is easy, according to Jared. The company has 40 different
programs for its three different products, the two AutoFlaggers
and the axle router which comprises 10 different components.
programming the robot with the hand-held device. Jared points to
the FlexPendant’s easy touch screen, easy interface and joystick
control as time savers for the welding process.
Fast, Agile and Reliable Solution
That was exactly the result that ABB was looking for when
it introduced the IRB 1660ID. “Our aim from the beginning was
to deliver a robot that offers superior and consistent quality in
arc welding as well as a fast, agile and reliable machine tending
solution,” explained Dr. Hui Zhang, head of global product
management for ABB Robotics.
“This robot allows our customers to increase productivity,
deliver better workpiece quality and reduce cycle times. As a
direct result of close collaboration with our customers, the IRB
1660ID also includes a new generation of accurate, efficient
and reliable motors,” added Zhang. “We spent a great deal of
engineering effort making the robot as rigid as possible to better
protect it, and to equip it for the confined spaces in which it is
designed to operate.”
For Safety Technologies, volume and sales have increased
since adopting the welding cell, said Jared. “We’re selling about a
dozen a year to construction companies, contractors and govern-
mental agencies and municipalities.” Jared credits the automated
robotic welding for the sales increase due to Safety Technologies’
ability to meet deliveries promptly as well as developing its other
products. “For a small company like ours, it was pretty daunting
to get involved with robotic automation but it’s not as complicated
as it might seem,” said Jared. “My advice is don’t be afraid of
robots. They are a great investment.”
For more information from ABB Robotics, go to
www.abb.com/robotics, or phone 248-391-9000.
Jared makes
special
fixturing
with a jig
table, with
some jigs
taking 20
minutes
and others
taking as
long as
a whole
weekend.
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 SHOP SOLUTIONS
Photos courtesy Dwight Cendrowski
At Bridge Tool & Die, CNC
grinding technology from
United Grinding turns the
expert “feel” of manual
grinding into “facts” that help
optimize the grinding process.
26 Manufacturing Engineering | December 2018
BRIDGE TOOL & DIE
CNC Turns
‘Feel’ Into
High-Precision
Carbide Grinding
G
lenn Bridgman describes the difference between
his shop’s manual grinders and its newest state-
of-the-art CNC ID/OD grinder, a Studer CT960 OD/
ID from United Grinding (Miamisburg, OH), as “feel
vs. facts.” Bridgman, president of Bridge Tool & Die (Buckley, MI),
believes that manual grinding is a somewhat personal operation.
The machinists are physically closer to the process and can hear
and “feel” it, he said. On the other hand, he sees today’s advanced
CNC grinding technology as a way to turn that expert feel into
cold hard facts and numbers. Those facts ensure a much more
repeatable process that significantly boosts the shop’s workpiece
consistency, quality and precision, as well as its production output.
With his substantial background in grinding, Bridgman bought
the company he had been working for and created what is now
Bridge Tool & Die. And with the purchase of the shop came
decades of grinding experience, particularly with grinding carbide,
which remains the shop’s specialty.
Bridge Tool & Die grinds carbide and encases it in steel for
tooling used in high-volume extruding and forming processes,
producing tooling and other components for the mold and die, oil
and gas, and automobile industries, among others.
“Carbide is an extremely hard material to grind,” explained
Bridgman. “It requires diamond grinding wheels. But most impor-
tantly, the process involves finesse in terms of speeds, feeds
and material removal rates. That is why we acquired the CNC
technology. We not only needed predictability and consistency,
but also an increase in our capacity.”
Bridge Tool & Die’s new Studer CT960 does both ID and OD
grinding. Its indexable head houses three ID spindles and one OD
spindle, plus a probe. The shop can run an operation, have the
probe check the part and, if needed, tweak the program on the fly.
According to Bridgman, the Studer CT960 dramatically short-
ens setup times and eliminates the need to move parts between
as many as five separate OD machines before completing the
part in an ID machine. Instead of these five individual setups on
five different machines for one component, the Studer CT960
completes the part in a single setup.
For its wheels, the shop uses a variety of diamond wheels, rang-
ing from metal bond to dressable vitrified for finishing operations.
The machine tracks the wheel size, limits and corrections in a tool
library that makes part setups even faster. Wheels can be loaded,
unloaded and reloaded again and be in the exact location every time.
Many parts require small ID ground holes, which is why, accord- According to Greg Mort, the B-axis
capability of the Studer CT960 has been
ing to Bridgman, the shop gets the speed it desires from the Studer a game changer when it comes to grinding
radii, producing perfect radii while also
CT960. He explained that the smaller the hole and the smaller the
eliminating much secondary benchwork.
grinding wheel used to create it, the higher the required spindle
speeds. Higher speeds allow the small wheels to act harder and
grind with fewer breakdowns, and for this, the machine delivers
42,000, 45,000 and 60,000 rpm spindle speeds. The shop also has
the option to boost its top speed to as high as 120,000 rpm.
How the Studer CT960 turns feel into facts, according to
Bridgman, is through its StuderSIM software. It shows a live
simulation of the wheel position, spindle speeds and feed rates
while providing acoustic grinding feedback on the workpiece and
dresser. Plus, it allows the shop to run offline simulations to avoid
problems during actual part runs.
“We considered other grinder brands, but from a quality point
of view, the Studer CT960 was far beyond the others, especially
in terms of precision and software,” said Bridgman. “StuderSIM
really sets the machine apart from the competition because it is
software designed specifically for the grinding process. Others
just try to adapt conventional milling or turning machine software
to grinding operations.”
In addition to its software, Greg Mort, business manager
at Bridge Tool & Die, finds that the Studer CT960’s B-axis has
improved the shop’s ability to grind radii. It allows the workpiece
to swivel as it’s being ground and thus produces perfect radii.
“Especially beneficial for part radii, the machine eliminates the
need for secondary hand polishing to achieve required surface
finishes, and it does so about three times faster,” said Mort.
“Whatever the amount of time it takes for hand polishing a part,
the Studer CT960 can produce the same surface finish three Glenn Bridgman (left) discusses
times faster. We simply give those parts coming off the Studer programming the shop’s Studer CT960
with Pat O’Halloran, CNC programmer/
CT960 a quick buffing and they are ready to ship.” operator, at Bridge Tool & Die.

December 2018 | AdvancedManufacturing.org 27

SHOP SOLUTIONS
For Patrick O’Halloran, CNC programmer and operator
of the Studer CT960 at Bridge Tool & Die, the learning curve
for the machine was made easier thanks to United Grinding’s
nearby Miamisburg, OH headquarters. “We did training at United
Grinding, then they came to the shop for even more training and
to help us further optimize our processes,” he said. “This allowed
us to take full advantage of the machine’s capabilities, some of
which we have yet to even use. But we are quickly progressing
and continue to do more and more with the machine.”
Unlike its customers, Bridge Tool & Die’s high-mix/
low-volume production schedule averages about 300 jobs per
month. Lot sizes range from a single piece to blanket orders of
30 parts per month. Over 80% of the shop’s customers place
recurring orders.
“We build special relationships with our customers, mainly
because we are all involved with carbide in some way, and they
know that there are few shops that specialize in the material,
especially grinding it,” explained Bridgman.
Most carbide inserts are shrink fit into mating steel casings.
Doing so is cost effective for customers because only the high
wear sections are carbide rather than the entire component.
Smaller parts are often made completely from carbide. Almost all
parts require mirror surface finishes of between 2 to 4 µm.
The shop does all necessary operations for its customers’
parts. It turns the steel cases, grinds the carbide and assembles
the two portions for a finished component. Part tolerances are
typically around ±0.0002" (0.005 mm), and some are as tight as
±0.0001" (0.003 mm).
28 Manufacturing Engineering | December 2018
In addition to adopting advanced grinding technology like the
Studer CT960, Bridge Tool & Die has arranged grinding cells, or work
centers, on its shop floor. These cells have several machines in close
proximity, which allows one operator to run multiple machines.
“Having these work stations with fully automatic, semi-auto-
matic and manual machines has allowed us to keep pace with
demand using the people we have because it’s tough to find good
help these days,” said Bridgman. “We have to be as productive as
possible with what we have.”
The company has expanded its processing capabilities to
include steel milling and turning operations with the acquisition
three years ago of a general machining shop. Acquiring the
shop across the street, formerly known as American Mold, has
allowed Bridge Tool & Die to diversify into the injection mold
machining arena. The new space also gives them room to grow.
At the second shop, Bridge is now machining tool steel compo-
nents for dies and molds, mainly for plastic injection molds and
aluminum extrusions.
An expansion into other machining operations has helped
increase business, especially from existing customers. In addition
to grinding, customers are now asking Bridge Tool & Die to do
conventional millingÑwork the shop would have previously
farmed out. In the midst of the current business boom, the shop
already has its new Studer CT960, as well as its manual opera-
tions, practically maxed out in terms of capacity. And Bridgman
already has his sights set on increased CNC grinding capacity.
For more information from United Grinding,
go to www.grinding.com, or phone 937-859-1975.
Glenn Bridgman,
president (center
right), Contessa
Spaulding, account
coordinator
(center), and Greg
Mort, business
manager, along
with the rest of
the team at Bridge
Tool & Die, with the
shop’s new Studer
CT960 grinding
machine.
REVIEW & OUTLOOK

Outlook: Solid U.S. Economic

Momentum Poised to Cool in 2019
U.S. economic growth is expected to continue in 2019, while outlooks for
the aerospace and defense, automotive, energy and medical industries vary

OXFORD ECONOMICS

E
conomic momentum has been solid through the first
three quarters of 2018. Real GDP growth is poised to
average almost 3.0% this year, reaching its strongest
growth pace since 2005.
On the household front, a robust labor market will deliver
over two million new jobs for an eighth consecutive year, as
the tighter labor market also gradually pushes up wage growth
to its fastest pace in nine years. Rising income growth and a
reduced tax burden have supported solid consumer spending
growth of around 2.5-3.0% year/year—while keeping the
personal savings rate healthy and stable for a fifth straight year.
On the business front, investment has strengthened
in response to fiscal stimulus, solid global growth and
stronger energy sector activity. With the impetus from
tax cuts and expensing allowances likely to fade, we
see business investment growth around 7.0% this year,
gradually slowing to an average 3.5% in 2019. Residential
investment, on the other hand, is expected to be roughly
neutral to growth in 2018 and 2019. Despite pent-up
demand for new homes, cost pressures, labor shortages
and lot shortages are constraining homebuilders and new
home construction.

30 Manufacturing Engineering | December 2018

GDP Growth to Ease
Looking ahead, we see average real GDP growth easing
from nearly 3.0% in 2018 down to around 2.5% in 2019. Fiscal
stimulus will continue to underpin sturdy economic momentum,
though the marginal impact will be modestly lower next year.
We expect the boost from fiscal stimulus to fall from 0.7pp
(percentage points) in 2018 down to 0.5pp in 2019.
At the same time, increased protectionism and the trade
war against China will weigh on net trade, while the uncer-
tainty it creates will also cap business investment growth. The
U.S. has imposed tariffs on $250 billion of imports in China,
amounting to about half of all merchandise imports from the
country. China, on the other hand, has imposed tariffs on
$110 billion, nearly 80%, of U.S. merchandise exports.
These tariffs are already having a visible impact on trade
flows with exports falling by the most since the 2015 global
growth lull. At the same time, a rising number of U.S. firms
are reporting plans to reduce or delay capital expenditures
amid the heightened trade tensions. Altogether, we estimate
US: GDP and Consumption
% year
GDP
5
4
0
2010 2012 2014
Source: Oxford Economics
around a 0.2pp drag on real GDP growth in 2019 as a result
of the escalating tensions. Importantly, U.S. households
can also expect to face higher prices for common goods.
Since the U.S. production apparatus is not geared towards
producing most goods imported from China, import substitu-
tion will not be a readily available solution.
Elsewhere on the trade front, the United States-Mexico-
Canada Agreement (USMCA) will replace and modernize
NAFTA. While politicians on all sides tout a hard-fought
victory, the economics remain little changed. In the short-
term, the deal lets markets and businesses breathe easy
following concerns that the U.S. would exit the agreement.
The substance of the USMCA has not caused us to alter our
growth forecast.
Amid increasing tightness in the labor market and rising
inflation, monetary policymakers at the Federal Reserve have
turned increasingly hawkish. We look for sustained inflation
momentum around the Federal Reserve’s 2% target heading
into 2019.
Consumption
Forecast
2016 2018 2020
December 2018 | AdvancedManufacturing.org 31
REVIEW & OUTLOOK

Indeed, recent comments suggest that Federal Open
Market Committee (FOMC) participants generally agree
that inflation is “on a trajectory to achieve the symmetric
2% objective on a sustained basis.” With the Fed expected
to implement this year’s fourth rate hike in December, we
look for three additional federal funds rate hikes in 2019.
Alongside more restrictive trade policy, we expect a modest
drag from tighter monetary policy in 2019 to gradually turn
the policy mix less favorable in the next eighteen months.
Risks on the Horizon
Despite the positive outlook, several risks cloud the
outlook, including trade protectionism, emerging market (EM)
turmoil, volatile asset prices and elevated oil prices.
Resilient economic momentum has kept the U.S. econ-
omy insulated from ongoing emerging EM woes. Looking
ahead, while the economy remains well insulated from
idiosyncratic EM shocks—given limited trade, banking and
corporate exposures to the riskiest EMs—a generalized EM
slowdown would constrain the U.S. economy. In 2015-16,
during the last generalized EM slowdown, we estimate the
drag on U.S. GDP growth amounted to about 0.6pp—
enough to disrupt today’s solid pace of activity.
At the same time, financial asset prices remain near-re-
cord highs, despite the recent spike in volatility. After years
of ultra-low interest rates and globally accommodative
monetary policy, equity market valuations are at multi-decade
highs, increasing the risk of correction.
We estimate a sustained 10% fall in equity prices would
reduce U.S. consumer spending growth by 0.8pp and cut
real GDP growth by 0.6pp. While the initial wealth effect of a
stock market correction would be concentrated on the top
40% of income earners, the bottom 60% would be dispro-
portionately affected by reduced employment, low wage
growth and a negative confidence shock.
More recently, oil prices have risen alongside asset prices,
creating another headwind for the U.S. economy. Higher oil
prices are still a net negative for the U.S. economy, but less

US: Consumption & Sales of New Cars & Light CVS

% year % year
Light cv sales (LHS) Car sales (LHS) Consumption (RHS)

30 4.5

25 4.0
Forecast

20 3.5

15 3.0

10 2.5

5 2.0

0 1.5

-5 1.0

-10 0.5

-15 0.0
2011 2013 2015 2017 2019 2021

Source: Haver Analytics/LMC Automotive

32 Manufacturing Engineering | December 2018

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REVIEW & OUTLOOK

US: Oil Supply, Annual Change

mb/d

2.0

1.5

1.0

0.5

0.0

-0.5

-1.0

-1.5
1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97 103 109 115 121 127 133 139 145 151 157 163 169 175 181 187 193 199 205 211 217 223 229 235 241 247

so than a decade ago. The drag on consumer spending
remains significant, but the importance of shale activity
means there is now a greater boost from business invest-
ment. We estimate the net drag from higher oil prices could
lower real GDP growth by about 0.3pp in 2018, offsetting
nearly half of the fiscal stimulus.
Aerospace: Structural Tailwinds
Outweigh Cyclical Pressures
Recent annual benchmark revisions to Federal Reserve
data have markedly changed the profile of aerospace
output in recent years. Output growth in 2017 was much
stronger than expected, increasing by 0.4% (from a previ-
ously recorded 2.6% contraction). However, the trend was
deteriorating at the end of the year and that deceleration has
gathered pace so far in 2018.
Supply chain issues at Boeing have caused the com-
pany’s deliveries to hold roughly flat compared to the year
ago period, despite strong new orders. Overall, we expect
a gradual pickup in Boeing deliveries in the balance of the
year to keep the contraction in aerospace activity around
2.0% in 2018, before a gradually turning defense cycle and a
significant backlog in civilian aircraft combine to push growth
back above 2.5% in 2019.
While near-term uncertainty has caused doubt surround-
ing U.S. competitiveness in aerospace, the country maintains
a strong and influential position in the global industry. The
U.S. accounts for half of global aerospace production, an
especially advantageous position in an environment in which
global air travel has grown at a solid 6-7% annual pace since
the depths of the financial crisis. Lower air travel costs and
increasing incomes for middle-class families are expected to
continue to support global air travel.
In the near-term, however, the administration’s travel
restrictions on Middle Eastern countries may weigh on the
domestic industry, reducing passenger volumes. Other
relevant threats include pressure for aircraft manufacturers to
invest in efforts to improve fuel efficiency and reduce noise
and other pollution. Climate-change control measures are an
additional drag on airlines’ profitability, despite counter-pro-
posals by President Trump and the International Civil Aviation
Organization (ICAO).

34 Manufacturing Engineering | December 2018

 In the key global defense subsector—which comprises
about a quarter of total aerospace output—the U.S. enjoys
an even stronger competitive position with over a 60% share
of global sales. However, President Trump’s policy stance
looks increasingly damaging for U.S. defense prospects.
Tariffs on steel and aluminum could result in higher costs for
weapons systems, including the F-35 and other advanced
aircraft. This increasingly protectionist stance could also
trigger retaliatory tariffs against U.S. aerospace defense firms
and erode competitiveness.
Overall, the structural drivers outweigh the cyclical risks.
We remain optimistic about U.S. competitiveness in aero-
space and defense given (i) its reputation as a reliable and safe
producer relative to China, (ii) favorable fundamental indicators
(e.g., output per unit of capital and labor) compared to
European manufacturers, and (iii) its history as the birthplace
of aviation. We forecast U.S. aerospace production to grow at
a solid 3.5% annual clip over the next decade, outpacing real
GDP growth by nearly a full percentage point.
Automotive: After Solid Growth
in ’18 Expect Deceleration in ’19
The U.S. automotive industry is on track to return to
growth in 2018. After contracting 0.7% in 2017, we forecast
value-added output growth north of 3.0% driven by a
rebound for Fiat Chrysler as its plants resume operations
and a bounce-back for Honda after several key new model
introductions. However, output will once again be impacted
by new model changeovers in 2019.
Most notably, Ford’s Michigan assembly plant will shift
Ford Focus production to China and drop the C‐Max to
make room for the higher-margin Ranger midsize pickup.
At the same time, the domestic industry will be impacted by
slowing demand as rising interest rates, tighter credit and
higher used‐car prices are likely to erode buying conditions.
Overall, we see value-added output decelerating down
to 0.2% in 2019—though trade protectionism remains an
important downside risk.
The Trump administration’s national security investigations
into automotive imports threatens a retaliation from Germany,
Italy, the UK, Canada and Mexico and risks impeding sus-
tained industry growth. Meanwhile, cautious producers may
opt to delay investment decisions until trade policy uncer-
tainty is reduced. On this front, the recent announcement
of the USMCA should restore some confidence, though we
note Congress may not vote to fully pass the measure until
early in 2019.
Offsetting some of the downside risk from trade policy is
sustained momentum in key growth drivers. First, persistent
employment and gradual disposable income growth continue
to make motor vehicles more affordable for consumers.
At the same time, the multi-year trend away from cars and
toward crossovers, SUVs and pickup trucks has continued
unabated in 2018. This vehicle mix is bolstering OEM
profitability and improving industry fundamentals.
With the Big Three U.S. automakers’
domestic market share shrinking from 70%
in 2000 to 45% in 2014, worries continue to
mount about U.S. competitiveness.
All the while, innovative start-ups with state-of-the-art
powertrain and vehicle ownership models are looking to
disrupt industry stalwarts. On this front, General Motors’ sale
of its European operations may signal further cost-cutting
and plant rationalization measures, while also prompting
more M&A activity from large OEMs.
With the Big Three U.S. automakers’ domestic market share
shrinking from 70% in 2000 to 45% in 2014, worries continue
to mount about U.S. competitiveness. The growing trade deficit
and shifting supply chains outside of the U.S. have done little to
stem these concerns. However, U.S. share of global production
has in fact been relatively stable over the past three decades,
hovering steadily at a long-term average of 20%.
Indeed, the U.S. has fared much better than other past
automotive powerhouses. Japan, for instance, has seen its
share of global production gradually decline, down about
15pp in 25 years due to lower-cost competitors in South
Korea and China. Germany has suffered a similar fate, losing
share to cheaper Eastern European producers.
Increasing domestic labor productivity, which is up over
4% a year since 2000, is one way the U.S. has remained
competitive, combining the latest automation technologies
with a higher-cost, but skilled labor force.
In the broader trade picture, while it is true that the U.S.
automotive sector generates a $100 billion trade deficit each
year, the rising imports are due to rapidly increasing U.S.
automotive demand. Amid climbing domestic demand, there
December 2018 | AdvancedManufacturing.org 35
REVIEW & OUTLOOK
is evidence of enhanced U.S. competitiveness, with the
imports penetration rate actually declining in recent years,
down to around 20%.
Importantly, the U.S. is also appealing as a manufacturing
hub for foreign producers. In 2014, 36% of U.S. automotive
output was from foreign-owned firms, up by 23% from 2007,
and expectations are that this share will continue to rise. The
administration’s protectionist policies may coerce foreign
firms to further invest in the U.S.
Energy: Higher Prices Drive
a Cyclical Industry Upturn
After a solid year of 7% growth in 2017, value-added
output in the U.S. oil and gas extraction industry is
poised to grow more than 12% in 2018. Driven largely
by higher crude oil prices, the industry has seen a boom
in production in the U.S. tight oil sector (oil embedded
in low-permeable shale, sandstone and carbonate rock
36 Manufacturing Engineering | December 2018
formations). Extraction has also been lifted by a strong
upswing in oil services.
While the oil rig count has been on a steady upward
trend in recent years and productivity has increased in key
production regions, the industry will not be able to meet
solid demand growth in the near-term. One key reason
for this is that the industry is experiencing infrastructure
bottlenecks that are limiting the ability to ramp up produc-
tion further. While investments are being made to overcome
this constraint, it will not be fixed in the short term. Looking
ahead, we see value-added output growth decelerating to
around 3% in 2019.
Underpinning our industry outlook is a commodity price
forecast that sees crude oil prices soon reaching a peak,
before trending lower in 2020-21. We look for Brent crude
prices to average $77 a barrel in 2019, before easing to $73
per barrel in 2021. In 2018, fears about supply shortages
helped boost oil prices as consumers are starting to get
concerned about the potential disruptions of U.S. sanctions
on Iran. Oil exports from Iran have already started to fall
and tighter sanctions will kick in later in 2018. More bearish,
though, is that production from Saudi Arabia and the U.S.
is rising quickly to compensate. While demand growth has
remained strong—particularly in key consuming areas such
as China and the U.S., we expect a gradual slowdown in
demand growth.
Medical: Solid Long-Term Fundamentals,
Combined With Reduced Near-Term Risk
The medical sector is much less cyclical than the auto-
motive and energy spaces. The general detachment from the
economic cycle is a result of the public sector’s involvement
in financing healthcare spending.
In addition, longer-term demographic dynamics are
supportive of above-GDP growth in the medical industry. An
aging population will continue to drive above-trend spending
growth as the population aged 65 or older grows over 1%
per annum through 2050.
On the downside, however, the industry remains quite
prone to policy risk. After early attempts to repeal the
Affordable Care Act, the current administration has shifted
focus elsewhere. While this reduces near-term risk for the
industry the threat of future policy changes looms. General
efforts pertaining to entitlement spending containment
threaten to impact investment growth in the medical space.

MANUFACTURING IN
2050
THE WORLD TURNED
UPSIDE DOWN?
ED SINKORA
Contributing Editor
Y
ears ago
Warren Bennis
predicted that,
“The factory of the
future will have only two employ-
ees, a man and a dog. The man will
be there to feed the dog. The dog will be
there to keep the man from touching the equipment.”
We’re not quite there yet. But a number of powerful
and interconnected trends will push us close to that state
by 2050, while the people still in manufacturing will be
empowered to rapidly innovate and build like never before.
Multitasking and Automation
It’s a safe bet that by 2050 the average machine tool
will be fully automated and more capable. Multitasking
will be common, perhaps nearly universal. The trend is
well established.
As industry veteran Scott Walker, chairman, Mitsui Seiki
USA (Franklin Lakes, NJ) observed: “In the early 2000s, the
North American market for five-axis machines was 150.
Today it’s 3,000. Machines are also combining grinding and
milling, or laser metal deposition and milling, or grinding
Powerful trends will push manufacturing close to complete automation by 2050, while the
people still working in the industry will be empowered to rapidly innovate like never before.
FUTURE OUTLOOK
and work hardening.” He
added that while the benefit
is the ability to accomplish
more inside the work envelope,
the “nightmare” has been getting all
these functions to operate properly and
consistently. “But that will change as technology,
monitoring and software all get better.”
The elephant in the room for many manufacturers is the
extent to which 3D printing will alter the technology mix, and
beyond that, its implications for product design and a host
of other issues. So far, the speed limitations and high raw
material costs of additive manufacturing have severely limited
its viability beyond prototyping. But Terry Wohlers, principal
consultant and president, Wohlers Associates (Fort Collins,
CO), said speed “won’t be an enemy” by 2050.
Take a powder bed system: The bulk of the production
time is in tracing the surface with the laser to fuse the
material. “But systems are now available with many lasers
working simultaneously on a build platform,” Wohlers said.
“The energy from an electron beam can be split into as many
as 100 beams to help speed the process.” On the other
hand, these approaches require a lot of energy, which is
December 2018 | AdvancedManufacturing.org 37
FUTURE OUTLOOK
expensive. Wohlers thinks we’ll overcome those limitations,
perhaps by “harnessing the energy of the sun directly to melt
material, rather than plugging into a 440 outlet.”
SLM Systems and others are speeding additive manufacturing in
metals by applying multiple lasers on a build platform simultaneously.
Wohlers added that directed energy deposition is inher-
ently faster than the powder bed method for building metallic
components, but “users are limited in the objects they
can create and there is a trade-off in resolution, generally
requiring machining, and sometimes a significant amount.”
This brings us back to hybrid systems that combine additive
with CNC milling. Like Walker, Wohlers believes the problems
in getting these two approaches to work harmoniously will
largely be solved in the next 32 years.
Another factor arguing for greater use of additive tech-
niques is an expected drop in material costs and a wider
array to choose from. “Today’s machines work with only a
few dozen thermoplastics, for example,” Wohlers said, “yet
thousands are available for conventional manufacturing.”
Perhaps more important, the polymers currently used in
3D printing cost up to 50 times as much as similar polymers
for conventional manufacturing. That puts the breakeven
point in the hundreds to thousands of units depending on
the size of the part. But Wohlers said many of the patents
on machines that produce parts with polymers have expired,
leading to new machines that use lower-cost materials. “The
breakeven point will improve dramatically so that additive
will challenge injection molding for a much wider range of
products, including higher volume applications.”
38 Manufacturing Engineering | December 2018
There’s a similar case to be made for metal, but Walker,
for one, is skeptical that additive will achieve a cost profile
in metals that justifies replacing traditional methods. “It’s so
much easier to heat 60 tons and roll sheet metal
than building something with powdered metal
or cladding,” Walker said. “I look at additive as a
function you can put in a machine envelope to add
value to the process. But I don’t look at additive
as a replacement process for making steel, unless
the technology changes and we get to the point
of molecular manipulation using a different kind of
energy source.”
Additive manufacturing does have one ace left, at
least for some players: The ability to create forms that
would otherwise be impossible. This not only opens
up the potential for new products and features, it also
helps alleviate 3D printing’s speed problem. That’s
because an open lattice structure made possible by 3D
printing can achieve the required strength and stiffness
needed for many applications with far less material than
a solid structure. And 3D printing’s production speed is
directly proportional to the cubic volume of material. Strange
new structures overlap nicely with our next topic.
Automated, Creative Design
In Walker’s view, manufacturing is poised to achieve its
biggest productivity gains in two areas, one of which is in
digitizing all the work that’s necessary to prepare a manu-
facturing process. “Today a designer starts out with a digital
model, and then generates a tool path ... then someone
designs a fixture ... then you get a forging ... then an
application engineer drip feeds the program to the machine
and goes tool by tool and monitors how the cut sounds
and how it looks ... and eventually he gets the machine to
make the part ... and then he refines all the motions so he
can reduce the cycle time.” It’s actually even worse because
getting the initial design is also cumbersome. Luckily, many
bright minds are working hard to ease and speed every part
of this process.
At the front end, generative design technology is helping
an ever wider group of creatives to quickly explore new
geometric possibilities. In the case of Fashion 360 from
Autodesk (San Rafael, CA), the software runs on the cloud
and uses machine learning and artificial intelligence (AI) to
automatically generate hundreds of designs that each satisfy
 the designer’s criteria for strength, cost, manufacturing
method, material and so forth. What’s more, explained Bob
Yancey, Autodesk’s director of manufacturing and production
strategy, the designs are “not just some impossible-to-use
idealized geometry, they are real working CAD models that
can be further manipulated in CAD software.”
They are also what Yancey refers to as “manufacturing
aware,” which means they started with the desired manu-
facturing methods built in as a constraint from the beginning.
“So if you specify that the part needs to be able to be
machined on a five-axis CNC, all of your design options will
conform to that constraint,” he said.
It doesn’t eliminate the need for a human designer. As
Yancey put it, “Describing the design challenge with precision
and expertise is an engineering skill that will not go away.
What generative design software does is give you more
design options than any human could conceive on their own,
so you have greater confidence that you are considering far
ISO 9001 Certified
more options and getting better outcomes. We see this as
a future of co-creation between engineer and computer, or
human intelligence and artificial intelligence.”
Perhaps more profound, the designs are often startling
and superior to what a human would have envisioned. As
Diego Tamburini, principal industry lead—Manufacturing
Industry Communities / Cloud + AI Division for Microsoft
(Redmond, WA) put it, “If I sit in front of my CAD tool to
design a part, I already have 1,000 preconceptions about
how it should look based on centuries of previous designs.
AI has no such notions. And while I agree that automating
design is a hard problem and it’s difficult to imagine a
computer designing complex items, we have to recognize
that conversely there are many instances in which we’re
living with sub-optimal human designs.”
Some of our preconceptions stem from our expe-
rience with raw materials being limited to blocks, bars
and sheets. But 3D printing is not limited to those raw
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FUTURE OUTLOOK

materials. Nor is it limited in the shapes it can create. systems and understanding the nitty gritty of what works and
If you remove those constraints and let the AI work, what doesn’t.” The other is empathetic understanding of the
generative design often creates shapes that are “com- needs of the customer and market opportunities.
pletely different from what we’re used to. More organic, What skills become less critical? Actually running the
like animal bones,” said Tamburini. machines. The process from design to CAM will be more or
Wohlers echoed this and said that nature offers less automated. As Walker explained, if the design model
excellent examples of structures with remarkable strength- included information about the material (as is becoming
to-weight ratios. Until recently, 3D printers produced standard), the machine should “have the intelligence to do
lattice, mesh or cellular structures defined by canned the rest. Take the right tools out of an 8,000 tool rack and
programs with little understanding of their strength follow the correct toolpaths at the appropriate speeds. The
properties. “The newest topology optimization tools can machine should have the vision and audible monitoring
produce engineered lattice and mesh structures with capabilities to avoid collisions and also gauge the cutting
certainty of strength,” Wohlers said. “In the future, we conditions and adjust speeds and feeds accordingly. That’s
could see super lightweight structures in different metal what applications engineers do today. How many will we
alloys that are lighter than carbon fiber composites, which need in 30 years? Hopefully none.”
is time-consuming to produce and expensive.” Having said that, Holly cautioned against a focus solely
Tamburini said he’s seen cases in which the computer on jobs. First, there will be jobs—just different, more creative
comes up with a latticed shape that doesn’t inspire con- jobs. And second, “The important thing is keeping innovation
fidence in the human (it looks too light and flimsy), so the local,” she said. “There are a lot of negatives to sending
designer covers it with something so it looks sturdier. People design and manufacturing overseas. You lose control of the
remain people, after all. intellectual property. It’s not good for the environment. And
you lose sight of what’s possible unless you have your hands
Speeding the Process in manufacturing itself.”
Krisztina “Z” Holly, founder and chief instigator of Make It
In LA (Los Angeles) underlined the benefit of combining ever Built to Order...Locally
smarter software with 3D printing and other new technologies Everyone seems to agree that manufacturing will become
(like virtual reality) to greatly speed the iterative product much more geographically dispersed, a process greatly
development cycle. Besides the ability to get
Photo courtesy Lightning Motorcycle
more feedback from the consumer earlier in
the process, which may lead to much better
products, she pointed out that the new tools
democratize the design and build process.
“What does that mean in terms of how
we innovate and who innovates? I think
the world will be a different place if we
allow non-engineers to design the kinds of
products they want,” she said. “It will also be
easier for entrepreneurs to start a manu-
facturing business. What kinds of products
will become available if people can start a
physical products business as easily as they
can a digital products business?”
One outcome she envisions: “Two sets
of skills become incredibly valuable. One is
Lightning Motorcycle used generative design to generate multiple options
in-depth technological skills for coding these for a new swing arm, settling on the unusual lattice structure shown here.

40 Manufacturing Engineering | December 2018

aided by the multiplying capabilities of individual machine to buy, program and tool up a machine to make the part
tools. Yancey said many manufacturers want to both consistently and accurately is huge.” Make machines auto-
decrease risk and make products closer to the customer to mated and multi-functional and eliminate much of the setup
better adapt them to the market.
Walker agreed and also predicted
that transportation costs and environ-
mental impacts will drive companies to
produce locally. He added that there
are also government mandated offsets,
in which a manufacturer must produce
a certain number of parts in a country
in order to sell products in that country. THE FUTURE STARTS HERE
Another motivator is maintaining
profitability despite fluctuations in
currencies, a problem exacerbated by
tightening margins.
At the same time, there will be a
much greater degree of customization
and a much tighter supply chain. As
Tamburini summed up: “The practice of
forecasting demand and mass produc-
ing parts to meet expected demand will
be turned on its head. It will be closer
to the customer telling the manufac-
turer exactly what they want and the
manufacturer making it then and only
then. Digitization and automation are
making this dream more technically,
and even economically, feasible.”
This would not apply to every
product, and the lines between
standardization, customization and
personalization are blurry. But Tamburini
is certain that the practice of custom-
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FUTURE OUTLOOK
Photo courtesy GM
GM used Autodesk’s Fusion 360 generative design
program to create a seat bracket that was 40%
lighter and 20% stronger than the bracket it
replaced, a weldment of eight components. Fusion
360 generated more than 150 unique designs in the
time it used to take to consider one option.
effort and manufacturing becomes certain things happen and using AI
a more nimble, and perhaps a lower to predict what will happen. The next
margin business. As Holly of Make It in phase in this process is using AI and
LA would have it, the design process machine learning to enable autono-
and the design tools and interfaces mous responses.”
become even more important. In other words, with enough data to
analyze, machine learning can accu-
Keeping Things Humming rately predict specific part failures. With
Increased digitization, “hyper-con- good decision algorithms and knowl-
nectivity,” and AI should greatly edge about all the production demands
improve our ability to keep production on the shop floor, the system can
running with a minimum of manpower also decide for itself what to do about
and downtime. Tamburini said most the pending failure: order the part,
of the data now being collected is schedule the downtime, move certain
used to monitor what’s going on in jobs to alternate machines, and so on.
the factory and throughout the supply You could even envision a machine
chain. “But we’re starting to ask ‘why’ fixing itself or ordering the robot that
42 Manufacturing Engineering | December 2018
can, though Walker said he doesn’t think we’ll ever get away
from the need for human maintenance technicians. However,
he does think the machines will communicate audibly about
what needs to be done—no need for handheld devices or
screens and controls.
Tamburini said Microsoft has a head-mounted product
(HoloLens) that allows you to interact with holograms
around you. “It overlays digital info on top of reality, giving
you super powers, in a sense. People are finding that
augmented reality can be used to do things like provide
assembly instructions, or QC instructions, or maintenance
instructions, thus reducing the need for training.” For
example, a remote maintenance expert can assist a local
technician by pointing to a part or indicating how to move
a part, as if they are both looking at the same thing in the
same shop together.
Finally, Tamburini pointed out that one of the beauties of
machine learning is that “the moment they get better, that
capability or knowledge can be instantaneously broadcast
to the entire world, because it’s just software. So everybody
gets smarter and better, assuming we can share data.” He
contrasted this with relying on an expert in the plant who
uses his own years of experience to interpret the sounds of
the machines and the like. “It’s very challenging to distribute
that kind of knowledge.”
What WonÕt Change
To the extent it came up at all, the experts don’t
seem to think that manufacturing precision will advance
much in the next 30 years. “We’re working at tolerances
now where the metrology to determine the accuracy is
the bigger problem,” as Walker put it. “The next step to
getting better tolerances would be molecular manipula-
tion,” (which no one envisioned). No one seemed to think
FYI
Autodesk Inc.
877-335-2261 / www.autodesk.com/make
Make It In LA
213-663-3646 / makeitinla.org
Microsoft
800-426-9400 / www.microsoft.com
Mitsui Seiki USA
201-337-1300 / www.mitsuiseiki.com
Wohlers and Associates
970-225-0086 /wohlersassociates.com
that machining speed would be significantly faster either.
Even the improvement to 3D printing speeds discussed
earlier will be more evolutionary than revolutionary—not as
significant as the increase in productivity due to software
improvements. Likewise, our current ability to produce
tiny components is already amazing. Wohlers referred to
miniaturization as “partly a solution looking for a problem.
One of the few applications are tiny sensors embedded
within 3D printed parts.”
If you’re worried about the changes, Walker might
comfort you with this thought: “We’ve been tweaking
manufacturing since the 1780s. The next 30 years will be
more tweaking, unless we come up with something truly
revolutionary.” He asked me if anyone said they’d figured
out how to manipulate gravity so we could fly to the moon
without burning fossil fuels, knowing the answer. Come to
think of it, no one mentioned the dog who kept the man from
making changes to the machine, either.
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December 2018 | AdvancedManufacturing.org 43
CYBERSECURITY
EYEBROW

Cyber Secure
Manufacturing
Is Smart
Manufacturing

Large corporations have IT departments

with considerable resources. SMMs need
all the help they can get to guard against
and ward off cyber-attacks

JIM LORINCZ
Contributing Editor

Image courtesy Kirill Savenko
I
t’s probably not a bad idea for smaller and mid-sized
manufacturers (SMMs) to adopt an “us against them”
attitude as they become aware of the prevalence of
cyber-attacks in the digital age of the Industrial Internet
of Things (IIoT) and Industry 4.0.
The sources and agents of cyber-attacks include, but
are not limited to, malware, ransomware, careless humans,
nation-state hackers and industrial espionage. Manufacturing
has been a bit late to the party when it comes to adopting
cybersecurity safeguards for its multi-million dollar machine
technology investments on the shop floor.
Both newer, advanced machines and technology and
legacy equipment have vulnerabilities to malicious or even
accidental intrusions that can result in demands for ransom,
denial of service, industrial espionage or just plain costly
downtime. Legacy equipment may be the most vulnerable,

44 Manufacturing Engineering | December 2018

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CYBERSECURITY

but even networks with the latest equipment require
constant vigilance on the part of shop floor folks and their
soon-to-be new best friends in IT.
According to Koushik Subramanian, strategic advisor
to the National Center for Cybersecurity in Manufacturing
(NCCM), industries that depend on payments like the
banking and retail sectors are much further along in adopting
the necessary cybersecurity safeguards.
NCCM was launched by the Digital Manufacturing and
Design Innovation Institute (DMDII; Chicago) with $750,000
seed funding from the U.S. Department of Defense with
the express objectives of lowering the educational and cost
barriers that manufacturing faces to increase readiness to
thwart cyber-attacks.
“Manufacturers are much more prone to threats to
their security because of connectivity in IT and OT systems
through Industry 4.0 digitalization,” said Subramanian, citing
a 2017 Verizon data breach investigation report that found
that 35% of all cyber-espionage attacks in the U.S. target the
manufacturing sector.
“First and foremost, manufacturers must undertake a
risk assessment of their operations,” he said. “Risk can be
technical—found in machines, controls or software, and
also found in personnel, practices and processes. Risk
takes many different forms, but the most common is from
cyber-attacks where malicious individuals or groups try to
break into systems by taking advantage of the weakest
link: people. That’s the reason phishing and ransomware
are so popular and why attacks are trending higher. They
target getting into the SMM environments through e-mails
or telephone calls, where they are counting on a human
response to an e-mail or phone call by clicking on a link,
and that provides a way into the system.”
Subramanian added that NCCM is working with SMMs on
pilot cybersecurity projects and with the National Institute of
Standards and Technology (NIST) Manufacturing Extension
Partnership (MEP) National Network. “Each state and Puerto
Rico have a MEP,” he said.” SMMs tend not to know where
to start, so we give them a high-level strategy and introduce
them to tools so they can start to figure out what to do and
how to identify and prioritize the security risks.”

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46 Manufacturing Engineering | December 2018

have to make every day, cybersecurity is not high on their
radar,” he observed.
But it should be. Breaches designed to steal intellectual
property and critical engineering data are happening at lower
levels up and down the supply chain, according to Forsyth.
“If you look at some of the significant breaches that affect
our security, in June it was reported that China now has all
the secrets of our most advanced nuclear submarine, the
Sea Dragon, and has built its J-31 fighter jet to duplicate the
F-35, our most advanced U.S. warfighter,” he said. “Hackers
discovered critical IP and engineering and design data up
and down the supply chain and by hacking as low as a Tier
Four manufacturer.”
Information is a vital part of running a company. As
manufacturing becomes more digitized, cybersecurity must
become a standard component of doing business.
Staying in Control of CNC Machines in an IIoT World
IIOT SYSTEMS AND DEVICES are susceptible to cyber-attacks,
said Brad Klippstein, supervisor product specialist, Okuma America
Corp. (Charlotte, NC). “Plain and simple, hackers are trying to get user
IDs, passwords and financials or control of devices to deploy denial
of service attacks against other networks.” In an article by Heather
Johnson, Hartwig Inc., an Okuma distributor, Klippstein outlined
Okuma’s nine-point IT recommendations that its customers should
consider before connecting machine tools to their networks to guard
against malicious hackers gaining access:
1. When integrating firewall settings to the machine tool, consider dif-
ferent things about the device, such as what ports it will connect to and
what type of information packets will be sent or received. For instance, a
manufacturer could have all the machines use port 80 and have all other
devices use port 90, then set different rules for each port.
2. Keep all software patches current.
3. Change all default passwords on routers and managed switches.
4. Turn off automatic updates, and then only apply them individually.
Brad Klippstein
traces the reach
of machine tools
in the Okuma
Smart Factory
through digital
connectivity in an
IIoT manufacturing
environment at
IMTS 2018.
“If sensitive information such as employee records,
customer transactions or proprietary data are compromised,
the consequences to SMMs of a serious breach can be dev-
astating. There are reports that 60% of the SMMs that have
suffered a serious breach through cyber-attacks that result
in a substantial amount of downtime or loss of intellectual
property are out of business within a year,” said Forsyth.
“The FBI estimates that more than $400 billion in intellectual
property (IP) leaves our country every year.”
An essential first step in getting cybersecurity up to speed
is risk assessment and management, according to Forsyth.
“A company’s intellectual property has to be secured no
less than its physical plant is secured. First and foremost,
SMMs should have adequate backup systems in place.
Information and IP have to be filed away in a protected
area, and employees have to be trained in and have a clear
5. Put your CNCs on a Virtual Local Area Network (VLAN):
Manufacturers can lock down the equipment on a VLAN in a way that is
separate from your primary network. This prevents access to PLCs that
run many machine tool subsystems. These controllers might be easily
overlooked by IT, leading to software not being updated properly. This
software is more susceptible to viruses and should never have open
access to the Internet. Your VLAN also should have no access to the
public Internet.
6. Update older operating systems.
7. Manage connections to and from machines with a gateway. By
putting the machine on a gateway, with two interfaces acting like a
managed switch, the machine can remain on a network separate from
the employee network while also allowing the machine-monitoring
service to have real-time access to machine data. One network
interface communicates with the locked-down machine’s VLAN. The
other network interface communicates only with the machine-moni-
toring service. This protects the machines from communicating, even
indirectly, with anything but the monitoring service.
8. For wireless networks, use WPA (Wi-Fi protected access)
wireless encryption. Note that a wireless network should never be used
without encryption. While WEP (wireless encryption protocol) is easy to
hack, the newer alternative, WPA is not. However, given the right tools
and time, anything can be hacked. Therefore, any highly sensitive data
should never be accessible from a wireless connection.
9. Install a Windows anti-virus protection service.
December 2018 | AdvancedManufacturing.org 47
CYBERSECURITY
understanding of procedures. Finally, any threats that hit a
firewall have to be reported and acted upon, especially if a
change-out of an operating system is needed.”
The Up and Down Side of Connectivity
In the new Industry 4.0 environment, data and data
analysis are mission critical, according to Neil Desrosiers,
application engineer/developer MT Connect specialist,
Mazak Corp. (Florence, KY).
“The problem lies on the factory floor. Multi-million dollar
machine tools have to keep making parts for the company
to stay in business,” he said. “These aren’t $1,200 laptops
that can be isolated with the goal of protecting the office.
When management comes in and wants to connect all these
machine tools to the network for Industry 4.0 connectivity,
they are creating what I call a petri dish because now you
have these Windows 95, Windows 2000 and Windows XP
systems that are susceptible to infection or malware in play.
Viruses can easily propagate across all of the equipment in
the network and right now that is the biggest threat.”
Mazak’s SmartBox
has the capability of
isolating machines
with a VLAN on the
iSmart factory floor
while still enabling
connection with
clients off the shop
floor for Industry
4.0 connectivity.
The SmartBox
features a Layer 3
managed switch
developed by
Cisco for industrial
applications.
According to Desrosiers, two key requirements of cyber-
security are establishing connectivity and implementing
ways to standardize and transport data. The requirement
to standardize and securely transport data involves the
MTConnect standardized communications protocol.
MTConnect provides an industry-oriented data dictionary
and vocabulary that standardizes transfer of data across all
devices, enabling the data to be read and understood by
any piece of software.
MTConnect is read-only so it is functionally unable to
forcibly send data to the machine tool or alter parameters
that could cause the machine to crash or otherwise mal-
function, Desrosiers pointed out. Connectivity means getting
48 Manufacturing Engineering | December 2018
every machine and device on the shop floor connected to an
Ethernet network. Many machines on the shop floor already
communicate with each other via automation protocols such
as Profibus, OPC-UA and Ethernet I/P.
A Network Inside a Network
“Cybersecurity practices typically employ a layered
approach; a network is housed inside a network, which
itself is housed in another network,” said Desrosiers.
“Typically, data does not flow between the layers and the
aim is to stop intruders in one layer from moving to the
next. IT departments often sandbox the factory floor in
its own Virtual Local Area Network [VLAN] to separate
it from a corporation’s global network and the cloud. A
key reason for such strict security is that the shop floor
equipment typically features legacy operating systems
such as Windows 95 and Windows 2000 that are highly
vulnerable to viruses.”
Mazak’s cybersecurity answer was to team up with Cisco
to develop a solution that is scalable for Industry 4.0. The
resulting SmartBox allows the IT department to be responsi-
ble for the entire factory network and is something that the IT
department can recognize and understand.
According to Desrosiers, “The Smart Box has the
capability to isolate the machine with a VLAN while still
enabling connection with clients off the shop floor. The
central element of the Mazak SmartBox is a Layer 3
managed switch developed by Cisco for industrial appli-
cations. As a managed switch, it becomes part of the IT
department network and IT can connect to it and manage
it via Cisco software.
“The software enables IT to see Mazak SmartBoxes
on its network, control access to them, install or remove
applications and know which boxes need software updates
and other services,” he continued. “It also enables an IT
department to add features to the SmartBox, such as audit
functions and the ability to perform deep scanning of the
data packets for viruses, worms and other abnormalities.”
The SmartBox is an edge device, according to
Desrosiers. One edge of the network is the firewall that goes
out to the Internet. The other edge is the door between the
office and the factory. “What we want IT to do is push the
edge of the network right out to the machine tool, own that
network and make sure that network is secure because
the factory floor is its own isolated network,” he said. “The
SmartBox allows getting the edge of for cybersecurity that can be imple- Self-Assessment Tool is available
the network so close to the equipment mented by businesses of any size. The online, or by contacting the local MEP
that I can deploy apps specific to MEP National Network Cybersecurity Center by calling 800-MEP-4MFG.
a device and isolate and monitor
high-frequency data with sensors.”
An essential cybersecurity-related
microservice involves secure file
transfer (SFT), which is especially
important for sending confidential
24,000 EED
information such as a machining
N D L E SP
program to the shop floor. Desrosiers SPI
described how an SFT can be used:
An engineer would use SFT to transfer
an encrypted piece of intellectual
property from the design office over
the network directly and automatically
to the machine. In this way, SFT would
be valuable with helping manufactur-
ers with their Defense Acquisitions

MITSUBISHI–
Regulations Systems (DFARS)
compliance, a DoD regulation regard-
ing unclassified, on-premise technical

TRUSTED BRAND
information that must be managed
and protected from theft.
Other machine tool builders and

HIGH QUALITY PRODUCTS.

software companies are following
suit with their own unique black box
cybersecurity solutions.

How to Get Started

The National Institute of
Standards and Technology has
developed a practical framework
FYI
Mazak Corp.
859-342-1700 / www.mazakusa.com
MEP National Network
800-MEP-4MFG / www.nist.gov
Michigan Manufacturing
Technology Center
888-414-6682 / www.the-center.org
National Center for
Cybersecurity in Manufacturing
312-281-6900 / www.uilabs.org
Okuma America Corp.
704-588-7000 / www.okuma.com
Since 1979 MC Machinery Systems
has been providing high-quality products to the
North American Market. From our Mitsubishi EDM
and Laser products to our ultra precise Roku Roku
and Ingersoll products our commitment has always
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December 2018 | AdvancedManufacturing.org 49

METROLOGY
EYEBROW
Testing the
METAL
As metals and other materials get more complex, knowing what you are getting
from your supplier, or what you have in stock, is more important than ever
BRUCE MOREY
Contributing Editor
M
aterials science has
opened new possibilities
for designers of cars,
planes and other prod-
ucts. Metal alloys are now as precisely
engineered as they are machined.
The result is longer lasting, stronger
parts. But with a wider selection of
materials comes risk—how can you
be sure that one piece of gray metal
stock is different than another? Careful
warehousing procedures and paper-
work only go so far.
Checking incoming material is
getting even more important as
supply chains grow in search of The Vulcan handheld LIBS analyzer from
Hitachi High-Tech collects data in one
better pricing. second, according to the company. Data
“Companies are looking at the is downloaded via WiFi and comes with
an alloy library preloaded.
growing world market and realizing that
[there is sometimes a] different nomen-
clature for alloys,” explained James
Stachowiak, technical sales manager
for Thermo Fisher Scientific (Tewksbury,
MA). “Sometimes the alloy material they
are receiving isn’t meeting the engineer-
ing specification they require.”
To help eliminate risk, manufacturers
need to know the constituent elements
of metallic alloys in their inventory.
They need to know a piece of stock
December 2018 | AdvancedManufacturing.org 51
METROLOGY
The Thermo Fisher Scientific
Niton XL5 XRF analyzer is
equipped with a 5W X-ray
tube and a silicon drift
detector. It can detect
up to 81 elements non-
destructively in real-time.
Users may edit material
libraries and download data
via a USB connection. It
weighs 2.8 lb with battery.
is indeed 304 stainless and not 316 stainless—or out of
specification entirely. There is even a term for it: positive
material identification (PMI). Typical methods for PMI include
X-ray fluorescence (XRF), optical emission spectroscopy
(OES), and laser induced breakdown spectroscopy (LIBS).
If you think these are terms for bulky, cabinet sized
instruments relegated to laboratories, think again.
Miniaturization and faster computers have given manu-
facturers a number of flexible options for PMI as well. This is
especially true for the XRF class of handheld devices. These
use a miniature version of an X-ray source that is pointed at
a sample surface, injects an X-ray into the material and then
detects an induced fluorescence with an advanced solid-state
detector. Just like in optical spectrometry, the dispersion and
strength of the induced wavelengths that the device detects is
used to determine the elements in the piece.
“Twenty-five years ago, a portable XRF device weighed
25 pounds, used radioactive isotopes with costly replace-
ment cycles—every three to five years—and were much
slower, with lower precision and accuracy. Our latest Niton
XL5 instrument weighs under three pounds with near-lab
performance,” said Stachowiak.
Handhelds and Limitations
Thermo Fisher offers a number of different XRF analyzers,
depending on the applications and materials an end user
52 Manufacturing Engineering | December 2018
wants to measure. There are some limitations to any XRF
device. “The lighter elements in the periodic table, starting
with sodium and lighter, cannot be detected with a portable
XRF device,” he explained. This includes carbon, a crucial
component in many types of steel.
Performance depends on the detector. “There are two
kinds of detectors in the industry. The silicon PIN-diode
detector, which will detect titanium, atomic number 22 and
heavier elements, and the silicon drift detector (SDD), which
will detect key light elements, such as magnesium, aluminum,
silicon, phosphorus and sulfur,” he said. Although OES can
be used to analyze a wide range of alloys, it is a technique
typically used for steels, due to its ability to analyze carbon.
However, OES is not as portable or convenient as a
handheld XRF and often requires an operator to have a
higher level of expertise. Mobile OES units are typically much
larger and heavier, and the highest performing units are
indeed large instruments used in a laboratory environment.
“To detect carbon and lighter elements, they also require
sample preparation. You need to remove surface oxidation,
oil, dirt or anything else that might contaminate the surface of
the sample,” he said. OES does leave a small burn mark on
the sample, making it a destructive test. Thermo Fisher also
provides a range of such desktop or laboratory OES devices.
But that leaves wide open a large market for a portable
XRF solution. There are many specialty alloys that do not
require carbon analysis to determine The Vanta analyzer is Olympus’ LAN, Bluetooth and USB connections,
the grade, such as nickel, cobalt or flagship handheld XRF. Like many as well as an 800 × 400 WVGA
nickel/cobalt alloys, many grades of devices in its class, it features wireless display. Vanta analyzers provide alloy
stainless steel, brass/copper alloys,
titanium alloys or aluminum alloys.
These are expensive, high strength
alloys where misuse can cause
risk of failure. Making sure they are
correct is worth a test, especially if
the test is convenient.

Convenience, Simple Training

Dr. Michael Hull, applications
scientist for Olympus (Webster, TX)
believes, along with others inter-
viewed for this article, that their more
sophisticated customers are seeking
speed along with the convenience of
a handheld XRF device. “They want a Fully integrated precision
reading in two to five seconds, not 30
seconds,” he said. Today’s users are
examining a large volume of product
and speed is essential.
They also need a device that
operators with little training can use.
Today’s shop floor operators wear
many hats and becoming an expert in
X-ray spectroscopy might be asking a
bit much. “The interface needs to have
a very shallow learning curve,” he said.
“They need to set up with ease and
Higher volumes, shorter production periods and an ever-growing pressure to keep costs low. In
then lock it down so that the interface today’s aerospace industry, suppliers are encountering ever-increasing demands. Fortunately, with
cannot be accidentally altered by Walter Valenite, Walter Titex and Walter Prototyp, a solution’s at hand. As professional high-tech tools
and operating solutions developed by competence leaders, they yield valuable results throughout the
lower-level users.” That means simple, complete machining process. From an increase in productivity of up to 100%, highest machining
reliability and extremely long service lives to an innovative chipping process, minimal component
intuitive and reliable. costs and a broad range of applications – tailored to the specific needs of your business, of course.
Beyond that, data management This is how we define efficiency – fully integrated into our client’s processes.

is vital as well, especially where

manufacturers are using it in high
volume situations. “The user interface
needs to follow the general consumer
technology trends and look like an app
on a smartphone with a touch screen,”
he said. “It needs to be just as easy to
www.walter-tools.com/us
use. The data needs to be transferred
easily via wireless or a USB stick.”

December 2018 | AdvancedManufacturing.org 53

METROLOGY

composition chemistry and grade identification in as little as

one to two seconds for materials, according to the company.
The Vanta analyzer also collects down to magnesium in the
periodic table.
Handheld XRFs are starting to migrate from shipping,
receiving and warehousing to in-process manufacturing.
“However, as we move into [Industry 4.0] or smart manufac-
turing, we have lots of customers that are looking for in-line
or automated solutions,” explained Hull.
In response, Olympus offers the FOX-IQ in-line XRF
analyzer that is primarily for metal rod, tube and bar material.
The system is engineered to endure high levels of vibration,
electromagnetic and acoustical noise, dust and moisture.
It measures down to titanium elements and heavier on the
periodic table. Designed to operate 24/7, the FOX-IQ XRF
system performs fully automated, in-line analysis.
“It measures product that is relatively clean and consists
of fixed shapes and sizes,” Hull said. “This is in situations
where you already have equipment moving it down the
assembly line. The FOX-IQ is relatively easy to integrate,
with a probe head and shoebox-sized analyzer with an XRF
source and detector in that shoebox. You bolt that on in-line
with the existing rod tube bar analysis equipment.”

Other Tools, Other Applications

The advantages of an XRF device is clear to Mikko
Järvikivi, product business development manager,
HHXRF, LIBS and mobile OES for Hitachi High-Tech
Analytical Science (Westford, MA). “An XRF leaves no
mark, which means you can use it for finished goods and
where an unblemished surface is needed,” he said. This
ranges from medical implants to aircraft turbines. Hitachi
also offers an XRF, the X-MET8000, which also measures
down to magnesium. Handheld XRFs, such as the Olympus Vanta
analyzer, can be safely used in a shop
According to Järvikivi, there is a growing need for all environment. Makers like Olympus are intent on
types of analysis, especially metal grades that contain nickel, making them easy to use with easy data transfer.

chromium and molybdenum. “These materials are getting

more expensive, so if you examine the specifications of a
steel that requires 8-10% nickel, steel makers are providing
steels on the low-end of the specifications,” he explained.
Operating on the edge means it is easier to miss the recipe
by accident, making the material unfit for its purpose.
But what about those applications where the limitations
of XRF demand another solution, especially in measuring
carbon? “The ultimate performance tool is optical emission
spectroscopy (OES). We have several products in this range.
These can examine difficult elements in steel, including
carbon, hydrogen, phosphorus and sulfur. OES gives you
by far the most accurate reading,” he said. “Carbon affects
most properties of steel, especially weldability.” However,
using an OES to measure a sample requires some tradeoffs.
OES requires an electrical spark to induce spectrometry,
leaving a burn mark on the sample. OES systems are also

54 Manufacturing Engineering | December 2018

 Olympus offers the FOX-IQ in-line
XRF analyzer, aimed at classifying
rod, tube and bar metals material in a
production setting. It is an automated
analyzer designed to easily integrate
into production systems.
heavier, though Hitachi High-Tech has responded with a
human transportable unit that weighs about 30 lb.
Hitachi High-Tech also offers a handheld LIBS unit
with its Vulcan units. “LIBS is very fast; you squeeze the
trigger and you can identify a metal in one second,” said
Järvikivi. While a laboratory grade LIBS unit is accurate
enough to detect lighter elements, the handheld LIBS unit
Hitachi offers can grade stainless steels, low-alloy steels,
tool steels and nickel alloys, with an option for cobalt,
copper, lead, tin, titanium, zinc, aluminum, and magnesium
alloys. LIBS also leaves a small mark on the surface of the
sample. “We think a handheld LIBS is ideal for 100% PMI of
incoming material,” he said.
Coatings Analysis
Coatings analysis is just as important as bulk PMI since
many engineered parts are coated with different materials
to improve their performance. Hitachi High-Tech offers two
technologies for coatings analysis. XRF analyzes coating
thickness and composition. The other method, electro-
magnetism, measures thickness, according to Matt Kreiner,
product business development manager of coatings analysis
for Hitachi High-Tech Analytical Science.
“XRF is used primarily to measure metal or metallic plating
in the range of nanometers and micrometers applied to
various substrates, including metals, plastics and ceramics,”
he said. The electromagnetic thickness gages use either
magnetic induction or eddy current techniques to measure
organic coatings such as paint and resin, as well as anod-
ized layers in the range of micrometers and millimeters on
metal substrates.
“Coating a material can improve the part’s corrosion
resistance, heat resistance, wear resistance or electrical
contact,” said Stachowiak from Thermo Fisher. “A handheld
XRF can save manufacturers a lot of money, for example, if
they are applying too much or too little of a specified coating
over their materials. Using too much of a coating increases
material costs, where using too little could affect the desired
performance or life of their products.”
Automotive manufacturing and the aerospace segment
in particular are adding more coatings to their repertoire
of materials, making non-destructive coatings analysis on
the manufacturing line increasingly important. According
to Stachowiak, Thermo Fisher’s handheld XRF devices are
easily calibrated for a wide range of coatings applications.
While coatings may be thin, precisely controlling that
thickness determines both cost and fitness for purpose,
according to Robert Weber product manager for Fischer
Technology (Windsor, CT). “Chrome plating, for example,
needs to be thick enough to withstand wear but not too
thick, both because you might be wasting material and
also because it might not fit in its assembly,” he said. Many
suppliers are now being required to certify the thickness
and alloy content of their coatings, especially in automotive,
according to Weber. This makes them responsible if
anything is amiss.
The advantage in using a handheld XRF for coatings
identification is that most coatings tend to be made of the
heavier elements, he said. Fischer Technology’s XAN500 XRF
device measures elements including titanium and heavier on
the periodic table, according to Weber, which includes typical
plating alloys containing chromium, nickel, copper and zinc.
December 2018 | AdvancedManufacturing.org 55
METROLOGY
“The fundamental parameter
approach determines elements and
calculates thicknesses,” he said. “The
Scientific Cutting Tools
New Helical
Chamfer Mills
60º, 90º, and 120º included angles
A Global Name in Cutting Tools
1.805.584.9495 www.sct-usa.com
1.800.383.2244 sales@sct-usa.com
Complimentary technical assistance is available.
Asistencia técnica disponible en español.
56 Manufacturing Engineering | December 2018
XAN500 does not need a preloaded alloys and thicknesses and does not
library of materials.” This means the need a return-to-factory representative
XAN500 measures a wider range of to create new library entries.
“An important coating for auto-
motive and aerospace applications
is zinc-nickel, a replacement for
cadmium, once widely used but now
recognized as toxic,” Weber said.
He noted that Fischer Technology’s
XAN500 handheld XRF can both detect
the thickness as well as the precise
elemental make-up of the coating,
both of which manufacturers need to
know. An additional advantage of using
a handheld XRF is that it can measure
larger parts that might not fit into the
cabinet of benchtop XRF (or OES or
LIBS) systems.
The XAN500 can be mounted in
a measurement box and become
a desktop unit, allowing precise,
repeatable measurements on small
parts like nuts and bolts. It can also be
integrated into the control system of
a production line for 100% inspection
and monitoring, though Weber noted
that this is not yet a common appli-
cation of the benchtop adaptation.
Nevertheless, he sees automation as
the future, both in general and for PMI
and coatings analysis in particular.
“We are starting to mount our units
THREAD MILLS onto six-axis robots for measurements
SINGLE POINT in-process in some specialized
PORT TOOLS industries,” he said.
CAVITY TOOLS
SPECIALTY
INDEXABLE BORING
FYI
Fischer Technology
978-670-7460 / www.fischer-technology.com
Hitachi High-Tech Analytical Science America Inc.
978-850-5580 / www.hitachi-hightech.com/hha
Thermo Fisher Scientific
815-284-0228 / www.thermofisher.com
See the Tool in Action Olympus
800-225-8330 / www.olympus-ims.com
 PRODUCT PREVIEWS
NEW TECHNOLOGY FOR MANUFACTURERS

CNC Lathe for Large Parts vertical pallet storage for

The new Multus U5000 is a two-saddle CNC lathe that
has a sturdy platform for machining large, process intensive
parts, providing a complete multitasking solution. Flexible
CNC machining is
achieved with a rigid
traveling column that
allows for cutting
along the entire Y axis.
Larger bed lengths,
sub-spindle and lower
turret configurations are available to provide solutions that
match application requirements. According to the company,
the lathe also offers maximum milling or turning performance,
thermal protection, and a OSP-P300SA controller that
reduces keyboard operations by 50% and maximizes uptime
with its collision avoidance system.
Okuma America Corp.
704-588-7000 / www.okuma.com/americas
Virtual Machining CAM Technology
The newest capabilities of hyperMILL CAM software
include virtual machining simulation as well as greater blending
capabilities, 3D-optimized roughing and finishing, global fitting
and rotational abilities for
CAD electrode applica-
tions. Developed with
Industry 4.0 standards
in mind, hyperMILL
Virtual Machining enables
constant real-time bi-di-
rectional communication
between the machine tool
controller and a remote hyperMILL Virtual Machining simula-
tion. For reduced programming time and improved milling, new
functions include hyperMILL for 3D Z-level Shape Finishing
and an automatic face extension capability can be used during
programming to extend the selected milling surfaces.
Open Mind Technologies USA Inc.
339-225-4557 / www.openmind-tech.com
Multi-Spindle Machine Tools
Work cells feature multi-spindle, five-axis machine tools
as well as integrated robotic loading and unloading, plus
workpiece blanks and
finished parts. These
plug-and-play manu-
facturing cells consist of
dual-spindle SW BA 222
or BA WO2-22 machin-
ing centers together with
integrated six-axis robot
for loading and unloading and vertical pallet storage unit for
blanks and finished parts. The SW cells are a crane-hook
system for straightforward installation and setup. The robot
is mounted overhead for increased freedom of motion and
the pallet storage unit is set off to the side, allowing manual
loading and unloading.
SW North America Inc.
734-736-4027 / www.sw-machines.de/en.html
Thread Former Features New Geometry
The TC420 Supreme thread former features a new
substrate and polygon geometry that provides better forming
behavior, less friction and longer tool life, the company says.
In addition, its polished surface yields a better surface finish
than is achieved
with thread cut-
ting. According
to the company,
this combina-
tion of features allows the thread former to achieve longer
tool life by producing up to 30% lower torque with higher
cutting speeds. Variants in the TC420 Supreme product
range include coolant configurations, thread tolerance,
chamfer forms and overall lengths. The thread former is
suited for most ISO material groups.
Walter USA LLC
800-945-5554 / www.walter-tools.com
Ceramic End Mills for HRSA Machining
The brazed ceramic CoroMill 316 and ceramic CoroMill
Plura end mills are optimized for machining nickel-based
heat-resistant super alloys (HRSAs). It is available in a
six-flute geometry that the company says delivers productive
side milling operations, while a four-flute geometry boosts
face milling in both the CoroMill 316 and CoroMill Plura

December 2018 | AdvancedManufacturing.org 57

PRODUCT PREVIEWS

versions. The 7/16-20UNF. The unit is suited for use on horizontal machin-
CoroMill 316 ing centers or in applications where external coolant cannot
is suited for wash the chips away.
difficult-to-reach Carmex Precision Tools LLC
applications while 888-628-5030 / www.carmexusa.com
the CoroMill Plura offers superior stability. The end mills can
also be used for pocket milling, helical interpolation, ramping Hybrid Press Brake
and slot milling. The CoroMill 316 series includes a ceramic A 150-ton, hybrid press brake line features servo-motor
ball-nose version for blisk machining. pump technology. The new drive, available on the company’s
Sandvik Coromant line of hydraulic and electric press brakes, runs during the
800-726-3845 / www.sandvik.coromant.com working portion of the
stroke, conserving energy
Collet Adapters Offer Low Tool Runout while the ram is stationary.
The PremierPlus Collet Adapter provides consistent and It requires less than 30
repeatable tool runout of ≤ 7 microns during production runs, gallons of fire resistant,
according to the company. Operators can adjust the collet biodegradable hydraulic
via adjustment screws. fluid. It operates at a ram
The clamp force is pre- speed of 550 ipm, has
set when the clamping precision ram repeatability
mechanism inside the of ±0.0002" (0.00508 mm), a 14" (355.6 mm) stroke, and
adaptor is preloaded 21" (533.4 mm) workpiece opening. Other features include
so the operator does an ergonomic sliding overhead control arm, protective
not need to remove the cylinder covers, and side and rear guards.
adaptor from the machine to change the collet. With three Cincinnati Inc.
times greater clamping force, achieved via a hydraulic pres- 513-367-7100 / www.e-ci.com
sure intensifier, tools are held more securely when grinding.
The company says that this increases the tool geometry Expanded Line of Micro End Mills
across a batch of tools. An expanded line of micro end mill tools now includes
ANCA CNC Machines two-, three- and four-flute designs, and a long-reach dimen-
613-9751 8308 / www.anca.com sion. The two-flute design, which has a reach dimension up
to 12XD, has wide
Mini Mill for Deep-Thread Applications flute spacing and is
The MTSB mini mill-thread, designed for small and deep suited for long reach
thread applications, is equipped with coolant bores that applications in soft-
facilitate chip removal when using high-pressure coolant. er-to-mill materials
According to the company, the solid-carbide construction like plastics. The
three-flute design
for long-reach
roughing appli-
cations has a reach dimension up to 25XD. The four-flute
and advanced PVD triple coating allows the mill to work design maintains a heavier core for maximum rigidity and for
at high machining parameters for increased productivity. long-reach finishing applications. The reach dimension on the
An increased number of flutes shorten cycle times and, four-flute design ranges up to 12XD.
combined with coolant, improve tool life, the company Kyocera SGS Precision Tools Inc.
says. Thread sizes range from M1.2 to M16 and 0-80 to 330-686-5700 / www.kyocera-sgstool.com

58 Manufacturing Engineering | December 2018

Cabinet Oven Holds Large Parts
The No. 903 is a 650°F (343°C)
cabinet oven that holds large parts
on rollout shelves. The oven’s
workspace dimensions are 38" x
38" x 38" (965.2 mm x 965.2 mm x
965.2 mm). It features 40 kW Incoloy
sheathed tubular heating elements,
while a 1000 CFM, 1-hp recirculating
blower provides horizontal airflow to
the workload. This Grieve cabinet
oven has 6" (152.4 mm) insulated
walls and an aluminized steel exterior.
Features include Type 430 stainless
steel interior and two rollout shelves,
each measuring 28" x 37" (711.2 mm
x 939.8 mm) and rated at 150 lb.
The Grieve Corp.
847-546-8225 / www.grievecorp.com
Arc Welding Robot
The BA006L is a compact arc
welding robot with hollow wrist and
increased reach
for welding large
workpieces. The
6 kg payload
model has a reach
of 2,036 mm.
Space and cable
utilization has
been improved.
For instance, the
45 mm ID of the
robot’s hollow wrist structure allows for bending and equipment interference
through-arm cabling and is compatible while allowing joint six to operate at
with torch equipment cabling needs. higher speeds. The system is equipped
Wire feeders are placed to minimize with arc welding software and features
The Ultimate CNC
Combination Lathes
Large Capacity Models Available with up to 30" Swing and 240" Centers
MR Series shown with optional 8 Station Automatic Bi-Directional Indexing Disc Turret
The Perfect Machine for Most of Today’s
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Clausing/MultiTurn XS Series: The XS series Clausing/MultiTurn MR Series:
features the Fanuc Oi control with ‘Manual Guide i’ Equipped with the FAGOR CNC Control.
programming allowing the operator to generate This user-friendly control offers both
part programs quickly and efficiently through the Icon-Key based conversational
use of easy-to-understand conversational style programming or Conventional ISO G-code
cycle prompts. Fanuc Oi control package comes programming. The extensive use of
with all digital control and drives offering exception- graphics at the display means that even
al value and reliability. With the change of a key complex machining tasks are accomplished
switch you access the exclusive Harrison Alpha and set-up time is minimized for both
control making one step programing an easy task. experienced and beginner operators.
The extensive list of machine features include: Anti-friction PTFE material between saddle and
bed for greatly improved surface finish • Heavy-duty cast iron hardened and ground bed ways
• Triangular web bed design CNC1000/2000/3000/4000 models • Extra wide bed maximizes
support for saddle and cross slide assembly • Variable AC spindle drive motor • Automatic three
range headstock • Superior headstock positive flow lubrication system • Automatic oil system to
guide ways & ballscrews • Digital AC servo drive system • Fully enclosed, interlocking guarding
(optional on CNC4000/120 models) and much more...
Available in models with: 13", 15", 18", 21", 26", 30" swings up to 240" between centers
Call 800-323-0972 for the Clausing Dealer Nearest You
or visit www.clausing-industrial.com
for detailed catalogs of the full line of Clausing Machine Tools
Over A Century in the Machine Tool Business
December 2018 | AdvancedManufacturing.org 59
PRODUCT PREVIEWS

adaptive welding functionality to modify the robot’s position, Multi-Axis Horizontal Machining Centers
weave pattern and speed. The Meteor series of twin-spindle, four- and five-axis
Kawasaki Robotics (USA) Inc. horizontal machining centers is engineered to produce
248-446-4100 / KawasakiRobotics.com aluminum automotive components, including structural
parts and components for internal combustion and electric
Multisensor Metrology System cars. The Meteor
The Fusion 350 multisensor metrology system combines TS630V allows the user
a large field of view optical system with touch probe, laser to adjust the distance
and micro-sensors to perform 2D between spindles. The
measurement of large parts or machining center can be
groups of small parts. It has a 450 programmed to process
x 450 mm measuring area and two identical parts,
dual magnification optics. Its large perform two operations
field optical system allows high on the same part, or simultaneously machine two different
accuracy imaging of a wide area of parts. The adjustment range is 21.4" to 71" (544 mm to
up to 100 mm and image analysis 1,803 mm). The X-axis travel is 24.8" to 51.1" (630 mm to
software processes and identifies 1,298 mm), with Y-axis and Z-axis travel of 24.8" (630 mm).
features and dimensions within the Absolute Machine Tools
field of view. AutoID and Feature 800-852-7825 / absolutemachine.com
Extraction identify and instantly measure single or multiple
parts. Laser and touch trigger probes are available. Power Chuck for Turning Center Spindles
Quality Vision International The Duro-A RC power chuck features a jaw-change
585-544-0450 / www.qvii.com system that allows the jaws to be adjusted, reversed or
swapped out in 50 seconds. The power chuck’s billet
Digital Force Gage with High-Resolution Display steel body has a compact,
The DFC and DFG Series of digital handheld force gages lightweight design and this
features a high-resolution OLED color backlit display and construction helps the chuck
auto-off function. A primary and secondary window shows keep up with the increased
test results, and rotational spindle speeds and
out-of-tolerance acceleration/deceleration
results are promi- rates that are standard on
nently displayed in current turning centers. The
red. A multi-func- Duro-A RC boasts centrifugal
tion keypad has force compensation that
programmable allows for fast feeds and speeds, as well as power savings
softkeys. up to 17%, the company says. An interchangeable back
Adjustable sam- plate makes it adaptable to a range of lathe spindles.
pling rates capture RÖHM Products of America
peak loads, and filters can be applied to peak and display 770-963-8440 / www.rohm-products.com
values. The DFC has a measurement accuracy of 0.1% full
scale with internal data sampling at 25 KHz. The DFG is Hydraulic Chucks for Swiss Lathes
a basic force gage that measures force at an accuracy of Fast changeout is a benefit of hydraulic chucks for Swiss
better than 0.2% full scale. lathes. The chucks use a hex wrench that requires two to
The L.S. Starrett Co. three turns to clamp and unclamp the tool on a gang slide.
978-249-3551 / www.starrett.com After a hydro-chuck is centered, runout will not vary, even

60 Manufacturing Engineering | December 2018

 CLASSIFIEDS
be achieved. The hydraulic chucks
PRODUCTS/SERVICES
have a clamping range of 4 to 8 mm in
diameter. The chucks have a standard
pipe thread for coolant-through
connection and are available for most
Citizen and Star machines with ¾"
(19mm) or 22 mm straight shank.
after repeated tool changes. Runout of BIG Kaiser Precision Tooling Inc.
fewer than three microns at 4XD can 224-770-2999 / www.bigkaiser.com

AD INDEX
Autoquip Corp, 29 Mastercam/CNC Software Inc, 41

Clausing Industrial Inc, 59 Methods Machine Tools Inc, 5

Doosan Machine Tools, 1 Mitsubishi Materials USA Corp, 9

OIL MIST & SMOKE
IN YOUR SHOP?
Enterprise Florida, 25 Newcomb Spring Corp, 42
www.mistcollectors.com
Epicor Software Corp, Cover 3 Promess Inc, 7 Tel: 1-800-645-4174
Greenleaf Corp, 22, 23 Renishaw Inc, 21

HORN USA Inc, 17 Royal Products, 43

HOUSTEX, 45 SME Corporate, 33

Hurco North America, 13 Sanborn Technologies, 46 Your Ad Here

Iscar Metals Inc, Cover 2 Scientific Cutting Tools Inc, 56
call Tim Simpson
J.W. Done, 36 Tapmatic Corp, Cover 4
at 313-425-3040
LEWCO Inc, 39 Walter USA LLC, 53

MC Machinery Systems Inc, 49

1000 Town Center, Suite 1910, Southfield, MI 48075
Phone: 313-425-3479 / Fax: 313-425-3417
Dave O’Neil–Vice President This Index to Advertisers is published as a reader service.
Direct Line: 313 425-3260 Although every effort is taken to assure accurate listing,
E-Mail: doneil@sme.org no allowances will be made for error or omission.
TO PLACE:
Employment, service, new and used
equipment, rebuilding, parts & service,
scrap metal, agents, business listings,
consultants and general admission.

EASTERN WESTERN CONTACT:

Leslee Faulkner Paul Semple Tim Simpson
1000 Town Center, Suite 1910 2170 Red Setter Rd. 1000 Town Center
Rocklin, CA 95765 Suite 1910
Southfield, MI 48075
Southfield, MI 48075
Phone: 313-425-3268 Phone: 916-880-5225
Phone: 313-425-3040
E-Mail: lfaulkner@sme.org E-Mail: paul@semplemedia.com Email: tsimpson@sme.org
MIDEAST (Detroit) CHINA, HONG KONG, TAIWAN Email: advertising@sme.org
Dean Dimitrieski Bruno Wase-Bailey
1000 Town Center, Suite 1910 Industrial Communications Group Ltd RATES:
Southfield, MI 48075 E-Mail: bruno@icgl.com.hk Line Ad. Per line $35 (minimum
Phone: 313-268-0597 www.ChinaEngineeringMedia.com 5 lines, 7 words per line avg.)
No agency commission.
E-Mail: ddimitrieski@sme.org
CENTRAL (Chicago) Display ad per inch:
Bill Lepke 1x: $195 6x: $180 12x: $165
529 Fairview (maximum 2")
Elmhurst, IL 60126 Color available, please inquire.
Phone: 630-975-0185
E-Mail: lepkeb@sbcglobal.net No agency commission.

MANUFACTURING ENGINEERING® December, 2018, Vol. 161, No. 7 registered in the US Patent and Trademark Office Display Ad Units.
(ISSN 0361-0853, USPS 011-770) is published 14 times annually, monthly, plus two extra issues in Spring and Fall, by SME, (Same as publications rates)
1000 Town Center, Suite 1910, Southfield, MI 48075. Telephone: 313-425-3000. Fax: 313-425-3417. Subscriptions: 2018 Agency commission allowed
domestic subscription rate is $140.00. For Overseas subscriptions special postage rates may apply. Periodical postage paid to recognized agencies.
at Southfield, MI, and additional mailing offices. Canada Post Publication Mail Sales Agreement No. 40732015. Postmaster:
Send address changes to Attn: CDC, Manufacturing Engineering®, 1000 Town Center, Suite 1910, Southfield, MI 48075.
Payment in advance on all listings.

December 2018 | AdvancedManufacturing.org 61

WORKFORCE PIPELINE
PERSPECTIVES ON WORKFORCE DEVELOPMENT
CWP Targets Training, Development and Marketing
to Help Build Connecticut’s Manufacturing Workforce
CAPITAL WORKFORCE PARTNERS (CWP) is the
regional workforce development board in North
Central Connecticut; our objective is to help
individuals overcome barriers to employment and
build the necessary skill sets to meet business
hiring needs.
Through the American Job Center network,
CWP invests in youth development, develops
sustainable career pathways for adult workers
and assists employers, all with a focus on our
sector initiatives: manufacturing, healthcare and
construction. Through labor market information
studies, we project thousands of new openings
over the next few years in manufacturing due to
economic growth and an aging workforce. Our
motto is “Find, Retain, Grow.”
Manufacturing has long been a robust part
of Connecticut’s economy. The Hartford region,
home to Pratt and Whitney and Sikorsky, is known
as the “Knowledge Corridor” or “Aerospace
TIMOTHY J.
BLONSKY
Alley.” Connecticut has hundreds of supply chain
Advanced manufacturers for larger regional companies,
Manufacturing
Coordinator,
accounting for over 169,000 manufacturing
Capital Workforce employees statewide, including 50,000 in the
Partners
North Central region alone. Nearly a third of the
manufacturing workforce is close to retirement
age and will take with them upwards of 30 years
of experience, leaving a need for new skilled
workers to take their place.
One of the tasks of workforce development
boards is to bring partners together to address
workforce needs. Here are some examples:
Education Partners
In 2012, with the aerospace industry
growing, Connecticut focused on revamping its
manufacturing education centers within several
community colleges around the state, creating
seven advanced manufacturing technology cen-
ters. In the North Central region, we worked with
62 Manufacturing Engineering | December 2018
Asnuntuck Community College and Manchester
Community College to recruit advanced manufac-
turing cohorts for short-term (six to 12 months)
training in areas such as CNC machining, 3D
printing, welding and quality control. We also
partner with Goodwin College, a private school,
which houses its manufacturing center in a former
Pratt and Whitney facility. Through our American
Job Center network, we provide hundreds of
scholarships annually through the Workforce
Innovation and Opportunity Act (WIOA).
These programs provide placement rates
above 90%, generally in well-paying jobs. We also
educate the general public about manufacturing
jobs and the credentials needed to secure them.
We opened a new American Job Center in the
Asnuntuck Community College building and will
soon be announcing another center located at
the Tunxis Community College satellite campus in
Bristol. Tunxis is opening an advanced manufac-
turing technology center this fall.
In East Hartford, CWP is working with Synergy
Alternative High School through our lead partner,
the Connecticut Center for Advanced Technology
(CCAT), to introduce high school students
to pre-apprenticeship education via CCAT’s
Manufacturing Education Center. The successful
program includes Tooling U-SME courses and
works with employers to provide 72 hours of
hands on experience. In these partnerships, we
are tweaking the paradigm of post-secondary
education to a model in which the general public
can take part in short-term training and continue
their education while working, thereby not
incurring college-related debt.
Manufacturing Partners
Our partners at CCAT serve as the manufactur-
ing sector intermediary to the Workforce Solutions
Collaborative of Metro Hartford and work with CWP

to convene quarterly Advanced Manufacturers Employers
Partnership (AMEP) meetings. AMEP is an employer-led
partnership that identifies alternative ways to build the manu-
facturing talent pipeline. Each meeting includes speakers on
topics such as apprenticeships, manufacturing innovation and
workforce forecasting. In 2017, AMEP spent several months
holding bi-weekly meetings to develop a strategic initiative.
Through this plan, AMEP will work to:
Establish a one-stop clearing house for manufactur-
ers in recruitment, retention and training. The workforce
development system can be confusing for employers; we are
eliminating the confusion by giving all regional employers one
point of contact to resolve issues or connect the employer
with the appropriate resource.
Assist employers with the recruitment process.
We do this by investigating employer time for hiring and
establishing baseline metrics. We are working to establish a
universal pre-training program (foundational technical skills)
as well as a pre-screening process. We also coordinate
regular career fairs with several manufacturing education
entities in our region. Additionally, we are helping to create a
manufacturing industry marketing plan to help area employ-
ers understand the importance of effectively marketing their
companies to potential workers.
Assist with employee retention. Employers need to
better understand how to retain employees. CWP started
by distributing a survey (which had a 30% response rate)
to hundreds of manufacturing companies. We asked
questions such as why people leave jobs, turnover rates,
etc. Through these findings, we hope to establish career
paths and/or succession rates, determine incumbent
worker training needs, and prepare an employer toolkit on
incumbent worker training.
These three initiatives will be addressed by represen-
tatives from several small and medium-sized employers
Phoenix Manufacturing Inc. (Enfield, CT) works with CWP
on various projects. The company supplies component
parts for aerospace industry companies such as United
Technologies, Parker and General Dynamics.
as well as large firms like Pratt and Whitney, a division of
United Technologies.
Funding for On the Job Training
Through various grants and initiatives, we have worked
with hundreds of manufacturing companies to help them
utilize funding intended to help cover the training costs
associated with new hires. Through programs like StepUp, a
state program that provides a $12,500 wage reimbursement
over a six-month period, as well as the National Emergency
Grant, we have dispersed over $1 million in wage incentives
to employers to hire unemployed individuals.
For the most part, these incentives are designed for
firms with fewer than one hundred employees. Our manu-
facturing partners continually express appreciation for the
area’s workforce development system’s focus on the need
for these incentives.
Moreover, Connecticut recently passed a legislative initia-
tive called the “Apprenticeship Connecticut Initiative,” which
will provide up to $50 million to help cover tuition costs for up
to 10,000 people in the state. Most of these funds, if bonded,
will have a manufacturing focus and CWP will make a major
push to market the potential careers to the general public. This
funding will also have a wage incentive and an apprenticeship
training component at employer work sites. Jim Boucher, our
chief strategy officer, was recently interviewed by the Hartford
Business Journal about this subject.
Workforce needs have been a key focus for CWP, the
consortium of public officials and private business leaders
on our board and area legislators. While no one program
or partnership will resolve every workforce need, we are
confident that a proactive approach to current and projected
needs will help staff our local aerospace industry and help
thousands of residents get the skills they need for good
paying, middle-skill jobs.
December 2018 | AdvancedManufacturing.org 63
VIEWPOINTS
OPINION, ANALYSIS AND IDEAS
Securing the Edge of the Network
AS IIOT-ENABLED DEVICES usher in a new era
of connected factory floors, manufacturers must
protect critical equipment at the edge of their
production networks. Companies are rapidly
investing in edge computing, which enables data
and analytics gathering at the source, pushing
computing applications, data and services away
from centralized locations. While managing oper-
ational technology (OT), security has traditionally
been a major organizational headache, innovation
in manufacturing has helped establish a go-to set
of best practices for securing the edge.
Security risks often involve hacking attempts
and data theft, but the bigger risk for many man-
ufacturers can be less sensational issues, such
as decreased system performance or improperly
functioning devices. As IIoT devices proliferate
across the supply chain, one device losing its
integrity can lead to production problems.
That is why we are seeing more and more cus-
tomers deploying cybersecurity solutions for edge
JASON
ANDERSEN,
compute devices. Solutions like these can provide
Vice President, an additional line of defense to ensure smooth,
Business Line
Management,
reliable production processes. On-premise
Stratus Technologies computers can analyze security anomalies in real-
www.stratus.com
time, providing knowledge to staff who are in the
best position to address complications and keep
systems running. Insights from the edge can help
OT and IT teams identify and react to anomalies
in system performance, whether from malware
attacks or improperly functioning devices.
Manufacturers now view the deployment of OT
security software at the edge as an established
best practice. First, edge computing can make
OT security programs more effective. Locating
protection resources as close to critical data as
possible minimizes the time required for software
programs to register, analyze and address security
risks. Also, deploying OT security software at the
edge can be particularly useful for complicated
64 Manufacturing Engineering | December 2018
manufacturing environments. Security at the edge
is critical for manufacturers that introduce IIoT
devices. IT staff at these firms may not be able
to immediately secure each endpoint device, so
dedicating an edge computer to provide a degree
of umbrella protection from potential anomalies
can establish a vital line of defense.
Must-Haves for Edge Security
Despite the benefits, OT teams must
understand that there is a set of standard best
practices that often need to precede using these
security tools. Undeniably, software is the bedrock
of effective edge computing. The top security
risk in most edge deployments is obsolete or
outdated software applications and infrastructure.
Before implementing more complicated security
strategies and applications for edge deployments,
OT teams should ensure all edge devices have
up-to-date software. Otherwise, software integra-
tions may hamper or even defeat the purpose of
the larger solution. OT teams should move at a
comfortable pace and schedule regular software
updates over longer time frames.
Physical security is another edge security con-
sideration. While old-school physical attacks may
seem relatively harmless compared to malware
attacks and hacking attempts, companies must
consider physical risks as much as digital risks.
The good news is that many top-edge computing
solutions maximize physical security. For example,
some of the biggest industrial security issues in
recent times could have been prevented just by
locking the cabinet or the USB port.
Rapid innovation in IIoT and edge computing
presents both new risks and new opportunities
for manufacturers. Thankfully, best practices are
emerging that utilize the unique capabilities of
edge computing for individual devices, manufac-
turing environments and entire networks.
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