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As the momentum to go green continues to build across the globe, the number of environmental regulations for reducing hazardous substances keeps growing. At the same time, more and more customers are now setting their own environmental requirements, adding more complexity to the mix.

When considering a new robotic automation system, one of the biggest concerns can be the weight of the initial costs. While such a large capital expense may be hard to swallow at first, it’s industry-proven that manufacturers see an average ROI of 24 months from robots.

Automotive manufacturers and their Tier One suppliers spend endless engineering hours developing the PAB (passenger airbag) system, from the airbag and its propellant to the construction of the materials used in the composite instrument panel.

With the September issue, Smart Manufacturing introduces Collective Intelligence, a new initiative under which we gather experts in one room to go deep on one important topic. We focused this first roundtable on the intractable problem of the workforce skills gap.

Materials science has opened new possibilities for designers of cars, planes and other products. 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 paperwork only go so far.

Titanium, stainless steel, aluminum and other super-alloys and exotic materials are on the rise for use in component manufacturing in growth industries such as aerospace, medical, and automotive.

New systems, software and processes are replacing so-called islands of automation with seamless, automated manufacturing lines that boost overall equipment effectiveness (OEE) from 30 to 80% or more. Like a chess master, these systems think multiple moves ahead on the factory floor to ensure continuing production when circumstances change.

The next “dynamic duo” may not involve humans at all. “Machine vision and robots make for a perfect marriage,” stated Klas Bengtsson, global product manager, vision systems for ABB Robotics (Auburn Hills, MI). This is not new. Vision and robotics have gone hand in hand for years.

The University of Illinois at Urbana-Champaign (UIUC; Urbana, IL) has a long, distinguished history and tradition in mechanical and applied engineering sciences, and the university will soon celebrate the opening of a long-planned, multi-million-dollar expansion to its Mechanical Science and Engineering (MechSE) building.

Tony Hemmelgarn, CEO, offers free subscriptions to learning memberships, limited time licenses in key software offerings for workers and students.