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It’s getting harder to imagine any market that isn’t benefiting from the latest developments in parts manufactured from advanced composites. “Advanced composites will arguably dominate consumer and production products, especially in the near future,” says Bert Erdel, industry consultant and executive technology advisor, Morris Group Inc. (Windsor, CT), “as they have begun to gain wide acceptance in solving energy-related issues.”

The machining challenges for two of the most advanced concepts in cutting tool materials are pretty well known. Cubic boron nitride (CBN) tools of varying designs are being used to cut hardened ferrous metals with or without interrupted cuts, as well as welded and clad metals.

Machining composites presents unique challenges compared to metals. Reinforcement fibers are abrasive, shortening tool life. The plastic matrix carries away little heat, unlike metal chips, and overheating can melt the matrix.

Advanced materials for automotive manufacturing are helping automakers build lighter, more fuel-efficient vehicles.

Composites engineers are expanding their craft to build more complex, durable parts at higher production volumes. One way they are achieving this objective is by using infusion-molding processes based on Resin Transfer Molding (RTM) and Vacuum Assisted Resin Transfer Molding (VARTM).

Many industries have been making parts with micron dimensions for some time, but in the last few years, the market for miniaturization has expanded. The demand is not only for small parts, but also for small complex features on larger parts. This is due chiefly to the switch to modules in which the functions of several parts or subsystems are not handled by a single complex unit.

Off-line programming software tools for CMMs allow manufacturers to increase measurement capacity and throughput by programming CMMs, probes, and fixtures before parts are made.

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For global automakers, removing weight from their vehicles remains the top priority as they seek ways to meet a stringent federal fuel economy mandate by 2025 and other new pollution-control regulations.

Nanodiamond material specialist Carbodeon of Finland has worked with metal finishing specialist CCT Plating of Germany, to develop a new electroless nickel, PTFE and nanodiamond composite coating.