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In the aerospace world, as in all sectors of manufacturing, the race is on for faster, more automated and connected machining operations. Aerospace builders have steadily pushed for more automotive-like automation over the past several years in order to improve productivity and more effectively handle large order backlogs in commercial aviation.

As inventive and imaginative as 3D printer technology is, so are the materials that R&D labs have come up with to build parts, including conductive thermoplastics.

Nothing seems so obvious in subtractive machining than that milling and turning processes really are very different: single point vs. multipoint tools; rotating workpiece vs. rotating tool; static tool vs. rotating tool, etc.

In an automobile engine, seven types of screws out of approximately 70 are considered critical to achieving the engine’s specified design performance, despite high vibration and heat. The seven include bolts for the cylinder head, crankshaft, con rod, flywheel, and main bearing cap, as well as for the camshaft cap, camshaft sprocket and VCT.

New work materials are developed continually to improve the capabilities of finished parts, making them lighter and stronger, among other properties. When these materials catch on, cutting tools must adapt to their often challenging properties.

Scientists at Rice University (Houston) are smashing tiny silver cubes into a hard target in order to make these metallic microcubes ultrastrong and tough by rearranging their nanostructures upon impact.

A new breed of turbochargers constructed of super tough alloys operates at higher temperatures and rotational speeds than ever before, resulting in greatly increased output in a smaller package for gas and diesel engines alike.

Industrial lasers require cooling to remove excess heat generated in the resonator power electronics and the optics system. The type of cooling required is determined by laser wattage, resonator efficiency, resonator and optics temperature requirements, and ambient temperature.

While laser marking and engraving are well-established processes, innovations and investments in the sector are continuing to push performance boundaries.

From producing lithium-ion batteries to processing sheetmetal, new laser welding systems are “pushing the envelope” of light absorption, beam control, speed and programming flexibility.