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The challenge of machining hip replacement implants out of cobalt chrome

Solid-state laser technology has matured, leading to development of new, cost-effective welding applications, such as hybrid welding

The growing need for nano and micro components in the medical industries is challenging manufacturers to continually improve upon their manufacturing processes and take a scientific approach to injection molding and tooling.

Nesting is the process of arranging parts to be cut from sheets of metal or wood in the most efficient manner possible in order to maximize yield and speed the cutting process. By reducing scrap and accelerating the cutting process, fabricators are saving on material cost while running more jobs.

Highly realistic 3-D simulation software can greatly improve manufacturing processes, lending sophisticated visualization tools that help increase manufacturing productivity and product quality.

When you walk into the Redeye On Demand facility in Eden Prairie, MN, you enter into one version of the factory of the future. There you will see a bank of 100 high-end Fortus fused-deposition modeling (FDM) machines from Stratasys that provide the capacity to build real, functional parts with production-grade thermoplastics directly from CAD data.

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.