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It is reported that, not too long ago, before the current precipitous decline in machine-tool shipments, the number of 30-taper machines that were being manufactured and sold in Japan had surpassed the numbers of 40-taper and 50-taper machining centers.

Simulation tools are making it much easier for manufacturers to optimize their processes, visualizing the entire path of production from NC metalcutting simulations through 3D design and factory-floor imaging.

“Metrology and its relationship to manufacturing is rapidly evolving,” Ken Woodbine, president, Wilcox Associates, a brand of Hexagon Metrology (North Kingstown, RI), recently observed. “We are seeing larger quantities and faster speeds of measurement data collection. The next challenge is what to do with all that data.”

As additive manufacturing emerges from a long infancy, the industry is grappling with a key challenge: A file format and design tools from the 20th century are being asked to do 21st century jobs.

Today’s products require high finishes, burr-free edges, freedom from contamination, and often close tolerances. Electropolishing provides all of those conditions and more in a matter of seconds for many metal parts. It is a process that has been used for more than a hundred years. It is widely known and the science is widely discussed, but its ability to run job shop lots and high-precision high-volume parts in the same equipment makes it a bit unique.

The challenges to manufacturing as it evolves into the 21st century are now familiar, and impact how metrology must contribute. Manufacturers face uncertain production volumes with roller-coaster demand, shorter production runs and faster product development cycles. Automation, while alluring as a way to reduce cost, needs to adjust.

Why use a metrology device on or near a machine tool? It isn’t just useful for making sure a tool is present or monitoring tools for wear or breakage. On-machine measurement technologies can save time and money, by speeding up processes and eliminating extra personnel, and they are a critical step in the movement towards “lights-out” manufacturing.

Micro components continue to shrink in size, demanding ever-greater precision and improved handling of parts with sub-micron-sized features. New approaches in micro machining technology include higher-precision systems from traditional micro machining developers, as well as techniques using additive manufacturing processes and semiconductor wafer-scale technology on the smallest of micro parts.

As additive manufacturing (AM) moves from prototypes to mass production, manufacturers are setting their sights on the holy grails—the products and processes that will be game-changers. Many game-changers are already in play.

Smart factory systems benefit from improved technologies, as well as proven applications.