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This year’s RAPID + TCT show signaled a new wave of users, with 35 percent of the audience being new to adopting additive manufacturing technologies.

Eltool Corp. of Mansfield, Ohio, has announced that, in addition to 1:1 ratios, live lathe tools are now available with 5:1 and 1:5 gearboxes for high-torque and high-speed machining applications.

Makers of workholding devices face a moving target. The machine tools they work with are changing. There’s more high-speed machining. More high-feed machining. More multi-axis machines. New uses of coolant to reduce temperatures during cutting operations.

For certain machining applications, off-the-shelf cutters come up short. Here’s how to increase productivity, reduce costs, and improve part quality with a custom cutting tool solution.

According to McNamara, director of sales for Doosan Machine Tools America (Pine Brook, NJ), the most important tools in getting customers to move into five-axis machining are features within the control that make it simple to create, understand and prove out machining programs.

Mazak Corporation has announced its acquisition of MegaStir, a supplier of friction stir welding (FSW) tools and technology located in Provo, Utah.

Glenn Bridgman describes the difference between his shop’s manual grinders and its newest state-of-the-art CNC ID/OD grinder, a Studer CT960 OD/ID from United Grinding (Miamisburg, OH), as “feel vs. facts.” Bridgman, president of Bridge Tool & Die (Buckley, MI), believes that manual grinding is a somewhat personal operation.

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.

The rules of thumb for shops experienced in five-axis machining aren’t any different from those for first- time users of this sophisticated machining process. The difference is that the experienced shop has already traveled the learning curve for five-axis machining.