Topic Track: Alternative Session Topic: Delivering Efficiencies in Certified 3D Printed Aerospace Parts
In the aerospace industry, the slightest design improvement can have a staggering impact on the efficiency of flight, which is why aerospace manufacturers dedicate tremendous time and talent to advanced engineering. Metro Aerospace has an ingenious microvane product design which delivers small 3D printed modifications to the exterior of cargo aircraft to reduce drag and improve fuel consumption by 4%.
Invention of the part was only the tip of the iceberg. The final SLS 3D printed microvanes by Metro Aerospace had to meet all of the rigorous standards outlined by the engineers who designed them, as well as undergo a First Article Inspection Report (FAIR) with thorough documentation, to prove traceability for FAA regulations.
Traceability, reliability, and repeatability are the core requirements of any mass manufacturing process. During this presentation, Leslie Peters will address the rigorous process Metro Aerospace undertook with its partner, 3D Systems, to efficiently move the microvanes from prototyping to production and deliver this new product in the highly regulated aerospace industry. Jim Davidson will highlight some of the advanced solutions used to streamline the inspection and reporting processes.
3D Systems is the originator of 3D printing and an innovator of future 3D solutions. It has spent its 30-year history enabling professionals and companies to optimize designs, transform workflows, bring groundbreaking products to market, and drive new business models. This is achieved with the Company’s best of breed digital manufacturing ecosystem. It’s comprised of plastic and metal 3D printers, print materials, on demand manufacturing services and end-to-end manufacturing software solutions. Combinations of these products and services address a variety of advanced applications- ranging from Aerospaceans Automotive to Medical and Dental. 3D Systems’ precision healthcare capabilities include simulation, Virtual Surgical Planning, and printing of medical and dental devices as well as patient-specific surgical instruments.
Metro Aerospace LLC, headquartered in Dallas, Texas, holds the sole license to manufacture and supply globally Microvanes, a technology invented and patented by Lockheed Martin. Microvanes bring performance enhancement and cost reduction to military and commercial operators for the C-130/L-100/C-17, and other rear cargo airframes with similar steep aft-ramp design.
Metro Aerospace was established in 2016 by the founders of Catalyze Dallas, a venture development company specializing in creating value through the spin out of intellectual property, forming companies to target those assets into broad commercial markets.
Topic Track: Plant Operations Session Topic: Transform Traditional Manufacturing to Manufacturing-as-a-Service
Whether you are a job shop or OEM, this talk will discuss the technology required to build an agile customer-centric manufacturing operation, enabled by a digital ecosystem of continuous feedback, that will automate from design to delivery and make MaaS a reality for manufacturing today.
This presentation will discuss:
What is Manufacturing-as-a-Service (MaaS) aka On-Demand Distributed Manufacturing
How MaaS enables this transformation into an agile customer-centric manufacturing operation
The foundational role that analytics plays
Share real life examples of customers who are starting the journey
Vimana offers the state-of-the art discrete manufacturing predictive analytics platform for operational intelligence that transforms and optimizes manufacturing processes. It captures and enriches data from shop floor devices, operators, and IT/OT systems enabling machine learning, actionable real-time analytics, visualization, and historical trend reporting.
Vimana provides solutions that help manufacturers better manage performance, run smarter operations, automate and streamline processes, and enable closed loop communication and collaboration.
Better manage performance with transparency to plant and enterprise operations using Vimana’s portfolio of KPIs (ie. TrueOEE, Staff Utilization, Quality) so managers can make more proactive and informed decisions.
Run smarter operations with Vimana’s machine monitoring, providing data driven insight into machine performance so manufacturers can optimize assets and make proactive adjustments to achieve daily production schedules. Use Vimana’s analytics to drill down into the underlying data for root casuals that help identify bottlenecks, solve problems faster, and lean processes to drive manufacturing efficiency.
Enable closed loop shop floor communications and collaboration with Vimana software that facilitates the immediate creation, tracking, and resolution of shop floor-related requests. This allows operators, managers, and engineers to notify team members about requirements and areas of improvement.
Vimana is driving the pace of innovation leading in the development and adoption of open standards and providing an adaptable platform for manufacturing analytics. The Vimana Platform is the enabling technology and data foundation for the Smart Manufacturing connected ecosystem, enhancing the value of the existing footprint of factory devices, IT, and OT systems, laying the groundwork for on-demand distributed manufacturing.
Topic Track: Process Innovations Session Topic: Achieving Maximum Productivity by Addressing the Weakest Link – Your Connection
How do we solve the most difficult challenge in manufacturing and maximize productivity?
This session will discuss case studies, all of which started with the end-result in mind, and applied end-to-end thinking from the machine connection to the cutting edge.
How it all needs to work together – machine, spindle connection, cutting-edge solution
How to work with machine tool partners to select the right machine for the job, for the future
How to ensure you don’t settle for what you have always had
The latest process innovations enabled by the market’s strongest connection
Kennametal delivers productivity to customers seeking peak performance in demanding environments by providing innovative custom and standard wear-resistant solutions. This proven productivity is enabled through their advanced materials sciences and application knowledge.
Topic Track: Plant Operations Session Topic: Minimum Quantity Lubrication (MQL) – Benefits and Lessons Learned for Production Implementation
The seven wastes are a fundamental part of lean manufacturing. Minimum quantity lubrication (MQL) is an environmentally and worker friendly means of reducing these wastes. MQL has been widely adopted in the automotive and aerospace industries with remarkable results. In automotive production it permits moving manufacturing cells closer together, reducing movement, and transporting waste. Additional benefits include reduced workforce exposure to mists, smaller cell footprints, reduced cycle times, lower variable costs, and reduced energy and water use. This can result in a 15% lifecycle cost reduction compared to conventional high-volume water-based coolant. Furthermore, inappropriate processing waste can be greatly reduced. One plant halved the energy needed to produce diesel engines and cut water requirements by 99.8%.
Many manufacturers could benefit from implementing MQL in their operation, but they often do not know where or how to start. This session will share experience and knowledge of what is needed to implement MQL in CNC machines:
MQL overview: Definition, advantages, types
Materials & operations: What does, doesn’t work
What Is Needed: Walk through the system explaining what is needed and what is desirable, from the applicator down through spindle and through the tool
Other process considerations
Air and chip handling
Unist has been manufacturing minimum quantity lubrication (MQL) solutions for metal cutting since 1957. The company provides solutions that save money in manufacturing processes by reducing the amount of fluids consumed. The consistent application of minimum quantities of fluid improves process efficiency, reduces waste, and is friendly to the environment.
Topic Track: Quality Session topic: Industry 4.0 and Model-Based
Enterprise for Quality Assurance – Inspection
Efficiencies, Design Inputs, and Manufacturing Outputs The Industry 4.0 roadmap helps us visualize the path toward a complete digital enterprise, as model-based enterprises (MBE) use today’s 3D CAD models to contain and provide rich content information to create, connect, and fully track relevant information for a part through its entire life cycle.
MBE can contain product and manufacturing information (PMI) including design intent, specifications, tolerances, toolpaths, and reporting standards. It provides interoperability, standardized methods and processes, and information efficiencies across design, supply chain, manufacturing, and quality assurance for a worldwide factory network.
This presentation will focus on one portion of this continuum – quality assurance, and its neighboring disciplines, and will explore the following:
What design intent information resides within a MBE CAD model that can promote quality assurance efficiency and correctness?
How can inspection machines use PMI and MBE for automatic programming to minimize machine downtime and maximize inspection throughput?
How can quality assurance output data improve, define, and control manufacturing methods?
How does quality assurance use data organization and standardized reporting methods in a model to provide results in an annotated and organized manner – usable in a common form by all disciplines in the product life cycle? Get these questions answered and begin to understand today’s best practices in quality assurance and cross-discipline part inspection methods.
OGP offers precision video and multi-sensor coordinate measuring systems for dimensional inspection, designed and manufactured at our corporate headquarters in Rochester, New York. We have more than 70 years of industry experience, making the products that fit a range of categories including; multi-sensor metrology, optical inspection, video measurement, laser scanning, and more.