#MACHINING

Aerospace

CNC Machining as a Business Strategy for Additive Manufacturing

As 3rd Dimension Industrial 3D Printing ramps up for production — including a fleet of new 3D printers in a custom-designed building — it's the company's traditional machining capabilities that provide a unique competitive advantage.

Tooling

3D Printed Tool for CNC Machining: The Cool Parts Show S3E1

Guhring uses additive manufacturing to make an end mill with optimized internal channels. We visit a machine shop to test the tool on this episode of The Cool Parts Show.

Automotive

A New Partnership Offers Large-Scale 3D Printing and Five-Axis Machining

The side-by-side product offering from Cincinnati Inc. and Multiax America aims to provide high-throughput AM production for large parts under one roof.

ExOne X1 160Pro Turns Powder to Parts

RAPID 2020: ExOne X1 160Pro, said to be the industry’s largest metal binder jet 3D printer, offers an 800 × 500 × 400 mm build envelope for turning powder to parts.

Medical & Dental

Leveraging Additive Manufacturing to Improve Joint Replacement Surgery

A German medical device company has turned to metal additive manufacturing to manufacture its acetabular cup cutter for hip and knee replacement surgeries. The cutter’s 3D-printed blades are more reliable and cost-effective, and have improved the surgical experience for both patient and physician.

Aerospace

The Hidden Complexities of Wire Arc Additive Manufacturing

Lincoln Electric Additive Solutions’ robotic metal 3D printing process is a choreographed dance between welding, robots, automation, heat management and machining. The new venture may have a distinct advantage in the field: its parent company’s 125 year-old legacy.

Tooling

AM Is Advancing into Tools for Machining: Examples from EMO

The design freedom of additive manufacturing delivers increased performance to tools used in subtractive processes. At the world’s leading exposition for machine tools, I saw various examples of this.

Production

Jabil Prepares for Production AM: It’s Down to the Basics Now

Jabil is getting ready for additive manufacturing to take its place as a production option in addition to conventional processes such as molding and machining. AM can and will fill this role, the company says — the focus now is on controlling cost and assuring quality and reliability.

Video: How Simulation Assists Directed Energy Deposition

Scrapping an AM part is potentially as costly as scrapping a machined part. Directed energy deposition is an additive process that can benefit from a resource that safeguards machining: simulation software. 

GF Machining Solutions Thinks Additive and Beyond

At the GF Machining Solutions 2019 Solution Days event, the company showcased two technologies that make clear its intention to move additive manufacturing into production.

Tooling

Lightweight Sandvik Cutting Tool Employing Topology Optimization Now Available

Additive manufacturing aids “subtractive” CNC machining. We first saw this tool in an early version last year. See the video in this post.

Video: 3D-Printed Brackets Are Key to Automated Coolant Delivery for Lights-Out Machining

An on-site look at the different elements of the coolant-delivery system developed by a machine shop committed to running unattended.

Tooling

Video: In Conventional Manufacturing, 3D Printing Is a Solution for Tooling

Tooling for conventional operations doesn't have to made conventionally. Rather than being made through machining, these welding fixtures are now made via 3D printing.

Aerospace

DMP Factory 500 Offers Workflow-Optimized Metal 3D Printing

Designed by GF Machining Solutions and 3D Systems, the DMP Factory 500 metal additive manufacturing (AM) printing solution is said to create seamless large parts with increased quality and lower total cost of ownership (TCO) for aerospace original equipment manufacturers (OEMs) and their suppliers.

Production

Metal 3D Printing in a Machine Shop? Ask the Marines

A hybrid system combining metal 3D printing with machining gives the Marine Corps perhaps its most effective resource yet for obtaining needed hardware in the field. It also offers an extreme version of the experience a machine shop might have in adding metal AM to its capabilities.

CGTech Machine Simulation Software Operates Independently

Rapid 2019: CGTech’s Vericut version 8.2 CNC machine simulation, verification and optimization software simulates CNC machining, additive and hybrid manufacturing processes.

Three Cool Uses for Directed Energy Deposition

Most machining professionals don’t like to admit that they ever make mistakes, but every now and then wouldn’t it be nice to have an “eraser” to go back and repair a gouge or fix a nicked edge? Or maybe you took off a bit too much material on that last machining pass and you’d like to add it back? Well, directed energy deposition (DED) enables you to do that and more.

What Is Directed Energy Deposition?

Analyzing directed energy deposition and powder-bed fusion provides a thorough understanding of the extra machining necessary for a “near-net shape” versus a “net shape” manufacturing process.

Thermwood Hybrid Machine Produces Near-Net-Shape Parts

Rapid 2019: Thermwood’s Large Scale Additive Manufacturing (LSAM) system uses both 3D printing and machining to produce a near-net-shape product.

Options for Finishing and Postprocessing Metal 3D-Printed Parts

There is a host of technologies available for finishing and postprocessing your AM parts. This column identifies options beyond machining.

Materials

Video: Redesigned Milling Cutter Demonstrates Design Possibilities of AM

Topology optimization plus a material change realize an 80 percent reduction in mass.

5 Ways to Use AM in a Turning Shop

Additive manufacturing systems are not replacing lathes, but the two processes can work together and complement one another.

Hybrid Manufacturing Requires Advanced Inspection Software

Machining excess material to finish hybrid parts requires in-process validation to verify that the part is reaching desired profiles and tolerances.

DMP Factory 500 Integrates 3D Systems, GF Machining Solutions Expertise

The modular solution is optimized for scalability, repeatable high-quality parts, high throughput and low total cost of operation.

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