Real Time Machine Data Collection for Machine Shops
Decades ago, Distributed Numerical Control or DNC consisted of serial cables run from a computer system to a very expensive, proprietary DNC serial hub. Proprietary shop floor boxes were often times used to initiate the transfer of files. All this for the sole purpose of downloading and uploading G-Code programs to CNC machines. So what’s different today? One of the biggest changes is the shift from very expensive, proprietary hardware to open systems with commercially available, inexpensive hardware. Many modern-day CNC machines now support communications through Ethernet, allowing far greater distances from machine to computer plus an exponentially faster transfer rate, not to mention the support of much larger program transfer without the need to drip-feed. In fact, many shops, whether owning ethernet-based machines, serial machines or a combination of both are transferring files wirelessly through the use of special boxes located on or near each CNC control. So what’s next? What else can revolutionize DNC? What are the latest advances in DNC technology that extend beyond the traditional transferring of files? Machine Data Collection, or MDC, offers shop owners the ability to capture information electronically, automatically and in real-time with little to no human interaction, primarily through a combination of software pushing [...]
Nexa3D and Henkel Launch New Medical-grade Polymer 3D Printing Material
reprint from https://3dprintingindustry.com/ California-based SLA 3D printer manufacturer Nexa3D and global chemical company Henkel have launched a new polymer for 3D printing called xMED412. The polypropylene (PP)-like material combines enhanced strength properties with the biocompatibility of medical-grade materials, potentially making it well-suited to producing medical devices. What’s more, the high-impact, durable plastic has also been tested and cleared by the U.S. Food and Drug Administration (FDA) for use within clinical environments. As a result, the polymer could be used for manufacturing products such as orthotics guides and braces, or even to print nasal testing swabs for COVID-19. “We are thrilled to bring this product to market in collaboration with Nexa3D,” said Ken Kisner, Henkel’s Head of Innovation for 3D printing. “We developed and tested with Nexa3D’s NXE400 3D printer a multitude of approved workflows designed to unleash the full potential of xMED412’s outstanding physical properties and biocompatibility.” “WE ARE PLEASED THAT NASOPHARYNGEAL SWABS MANUFACTURED WITH XMED412 ON THE NXE400, IN ACCORDANCE WITH OUR PUBLISHED PROCEDURES, HAVE ALREADY BEEN CLEARED THROUGH CLINICAL TRIALS AND ARE IN COMPLIANCE.” Henkel and Nexa3D’s ongoing 3D printing partnership While Nexa3D is better known for its stereolithography (SLA) machines, Henkel has a strong recent track record of developing new [...]
Deviation Analysis in Design X
Let’s take a look at the basics behind Deviation Analysis in Design X. This is an essential tool for reverse engineering and will ensure that you get the most out of your 3D scans. In Geomagic Design X, Deviation Analysis tells us how far off our derived CAD model is from our scan. There are typically three sources of error when scanning a part: There could be a slight error in the actual manufacturing of the part, whether it was machined, molded, welded, or made in some other fashion. The second error could be that the part is worn or used. There could also be an error from the actual scanner. When reverse engineering, it is important to consider if you want to reverse engineer to your design intent, or simply reverse engineer as is. For example, the scanned cylinders' diameter may show up as 1.999827 inches. But in most cases, you would typically want to correct the specifications to 2 inches. In this gas valve example below the derived solid model was created from a scanned mesh. You can navigate to the Deviation for body tool. Everything you see in green is within +-4 thousandths of an inch of the scan. The [...]
What PMI means to the future of integrated CAD/CAM
Since the mid-1980s, when PC based CAD/CAM started its explosion due to the advent of 386 computing technology, our industry has had an ongoing hurdle to overcome . . . How to convey manufacturing and inspection information with the original model design. Historically a manufacturer would provide a job shop with a CAD model and an inspection drawing, increasing the likelihood for inspection drawing interpretation error. Wouldn’t it be ideal if the manufacturing and inspection data could all remain with the model throughout all post-design functions? Looks like PMI (Product Manufacturing Information) has us finally following a path that will enable this groundbreaking technology to become a reality. Being able to seamlessly connect all manufacturing and inspection data to CAD models, including dimensions with tolerances, GD&T, datums, notes, labels and any other pertinent information modern-day CAD product users can seamlessly convey this information to downstream applications. This helps to greatly minimize the likelihood of error while reusing the PMI data for CAM systems to automatically select optimal toolpath parameters. Additionally, FEA and inspection products can also ‘share’ this data for their respective disciplines, again promoting the reuse of original PMI CAD data for ALL downstream applications. While many CAD, CAM, and FEA products [...]
Mold Making with Formlabs 3D Printers
This post will explore 3D printing for mold making using Formlabs 3D printers. Mold making with desktop 3D printing allows engineers to expand their prototyping toolkit. It opens up a world of production materials, offering the ability to make short-run batches and to test designs before larger-scale production. Three types of molding strategies can be applied with Formlabs. These include injection molding, thermoforming, and casting elastomers. The Form 3 can print inexpensive injection molds to validate and improve designs before metal tooling. They can be printed at both 100 microns for speed or 50 microns for high detail and smoothness. In this example, the newer High Temp resin was used to print an enclosure for a USB device. High temp resin eliminates the thermal shock or deformation found with lower temp materials. The beauty of this example is that the team was able to create three iterations, helping them to remove sink marks, air taps, and correct part shrinkage. Thermoforming is common for packaging, orthodontic retainers, and food-safe molds. The dies experience less pressure than injection molds, but High Temp is still the best choice. Standard resins can still be used for lower temperature plastics like vinyl. In this case study, a thin [...]
Metrology Minute – How Do I Choose My First Scanner? – Part 1
Considering part sizes Notice that the title says first scanner. More than likely, companies who invest in non-contact inspection, scan-based reverse engineering or need to perhaps scan and 3D print objects will own multiple scanners in the course of a career. However, some scanners have the ability to swap out lenses, projectors and the like and can change a scanner’s capabilities by swapping hardware. Just like CNC machinery or 3D Printers, scanners can vary greatly regarding speed, accuracy, resolution, repeatability, part sizes (Field-of-View), price, ongoing warranty, post-sales service and support, and so on. So perhaps one of the first realizations to accept is that there isn’t a ‘One-Size-Fits-All’ scanner. This three-part Metrology Minute will go through what you should consider when choosing the best, first scanner for your company. Whether the scanner is based on laser or structured light you will want to review scanners that can handle the bulk of your scanning requirements because solving them all using a single scanning device may not be possible. As a general rule of thumb, scanners designed to scan tiny objects offer higher accuracy and resolution capabilities, whereas scanners designed to scan a plant or exterior of a building generally are far less accurate with [...]