Explore control options for Deep Trekker ROVs, including handheld, tablet, console, and BRIDGE Box for diverse environments and operator needs.

Flexible ROV Control Options: Tailored Solutions for Every Mission

<p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/F5X7waUX8Sc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">How a technical service bureau makes FFF the leading 3DP technology for product development and series production</h2><p>Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing. This is where the experts at IMES3D come in, offering professional support and comprehensive services to ensure a smooth transition and successful implementation.</p><p>Located just 30 minutes from Barcelona’s city center, IMES3D boasts an impressive office equipped with over 60 UltiMaker 3D printers. With over 10 years of experience, their team of experts support professional clients in need of 3D-printed parts. Their clientele spans a wide range of industries, including automotive, food and beverage, military, and medical sectors. This diversity underscores the importance for IMES3D to offer 3D-printed parts in a variety of materials with different properties.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697022407-picture-1.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">Challenges customers face</h2><p>IMES3D supports both customers who are new to 3D printing and those who already own 3D printers. Newcomers can receive advice and support in selecting the right printers and setting them up in a suitable environment. Both new and existing users benefit from IMES3D’s team of skilled engineers and designers. They use their expertise to help identify practical applications and create 3D models suitable for printing. With many years of experience and in-house support for both design and 3D printing technology, IMES3D is truly an expertise center for professionals requiring custom part production.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697042514-picture-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted">The printfleet of IMES3D</h2><p>When customers are unable to produce parts themselves, IMES3D can scale up capacity using their UltiMaker printers. This enables them to assist customers with tight deadlines and large volume orders. Many of the printers at IMES3D are UltiMaker S5 models, which offer a large build volume and can use different nozzles to print in a wide range of materials.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697058969-Fleet-of-printers.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Besides common materials such as PLA, ABS, Nylon and TPU, these printers are also able to print more advanced materials. For added strength IMES3D can print parts made from carbon-fiber reinforced nylon which is great for mechanical spare parts. Customers in the food and beverage industry can benefit from FDA-approved materials. For example, parts that carry food products from one machine to another. They can even print flame-retardant or ESD-safe materials. Whenever IMES3D has a request for a very specific use case, they can simply look in the UltiMaker material marketplace, find the right material and add the print profile to UltiMaker Cura.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697080987-S-line-Application.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">This FDA-safe part is used on a conveyor belt to transport food products, specifically almonds and nuts, along the belt.</span></span></span></p><p id="isPasted">Smaller parts that do not require advanced materials are printed on older UltiMaker models, such as the UltiMaker 3 and UltiMaker 2. Although these models are discontinued, their continuous 24/7 usage is a testament to UltiMaker’s reliability and future-proof design.</p><h2>Adding new possibilities with the Factor 4</h2><p>The latest addition to IMES3D's impressive print fleet is the all-new UltiMaker Factor 4. The machine’s direct drive enables printing with much softer and more flexible materials, opening up new possibilities for applications requiring protection, impact absorption, or enhanced grip. This advancement has allowed IMES3D to expand into a broader range of industrial applications. For example, IMES3D has printed custom bumpers for mobile devices, protecting them from damage after an accidental drop. These materials are also used as an interaction surface for tools to prevent products from being damaged during work or quality control.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697122519-1732697122519.png" class="fr-fic fr-dib"></p><p>The actively controlled build chamber and new High Temperature (HT) printcore give IMES3D the option to print with various new materials, such as PPS CF. This carbon fiber-reinforced material can withstand even higher temperatures and more tensile stress than materials like carbon fiber-reinforced nylon. These characteristics make it ideal for mechanical parts that endure larger forces or impacts, such as spare parts for manufacturing machines. Parts printed in these materials are often strong enough to replace metal parts, while also being lighter, faster to produce and more cost effective. This makes these materials not only ideal for on-demand spare parts, but also for end-use parts. Especially when the parts are needed in small quantities or with customizations.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697149161-Applications.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Additionally, IMES3D utilizes the Factor 4’s&nbsp;<a href="https://ultimaker.com/software/print-process-reporting/">Print Process Reporting</a>. This insightful analysis ensures print quality by highlighting any discrepancies in the print data. After every print job, the operator receives an in-depth report on extrusion parameters deviations from nominal values, their locations, and their severity in the 3D model. Using a suite of sensors in the print head, build chamber, and material loading system, this print process reporting helps to verify and validate part quality before use in the field.</p><h2>Managing a large print fleet through Digital Factory</h2><p>To ensure optimal printer management, IMES3D uses Digital Factory. This platform ensures the entire print fleet is utilized as efficiently as possible. When a 3D print job is sent to the group of printers, Digital Factory selects the right printer for the task. If all printers with the appropriate materials are in use, print jobs can be queued and scheduled. During printing, IMES3D monitors the job over the network to track its progress. Digital Factory also aids in logging and planning regular maintenance, allowing IMES3D to align maintenance schedules with the printers’ workload. Maintenance is now performed regularly during periods when the printers are not required for production.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697165879-Digital-factory-IMES3D.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>IMES3D also assists their customers in setting up Digital Factory. This enables their clients to manage print fleets, often spread across multiple locations. Not only can their central 3D printing team manage their printers, but IMES3D can also provide support remotely from their own offices. Customers can create an internal catalog of 3D models and prints, enabling anyone in their company to simply select the part they need and start the print.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732697182017-Fleet-of-printers-IMES3D.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>IMES3D has proven to be a professional and reliable expertise center for 3D printing, and with the support of UltiMaker's local partner in Spain,&nbsp;<a href="https://sicnova3d.com/" id="isPasted">Sicnova</a>, IMES3D has developed into the service bureau with the largest number of UltiMaker printers in the world. With over 60 UltiMaker printers creating large quantities of parts for so many different industries with different requirements, they really showcase the agility for 3D printing. The UltiMaker Factor 4 is a big step up, extending their possibilities. This enables them to keep innovating and explore even more solutions for their customers.</p>

Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing.

IMES3D: Expert Support for Industry-Level 3D Printing

<p dir="ltr" id="isPasted">Plastic injection molding is the most common production process for simple plastic parts with thin walls. It is fast, cheap, and ideal for mass production. However, an injection molding machine is a complex piece of equipment, and the process is prone to a few specific problems that can lead to part defects.</p><p dir="ltr">Injection molding defects can significantly impact the quality and performance of manufactured products — or render them completely unusable and destined for the scrapheap. This can in turn lead to increased production costs, reduced efficiency, and compromised product reliability. For manufacturers, addressing these issues is key to maintaining quality standards and ensuring customer satisfaction.</p><p dir="ltr">Understanding plastic injection molding defects involves identifying their causes, diagnosing their presence, and implementing preventive measures. This article looks at some of the most common injection molding defects, examining why they occur and how to prevent them.</p><h2 dir="ltr">What Are Injection Molding Defects?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733143119052-yellow_black_plastic_parts.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="parts"><span class="fr-inner">Because they are made quickly and affordably, molded parts can exhibit defects</span></span></span></p><p dir="ltr">Injection molding defects are imperfections or anomalies that occur during the manufacturing process of molded products. These defects can manifest in various forms, such as surface blemishes, structural inconsistencies, or dimensional inaccuracies. They can undermine the functionality, aesthetics, and durability of the finished products, often leading to increased waste and production costs.[1]</p><p dir="ltr">Proactively identifying and mitigating defects can save resources, reduce operational costs, and lead to high-quality parts. By prioritizing defect management, manufacturers can enhance their competitiveness and foster sustainable production practices.</p><h2 dir="ltr">Common Types of Injection Molding Defects</h2><p dir="ltr">Injection molding is a highly efficient manufacturing process, but it is not without its challenges. Defects can arise at various stages of production, affecting the functionality, aesthetics, and overall quality of the final product. Below are some of the most frequent defects encountered in injection molding, along with their causes and implications:</p><h3 dir="ltr">Sink Marks</h3><p dir="ltr">These are shallow depressions or dimples that form on the surface of molded parts, often around thicker sections of material. Sink marks occur when the material inside the part cools and shrinks unevenly, pulling the surface inward. They are commonly caused by insufficient packing pressure, inadequate cooling time, or poor mold design features such as inconsistent ribs.[2]</p><h3 dir="ltr">Warping</h3><p dir="ltr">Warping is the unwanted bending or twisting of molded parts after ejection from the mold. It is primarily caused by uneven cooling rates across the part, leading to residual stresses that distort the shape. Warping can also result from improper material selection, as some polymers are more prone to shrinkage and deformation than others.</p><h3 dir="ltr">Short Shots</h3><p dir="ltr">A short shot happens when the molten material does not completely fill the mold cavity, resulting in incomplete or missing sections of the part. This defect is often caused by inadequate injection pressure or obstructions within the mold. It can also occur if the mold is poorly vented, preventing the material from flowing freely.</p><h3 dir="ltr">Flash</h3><p dir="ltr">Flash is an excess layer of material that seeps out of the mold cavity along the mold parting line or around ejector pins. This defect can occur if the mold is not clamped tightly enough or if the clamping force is uneven. Flash can also result from excessive injection pressure or worn mold components that allow material to escape.</p><h3 dir="ltr">Burn Marks</h3><p dir="ltr">Burn marks are darkened or charred areas on the surface of molded parts, typically caused by trapped air overheating during the injection process. These marks are usually found near sharp corners, flow path ends, or areas where air cannot escape the mold cavity. Factors contributing to burn marks include high injection speeds, insufficient venting, or improper gate design.</p><h3 dir="ltr">Flow Lines</h3><p dir="ltr">Flow lines are visible streaks or patterns on a molded part’s surface, caused by the cooling and solidification of material as it flows through the mold. These defects are often linked to inconsistent injection speeds, material temperature, or poor mold design. Although flow lines are typically cosmetic, they can indicate potential weaknesses in the part.</p><h3 dir="ltr">Delamination</h3><p dir="ltr">Delamination refers to the peeling or separation of surface layers on a molded part, resulting in a flaky or brittle texture. This defect is sometimes caused by contamination of the material, such as moisture or foreign particles. It can also occur if incompatible materials or additives are used together or if the material experiences excessive shear stress during molding.</p><h3 dir="ltr">Jetting</h3><p dir="ltr">Jetting appears as wavy, worm-like lines on the surface of molded parts, caused by irregular material flow of the molten plastic. This defect occurs when molten material is injected too quickly or at an improper angle, leading to turbulence rather than smooth filling. Jetting can also result from incorrect gate design or insufficient mold temperature. Proper flow rate and gate positioning can help mitigate this issue.</p><h3 dir="ltr">Voids</h3><p dir="ltr">Voids are small cavities or air pockets that form inside molded parts, often reducing their structural integrity. They typically occur due to uneven cooling, excessive material shrinkage, or trapped air during the molding process. Poorly designed runners or gates and insufficient holding pressure can exacerbate the issue. Adjusting cooling profiles and improving mold venting can help prevent voids.</p><h3 dir="ltr">Knit Lines</h3><p dir="ltr">Knit lines, also known as weld lines, are visible seams where two flow fronts of molten material meet but fail to fully fuse. This defect is often caused by insufficient material temperature or pressure, long flow paths, or improper gate placement. While sometimes purely cosmetic, knit lines can compromise strength. Enhancing material flow and optimizing mold design can reduce their occurrence.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/the-pros-and-cons-of-3d-printing-low-run-injection-molds" target="_blank"><em>The pros and cons of 3D printing low-run injection molds</em></a></strong></p><h2 dir="ltr">Root Causes of Injection Molding Defects</h2><h3 dir="ltr">Material-Related Causes</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733143131103-colorful_plastic_pellets.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="injection molding materials"><span class="fr-inner">Some injection molding materials are more defect-prone than others</span></span></span></p><p dir="ltr">The type and quality of plastic materials used in injection molding play a role in determining the success of the process. Factors such as moisture content, contamination, and material compatibility can directly influence the occurrence of defects.</p><ul><li dir="ltr"><p dir="ltr"><strong>Moisture Content</strong>: Excess moisture in raw molding materials can lead to defects like voids, bubbles, or delamination in the finished product. Certain plastics, such as polycarbonate and nylon, are hygroscopic and require proper drying before use to prevent moisture-related issues.</p></li><li dir="ltr"><p dir="ltr"><strong>Contamination</strong>: Foreign particles or impurities in the material can cause surface blemishes, inconsistent textures, or reduced structural integrity. For instance, contamination with incompatible polymers or dust can result in brittle or uneven parts.</p></li><li dir="ltr"><p dir="ltr"><strong>Material Selection</strong>: Some materials are simply more prone to certain defects than others. For example, polypropylene may exhibit sinking, fiber-filled plastics may warp, and moisture-filled nylon can sputter and create various defects.</p></li></ul><h3 dir="ltr">Process-Related Causes</h3><p dir="ltr">The parameters used during the injection molding process also greatly affect the quality and consistency of the final product. Variations in temperature, pressure, and injection speed can introduce defects if not carefully controlled.</p><ul><li dir="ltr"><p dir="ltr"><strong>Temperature</strong>: Inconsistent or incorrect material temperatures can lead to issues such as burn marks, short shots, or material degradation. For instance, excessive melt temperature can cause thermal degradation, resulting in discoloration or reduced material strength.</p></li><li dir="ltr"><p dir="ltr"><strong>Pressure</strong>: Insufficient or excessive injection pressure (back pressure and/or holding pressure) can lead to defects. Low pressure may cause short shots or incomplete filling of the mold cavity, while excessive pressure can lead to flash or damage to the mold.</p></li><li dir="ltr"><p dir="ltr"><strong>Injection Speed</strong>: The speed at which material is injected into the mold impacts the flow and cooling dynamics. High injection speeds may trap air within the mold, causing burn marks, while low speeds can lead to flow lines or incomplete filling.</p></li></ul><h3 dir="ltr">Design-Related Causes</h3><p dir="ltr">Product and mold design are important factors in the success of the injection molding process. Poor design choices can lead to a variety of defects, impacting both the structural integrity and aesthetic quality of the molded part.</p><ul><li dir="ltr"><p dir="ltr"><strong>Wall Thickness</strong>: Uneven or excessively thick walls can cause defects such as sink marks, warping, or voids. For example, parts with inconsistent wall thickness may cool unevenly, leading to residual stresses and dimensional inaccuracies.</p></li><li dir="ltr"><p dir="ltr"><strong>Rib Design</strong>: Improper rib placement or dimensions can result in defects like sink marks or weld lines. Ribs that are too thick relative to the surrounding walls can create localized shrinkage, causing surface imperfections and weakened structural areas.</p></li><li dir="ltr"><p dir="ltr"><strong>Gate Location</strong>: The placement of gates in the mold affects the flow of molten material. Poorly positioned gates can lead to defects such as flow lines, air traps, or incomplete filling. Researchers have argued that gate location is one of the most important considerations for minimizing wastage and energy costs and consequently increasing sustainability.[3]</p></li></ul><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/what-are-injection-mold-sprues-runners-and-gates" target="_blank"><em>What are injection mold sprues, runners, and gates?</em></a></strong></p><h2 dir="ltr">Identifying, Diagnosing, and Predicting Defects</h2><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732650534151-mold-and-inserts-large-1920x1080-v2.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="moldflow"><span class="fr-inner">Flow simulation tools like Autodesk Moldflow can prevent defects (image credit:&nbsp;<a href="https://www.autodesk.com/ca-en/products/moldflow/" target="_blank" rel="noopener noreferrer">Autodesk</a>)</span></span></span>Visual Inspection</h3><p dir="ltr">Visual inspection is a fundamental step in identifying defects in molded parts. By systematically examining parts after production, manufacturers can detect and address quality issues early.</p><ul><li dir="ltr"><p dir="ltr"><strong>Examine Surface Quality</strong>: Look for visible imperfections such as sink marks, burn marks, or flash. These defects often indicate problems with material flow, temperature, or mold clamping.</p></li><li dir="ltr"><p dir="ltr"><strong>Check for Dimensional Accuracy</strong>: Measure critical dimensions to detect warping, short shots, or shrinkage. Variances in size can compromise the fit and functionality of the part.</p></li><li dir="ltr"><p dir="ltr"><strong>Inspect Weld and Flow Lines</strong>: Observe areas where material flows meet or change direction. Flow lines may appear as streaks or discolorations, while weld lines can signal weakened structural points.</p></li><li dir="ltr"><p dir="ltr"><strong>Assess Overall Consistency</strong>: Compare parts from the same production run to identify variations. Inconsistent quality across parts can highlight issues with process parameters or mold design.</p></li></ul><h3 dir="ltr">Advanced Diagnostic Tools</h3><p dir="ltr">Advanced diagnostic tools play a crucial role in identifying and analyzing defects in injection molding processes (or predicting them in advance). These technologies provide deeper insights into the root causes of defects, enabling manufacturers to make informed adjustments and improve quality.</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>Tool</strong></p></td><td><p dir="ltr"><strong>Description</strong></p></td><td><p dir="ltr"><strong>Benefits</strong></p></td><td><p dir="ltr"><strong>Limitations</strong></p></td></tr><tr><td><p dir="ltr"><strong>Thermal Imaging</strong></p></td><td><p dir="ltr">Detects temperature variations across the molded part and within the mold during the injection process. Identifies areas prone to uneven cooling (e.g., warping, sink marks).</p></td><td><p dir="ltr">Non-invasive&nbsp;</p><p dir="ltr">Real-time analysis&nbsp;</p><p dir="ltr">Easy identification of thermal inconsistencies</p></td><td><p dir="ltr">Limited detection of internal defects&nbsp;</p><p dir="ltr">Cannot identify material-related issues</p></td></tr><tr><td><p dir="ltr"><strong>X-ray Inspection</strong></p></td><td><p dir="ltr">Examines the internal structure of molded parts, detecting voids, inclusions, or incomplete filling not visible externally.</p></td><td><p dir="ltr">High precision&nbsp;</p><p dir="ltr">Assesses material integrity</p></td><td><p dir="ltr">High cost&nbsp;</p><p dir="ltr">Requires specialized equipment and expertise</p></td></tr><tr><td><p dir="ltr"><strong>Flow Simulation Software</strong></p></td><td><p dir="ltr">Models the flow of molten material within the mold, predicting issues like air traps, weld lines, or improper filling. Optimizes mold design and process parameters.</p></td><td><p dir="ltr">Prevents defects proactively&nbsp;</p><p dir="ltr">Reduces costly trial-and-error processes</p></td><td><p dir="ltr">Requires accurate input data&nbsp;</p><p dir="ltr">Demands significant computational resources</p></td></tr></tbody></table></div><h1 dir="ltr">Material Quality Assurance Checklist</h1><p dir="ltr">Prevention of injection molding defects largely comes down to skilled part design and machine operation. However, choosing the right materials and ensuring their proper handling can also help to prevent injection molding defects. Material properties such as viscosity, thermal stability, and moisture absorption can significantly impact the quality of molded parts.</p><p dir="ltr">Some best practices when obtaining and handling materials for injection molding include:</p><ul style="list-style-type: circle;"><li dir="ltr"><p dir="ltr">Verify material certification and supplier quality standards.</p></li><li dir="ltr"><p dir="ltr">Inspect raw materials for signs of contamination, discoloration, or damage.</p></li><li dir="ltr"><p dir="ltr">Test moisture content before processing and ensure it meets the manufacturer’s specifications.</p></li><li dir="ltr"><p dir="ltr">Conduct small-scale trial runs to confirm material performance under intended processing conditions. Adhering to these practices helps ensure material integrity and minimizes the likelihood of defects during injection molding.</p></li></ul><h1 dir="ltr">Conclusion</h1><p dir="ltr">Effectively managing injection molding defects requires an understanding of their causes and the proactive implementation of preventive measures. Manufacturers can enhance product quality by selecting the appropriate materials, optimizing injection molding processes, and designing molds thoughtfully. These efforts not only minimize production costs but also ensure the reliability and consistency of molded parts.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/3d-printing-vs-injection-molding" target="_blank"><em>3D printing vs injection molding: process, materials, applications</em></a></strong></p><h1 dir="ltr">Frequently Asked Questions (FAQs)</h1><p dir="ltr"><strong>Q: What are the most common injection molding defects?</strong></p><p dir="ltr">A: Common defects in injection molded parts include sink marks, warping, short shots, flash, burn marks, and flow lines. Each arises from different factors such as material properties, processing conditions, or mold design.</p><p dir="ltr"><strong>Q: How does material selection impact defect prevention?</strong></p><p dir="ltr">A: Material properties such as moisture absorption, thermal stability, and viscosity significantly affect defect risks. Selecting materials suited to the application and process conditions is essential for defect prevention.</p><p dir="ltr"><strong>Q: What role does process monitoring play in reducing defects?</strong></p><p dir="ltr">A: Process monitoring helps detect anomalies in real time, ensuring consistent quality. Tracking parameters such as temperature, pressure, and cooling rates allows for early adjustments to avoid defects.</p><p dir="ltr"><strong>Q: Can flow simulation software help prevent defects?</strong></p><p dir="ltr">A: Yes, flow simulation software models the material's behavior within the mold, predicting potential issues like air traps, weld lines, or incomplete filling. This helps optimize mold design and processing parameters.&nbsp;</p><p dir="ltr"><strong>Q: Why is mold design critical to defect prevention?</strong></p><p dir="ltr">A: Mold design determines how material flows, cools, and solidifies. Features like gate placement, wall thickness, and rib design directly impact defect risks and product quality.</p><h1 dir="ltr">References</h1><p dir="ltr">[1] Chen YM, Liu JJ. <a href="https://www.sciencedirect.com/science/article/pii/S0736584599000058" target="_blank">Cost-effective design for injection molding</a>. Robotics and computer-integrated manufacturing. 1999 Feb 1;15(1):1-21.</p><p dir="ltr">[2] Gruber DP, Berger G, Pacher G, Friesenbichler W.<a href="https://www.sciencedirect.com/science/article/abs/pii/S0142941811000717" target="_blank">&nbsp;Novel approach to the measurement of the visual perceptibility of sink marks on injection molding parts</a>. Polymer testing. 2011 Sep 1;30(6):651-6.</p><p dir="ltr">[2] Huszar M, Belblidia F, Davies HM, Arnold C, Bould D, Sienz .<a href="https://www.sciencedirect.com/science/article/pii/S2214993715000093" target="_blank">&nbsp;Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure</a>. Sustainable Materials and Technologies. 2015 Sep 1;5:1-8.</p>

Injection molding problems like sink marks and flash can be prevented by addressing their most common causes. This article serves as a basic troubleshooting guide.

Injection Molding Defects: Causes, Identification, and Prevention

<h3 id="isPasted">Why Choose Metal 3D Printing for Fixture Construction?</h3><p>Metal 3D printing transforms fixture construction by enabling <strong>customized, efficient, and precise solutions</strong> tailored to specific applications. Its ability to directly produce components from CAD designs overcomes the limitations of traditional manufacturing methods.</p><p><strong>Key Benefits Include:</strong></p><ul><li><p><strong>Design Flexibility</strong>: Additive manufacturing allows for the creation of intricate geometries and application-specific features that traditional methods often cannot achieve. Fixtures can be optimized for exact functionality, enhancing performance and reliability.</p></li><li><p><strong>Time Efficiency</strong>: The streamlined process of designing and producing fixtures with 3D printing significantly reduces lead times. From concept to production, projects can be completed in days rather than weeks, allowing manufacturers to respond quickly to changing needs.</p></li><li><p><strong>Material Savings</strong>: Unlike traditional subtractive manufacturing, 3D printing uses only the material required for the design, reducing waste and lowering material costs. This makes it a more sustainable and economical choice.</p></li><li><p><strong>Cost-Effectiveness for Customization</strong>: 3D printing eliminates the need for tooling, making it ideal for low-volume or highly customized fixtures. Manufacturers can produce tailored solutions without incurring additional setup costs.</p></li><li><p><strong>Improved Workflow</strong>: The ability to go directly from CAD data to production simplifies the manufacturing process, eliminating the need for extensive preparation or machining. This leads to faster execution and greater adaptability.</p></li><li><p><strong>Durability and Strength</strong>: Metal 3D printing materials like stainless steel provide the robustness needed for demanding industrial environments, ensuring that fixtures can withstand rigorous use.</p></li></ul>

Metal 3D printing at Hoedtke metal solutions

Hoedtke metal solutions is using metal 3D printing to print fixture constructions. The video demonstrates how the use of additive manufacturing helps them to improve their processes and capacities. 

Fixture Construction

Joined by Adam Tipper, Managing Director and Co-owner at Next Gen Makers, our host Alex Edwards seeks to explore the experiences faced by apprentices and the best practices companies can deliver to retain young talent and rebuild the engineering workforce.

Manufacturing Apprenticeships: How can we rebuild the workforce?

<p dir="ltr" id="isPasted">Aerospace and defense (A&amp;D) manufacturing operates in one of the most regulated and complex environments, where precision, compliance, and safety are non-negotiable. Every component, from aircraft parts to defense systems, must meet rigorous standards, and a single defect can lead to costly rework, delayed timelines, and compliance failures that compromise safety. Despite advancements in manufacturing, non-conformance remains a pervasive challenge that disrupts production and drives up costs. Frequent quality issues, often stemming from the limitations of traditional methods and disconnected systems, have ripple effects throughout the supply chain, creating risks and eroding operational efficiency as production scales and becomes increasingly globalized.</p><p dir="ltr">Digital threads offer a transformative solution to these challenges. By creating an interconnected data flow that spans the entire product lifecycle, digital threads enable real-time quality control and predictive insights that empower manufacturers to detect, address, and even prevent non-conformances before they escalate. Quest Global is pioneering digital thread technology in A&amp;D manufacturing by integrating Model-Based Enterprise &nbsp;(MBE), digital twins, and predictive maintenance. Its approach targets zero defects and redefines quality management as a proactive, data-driven strategy that delivers unprecedented levels of control, reliability, and efficiency across the industry.</p><h2 dir="ltr">Quest Global’s Vision for Zero Defects in A&amp;D Manufacturing</h2><p dir="ltr">Quest Global combines cutting-edge technologies and industry-proven methodologies to set a new benchmark for precision in A&amp;D manufacturing. Their approach embeds continuous data flows and real-time feedback loops into production, enabling manufacturers to maintain rigorous quality standards without sacrificing speed or flexibility.</p><p dir="ltr">At the core of Quest Global’s strategy is the digital thread, a cohesive system that unites design, manufacturing, and maintenance processes into a single, continuous data stream. This interconnected framework addresses non-conformance by embedding real-time traceability and compliance verification directly into the manufacturing workflow, transforming quality management from a series of isolated checks into an integrated process. Through structured methodologies such as Root Cause Corrective Action (RCCA) and the 8D process, Quest Global systematically addresses quality issues at their source, preventing recurrence and ensuring comprehensive compliance.&nbsp;</p><p dir="ltr">This application of digital threads allows A&amp;D manufacturers to identify and resolve quality issues proactively, building a foundation of precision and consistency across global supply chains. By bridging the gaps between design, manufacturing, and maintenance, digital threads provide a comprehensive view of the product lifecycle, facilitating a proactive approach to tackling non-conformance.</p><h2 dir="ltr">Digital Solutions Transforming A&amp;D Manufacturing</h2><p dir="ltr">Quest Global’s digital thread strategy is built on foundational technologies that address the complexities and precision demands of A&amp;D manufacturing. MBE is central to this approach, allowing engineers to create, test, and continuously update dynamic models. It enables real-time adjustments and validation throughout the design phase, which helps maintain precision and minimize the risk of errors that could cascade through the production process. Enhanced by parametric modeling, MBE provides flexibility in testing and refining designs well before they reach production, effectively reducing the likelihood of non-conformance issues at their earliest stages.</p><p dir="ltr">Digital twins complement MBE by bridging the gap between virtual design and physical production. Acting as real-time digital replicas of physical assets, digital twins provide a continuous, data-rich view of equipment performance and conditions. For A&amp;D manufacturers, this means instant insight into how assets behave under specific conditions, helping them identify and correct potential quality issues before they impact the final product.&nbsp;</p><p dir="ltr">When coupled with predictive maintenance, digital twins go beyond monitoring by forecasting maintenance needs based on real-time data. Through advanced analytics and machine learning, digital twins enable manufacturers to anticipate failures, optimize equipment uptime, and prevent costly interruptions or defects in production.</p><p dir="ltr">Digital threads unify these core technologies into a single, interconnected data flow that spans the product lifecycle from design to manufacturing to aftermarket . This integration creates a “single source of truth” for all production data, allowing every team involved in the manufacturing process to work from the same, continuously updated information.&nbsp;</p><p dir="ltr">As a result, it facilitates traceability and enforces consistency, ensuring quality standards are upheld at every stage. Any deviation from the design or production process is instantly visible, enabling swift corrective actions that uphold compliance and minimize costly rework. By embedding these digital solutions within the production workflow, Quest Global empowers A&amp;D manufacturers to achieve precision, enhance operational resilience, and build a robust, data-driven foundation for addressing non-conformance issues on a global scale.</p><p dir="ltr"><a href="https://wevlv.co/qg-webinar2-articles" target="_blank" rel="noopener noreferrer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyNTMxMjAxNzAxLTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></a></p><h2 dir="ltr">Real-World Applications: The Benefits of Digital Threads in A&amp;D</h2><p dir="ltr">Traditional A&amp;D manufacturing has historically relied on manual inspections and outdated systems that struggle to keep pace with modern complexity. Quest Global’s digital thread approach replaces these inefficiencies with an automated, interconnected solution. This shift from reactive to proactive quality management empowers manufacturers to pinpoint potential issues long before they manifest, dramatically reducing the need for rework and ensuring high compliance rates.</p><h3 dir="ltr">Case Study: Streamlined Production Support for Aerospace Manufacturing</h3><p dir="ltr">An aerospace client sought to revamp their producibility flow line to improve efficiency and reduce non-conformance. Quest Global established a dedicated cross-functional team, to manage the overall operations and flowlines. Through data visualization tools, , Quest Global enabled real-time tracking of KPIs &nbsp;that helped identify and eliminate bottlenecks methodically.&nbsp;</p><p dir="ltr">This structured approach allowed for proactive root cause analysis, enabling effective trend analysis and forecasting of quality issues. Quest Global’s solutions achieved a 30% reduction in non-conformance on key products and a 65% reduction in backlog. Further, Quest Global enhanced the client’s real-time monitoring capabilities with a whiteboard-to-digital transformation, improving the quality of Non Conformance origination data by greater than 95% &nbsp;and total resolution time (TRT) within one day, leading to improved quality and efficiency across the production process.</p><h3 dir="ltr">Case Study: Predictive Quality Management with Data-Driven Insights</h3><p dir="ltr">Another aerospace manufacturer faced high costs of poor quality (CoPQ) and frequent production delays due to inconsistent quality management across a globally distributed supply chain. To address these challenges, Quest Global implemented a predictive quality management solution that combined DMAIC methodology, real-time data analytics, and machine learning.&nbsp;</p><p dir="ltr">This solution utilized correlation and regression analysis to build relation of process variables . By streamlining non-conformance management and enhancing the client’s ability to forecast issues, Quest Global reduced non-conformance rates by 28% and improved TRT by 50%, leading to $2.4 million in annual savings. Additionally, the solution helped improve productivity by 22% significantly enhancing overall production reliability.</p><p dir="ltr">These case studies highlight how Quest Global empowers manufacturers to reduce non-conformance, streamline production, and achieve substantial cost savings, setting a new standard for operational efficiency and reliability in the industry.</p><h2 dir="ltr">Pioneering a Digital-First Future in Aerospace Manufacturing</h2><p dir="ltr">Quest Global envisions a future where digital threads, automation, and AI-driven systems become fundamental to A&amp;D manufacturing. By transforming quality management into a strategic advantage, Quest Global’s digital solutions empower manufacturers to uphold rigorous standards without compromising efficiency.</p><p dir="ltr">This seamless, digital-first approach positions quality control as a competitive differentiator, enabling A&amp;D manufacturers to proactively address challenges, optimize production, and ensure consistent compliance throughout the supply chain. By unifying each phase of production within a data-centric framework, Quest Global’s digital thread solutions reduce non-conformance, improve transparency, and integrate predictive insights that strengthen operational resilience and overall efficiency.</p><h3 dir="ltr">New Webinar: Addressing Non-conformance in Aerospace &amp; Defense Manufacturing</h3><p dir="ltr">Join Quest Global’s upcoming webinar, “Zero Defects in Aerospace &amp; Defense: Achieving Perfection through Technology,” on January 22nd to explore how digital threads are reshaping A&amp;D manufacturing. Register now for the chance to gain insights from industry leaders and discover actionable strategies for driving quality and efficiency in your organization.</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243243175362453" title="Quest Global Form [Webinar 2]" allowtransparency="true" src="https://form.jotform.com/243243175362453" frameborder="0" style="min-width:100%;max-width:100%;height:1270px;border:none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p>

Aerospace and defense manufacturing faces strict quality demands where non-conformance disrupts efficiency. Read how Quest Global is leading the transformation to a more proactive, data-driven approach that delivers unprecedented levels of control, reliability, and efficiency across the industry.

Leveraging Digital Threads to Minimize Non-Conformance in A&D Manufacturing

<p id="isPasted"><a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a> is a versatile and precise manufacturing process capable of producing components with a wide range of complexity and sizes using various materials. However, it does come with size limitations dictated by various factors. Awareness of these constraints is crucial for optimising designs and ensuring that designs can be manufactured.</p><h2 data-counter-attr="value0"><strong>General Size Limitations of CNC Machining</strong></h2><p>This section highlights several design tips and considerations that could improve part manufacturability while optimising cost and lead time. It discusses part complexity and CNC manufacturing constraints such as fillets, holes, pockets, threads, and undercuts.</p><h3 data-counter-attr="value1"><strong>Material Blank Size</strong></h3><p>This refers to the size of the raw material used to create the finished part. Material blanks typically need to be slightly larger than the finished part’s measurements to allow for variations and to cut away rough faces of the raw material.&nbsp;</p><p>For example, if the final dimensions are to be 50 x 50 x 50 mm, then a suitable material blank would be roughly 53 x 53 x 53 mm. When designing, take this into consideration by adding additional X, Y, and Z dimensions to your part and matching it to the part size limits below.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514482046-blank-size-1.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value2" id="isPasted"><strong>Limitation for Milled, Lathe and Drilled Parts</strong></h3><table><thead><tr><th>Part/Feature</th><th>CNC Milling</th><th>CNC Turning</th><th>CNC Drilling</th></tr></thead><tbody><tr><td><strong>Maximum size</strong></td><td>The largest CNC milling machines, like the <a href="https://www.k-mm.com/large-machining/" target="_blank" rel="noopener">SNK HF-7VM vertical gantry mill</a>, have a pallet size of 3500 mm by 10000 mm, with X-axis travel of 11000 mm, Y-axis travel of 4700 mm, and Z-axis travel of 2450 mm.</td><td>The largest CNC turning centres, such as the SL 603, can handle parts with diameters up to 930 mm and lengths up to 4000 mm.</td><td>The largest CNC drilling machines, like the <a href="https://www.voortman.net/en/products/v200-plate-drilling-machine" target="_blank" rel="noopener">Voortman V200</a>, can handle plates up to 2400 mm in length, 1000 mm in width, and 60 mm in thickness, with a maximum weight of 600 kg.</td></tr><tr><td><strong>Minimum size</strong></td><td>Typically, the smallest feasible feature size is 0.5 mm. For practical purposes, machining features smaller than 2.5 mm in diameter is considered micro-machining and is generally avoided unless necessary.</td><td>The smallest practical diameter for turned parts is approximately 0.5 mm, with common practice starting from about 1 mm.</td><td>Standard practice for most drilling applications starts at 2.5 mm diameter for ease of production and accuracy. Although, the smallest standard drill bit size used is around 1 mm. For very small features, holes as small as 0.05 mm (50 micrometers) can be drilled, but this falls into the realm of micro-drilling, which requires specialised equipment and techniques.</td></tr><tr><td><strong>Better alternatives for larger parts (than maximum)</strong></td><td>• Injection molding (plastics)<br>• Die casting, metal extrusion (metals)</td><td>• Injection molding (plastics)<br>• Forging, casting (metals)</td><td>–</td></tr><tr><td><strong>Better alternatives for smaller parts (than minimum)</strong></td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics)<br>• Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics)<br>• Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>–</td></tr></tbody></table><h3 data-counter-attr="value3"><strong>Feature Size Limitations: Reference Chart</strong></h3><p>The following chart summarises the design guidelines associated with various features that can be made using CNC. Its purpose is to help designers optimise components for manufacturability.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514529304-diagram-cnc-machining-design-guidelines-1.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514573679-chart-cnc-machining-design-guidelines.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value4" id="isPasted"><strong>Size Limitations for Post-Processing</strong></h3><p>The different post processing operations that can be carried out on a part depend on the size of the part. For example, larger parts often do not fit in media-blasting cabinets, therefore such parts cannot be blasted. Another example is that custom racking may be required for parts larger than 3 meters that need to be anodized, electroplated or powder coated.</p><table><thead><tr><th>Process</th><th>Maximum part size&nbsp;</th><th>Notes</th></tr></thead><tbody><tr><td>CNC Turning</td><td>Diameter up to 500 mm and length up to 4500 mm</td><td>Xometry uses specialized tooling, including standard 2-axis lathes, live tooling systems, multi-spindle machines, and Swiss lathes, to produce parts with milled or intricate features.</td></tr><tr><td>CNC Milling</td><td>Xometry’s partner network can typically mill parts up to X-2000 mm, Y-750 mm, and Z-600 mm.</td><td>If your part exceeds 600 mm in machinable height, it will require specialized tooling and an additional manual review for manufacturability.</td></tr><tr><td>CNC Drilling</td><td>Equipment includes upright, bench, and radial drill presses, enabling Xometry to drill holes up to 7 cm in diameter in simple and complex patterns.</td><td>The complexity of the drilling pattern and material may affect lead times and costs.</td></tr></tbody></table><h3 data-counter-attr="value5"><strong>General Manufacturing Standards</strong></h3><p>Unless otherwise specified, Xometry manufactures CNC-machined components to the following standards:</p><ul><li><strong>Surface Finish</strong>: The as-machined surface finish is Ra 3.2 or better, with CNC machine tool marks possibly leaving a swirl-like pattern.</li><li><strong>Edge Treatment</strong>: Sharp edges will be broken and deburred by default. If critical edges need to remain sharp, this should be noted and specified on the CAD drawing.</li><li><strong>Plastic Components</strong>: Clear or transparent plastics will have a matte finish or translucent swirl marks on any machined face. Bead blasting will result in a frosted finish on clear plastics.</li><li><strong>Tolerances</strong>: Tolerances on foam or similar compressible materials cannot be guaranteed.</li></ul><h3 data-counter-attr="value6"><strong>General Tolerances</strong></h3><p>Unless specifically specified by the designer, Xometry will adhere to the industry standard ISO 2768 and ISO 286 tolerances listed below:</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514609862-cnc-machining-tolerances-2048x867.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">General tolerances for CNC machining start at ±0.1 mm. Tighter tolerances, defined as smaller than the general standard, can be achieved with CNC machining, reaching up to ±0.01 mm.&nbsp;</p><p>Specialized setups and additional operations like reaming and grinding can allow for even tighter tolerances depending on the material and part geometry. Geometric tolerances (GD&amp;T) can be applied to the drawing, but these may increase inspection times due to the necessary tools and time for checking.</p><p>While tighter tolerances improve a part’s form, fit, and function, they have drawbacks. They can lead to higher scrap rates, additional fixturing, special measurement tools, and longer cycle times from slower cutting speeds. These factors can increase pricing and lead times. Depending on the tolerance and geometry, the part cost can more than double compared to a standard tolerance.</p><h2 data-counter-attr="value7"><strong>General Size Limitations of CNC Machines</strong></h2><p>The physical dimensions of CNC machines’ work envelopes are the main factor limiting their part size capabilities. This constraint affects all types of CNC machines, including turning, milling, and drilling. Other limiting factors include the machine’s axis travel and the number of axes.</p><h3 data-counter-attr="value8"><strong>CNC Machining Work Envelope</strong></h3><p>The CNC machining work envelope refers to the 3D space within which the machine operates. Different machines each have their own work envelope, which limits the size of components that can be manufactured using the machine.&nbsp;</p><p>The physical size of the machine, and more specifically, the X, Y, and Z directions in which the machine can move, dictates the work envelope.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514654906-1732514654906.png" class="fr-fic fr-dib"></p><p id="isPasted">However, it is important to note that when designing components, the work envelope might be reduced due to tooling size. For example, as shown above, if the cutting bit were longer, the CNC work envelope would be smaller in the Z direction.</p><h3 data-counter-attr="value9"><strong>CNC Axis Travel</strong></h3><p>CNC axis travel is the range over which the cutting tool or workpiece can move along the X, Y, and Z axes. This has a direct impact on the size of components that can be machined. Below is an example of a 3-axis CNC milling machine. In this case, the rail lengths dictate the distances the machining bit can move in each direction.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514681918-cnc-axis-travel-1536x1536.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value10" id="isPasted"><strong>CNC Axis Types</strong></h3><p>CNC machines typically operate within 3 to 5 axes. Three-axis CNC machines move the cutting tool along the X, Y, and Z axes. Four-axis CNC machines add an additional rotation axis, which increases the complexity of the parts that can be manufactured.&nbsp;</p><p>Finally, five-axis CNC machines add two additional rotation axes to the X, Y, and Z movements. The number of axes significantly affects the size and complexity of components that can be manufactured.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514699442-3-axis4-axis-5-Axis-CNC-Machining.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Diagram of 3-axis, 4-axis and 5-axis CNC machines (Source: worthyhardware.com)</span></span></span></p><h2 data-counter-attr="value11" id="isPasted"><strong>CNC Turning Size Limitations</strong></h2><p>CNC turning involves a rotating workpiece, while a single-point cutting tool removes material. The physical geometry of a CNC lathe dictates the size limitations. CNC turning machines are constrained by their centre distance, swing distances, and how the workpiece is mounted.</p><h3 data-counter-attr="value12"><strong>Distance Between Centres</strong></h3><p>For a CNC Lathe, the distance between centres refers to the distance between the lathe headstock and tailstock. This limits the total maximum machinable length of the component that can be machined.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514792535-Technical-illustrations-01-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 data-counter-attr="value13" id="isPasted"><strong>Swing Over Bed, Cross Slide, and Gap</strong></h3><p>The terms “Swing Over Bed,” “Swing Over Cross Slide,” and “Swing Over Gap” define different clearance measurements on a lathe. Swing Over Bed indicates the maximum diameter that can be machined over the bed’s longitudinal guideway.&nbsp;</p><p>“Swing Over Cross Slide” is the diameter allowance over the cross slide, which is smaller than the Swing Over Bed. “Swing Over Gap” indicates a small gap allowing larger diameter parts, such as flanges, to be machined.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514816151-Technical-illustrations-06-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">These different swing parameters affect the CNC turning diameter limits and the component length. Here’s a more detailed description:</p><ul><li><strong>Swing Over Bed</strong>: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li><strong>Swing Over Cross Slide</strong>: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered. &nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm. If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li><strong>Swing Over Bed</strong>: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li><strong>Swing Over Cross Slide</strong>: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered.&nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm.&nbsp;If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li><strong>Swing Over Gap</strong>: The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility. The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility.</li></ul><h3 data-counter-attr="value14"><strong>Mounting Method of the Workpiece</strong></h3><p>In typical CNC lathe operations, the workpiece is secured in the headstock and supported by the tailstock. However, for certain tasks, the workpiece is only mounted in the headstock. In these cases, the material type and thickness determine the allowable length of the workpiece, as excessive length can cause flexing and potential issues.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514839913-Technical-illustrations-04-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 data-counter-attr="value15" id="isPasted"><strong>CNC Milling Size Limitations</strong></h2><p>CNC milling machines use rotating cutting tool to remove material from a workpiece. Milling machine size limitations are dictated by the CNC machining work envelope and tool reach.</p><h3 data-counter-attr="value16"><strong>CNC Machining Work Envelope</strong></h3><p>The physical size of the milling machine table (X and Y) and the maximum axis (Z) travel limit the size of the workpiece. One should note that the work envelope does not denote the exact maximum size of the workpiece, and the workpiece might be further limited by the tooling.&nbsp;</p><h3 data-counter-attr="value17"><strong>Tool Reach</strong></h3><p>The length of the cutting tool and the ability to reach different areas without interference places a size limitation on the workpiece. For example, deep features in the part could typically be limited by the tool length rather than the travel of the tool.&nbsp;</p><p>To further illustrate this, if you were to have a part with narrow grooves, as in the image below, the tool length would be the limiting factor as the tool holder would not be able to move past the top face of the component, should the depth of the grooves surpass the length of the tool.&nbsp;</p><p>In terms of accuracy, machines produced by Kern Microtechnik can achieve tolerances as tight as ±2 microns (±0.00007 inches).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514866771-cnc-mill-interior-1536x865.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Deep features in the part can typically be limited by the tool length</span></span></span></p><h2 data-counter-attr="value18" id="isPasted"><strong>CNC Drilling Size Limitations</strong></h2><p>CNC drilling is used to create holes in a workpiece, and the size limitations are primarily influenced by the machine’s Z-axis travel and the length of the drill bits. Thus, it is important to ensure that the drill bit length and axis travel surpass the thickness/height of the workpiece that needs to be drilled. Another size limit is the bed size of the CNC drilling machine, which dictates the maximum length and width of the workpiece that can be drilled.</p>

This article reviews the CNC machining size limitations, covering major constraints such as the work envelope of CNC mills and the diameter limitations of CNC-turned parts. It highlights CNC capabilities and size constraints at Xometry, available materials, and post-processing considerations.

CNC Machining Size Limitations: Everything You Need to Know

Real Time Production Monitoring System application in Smart Industrial Automotive Manufacturing

This article delves into the essentials of ICS, exploring the key types of industrial control systems, cutting-edge innovations, real-world applications and their critical analysis.

Types of Industrial Control Systems: Examples and Applications

<p dir="ltr" id="isPasted">Manufacturers operate in a rapidly evolving environment with a unique set of challenges. Global competition drives them to reduce costs while meeting rising quality expectations. There's also a race to achieve faster time-to-market to attract and retain clients. Meanwhile, government and industry bodies around the globe have been enforcing stringent sustainability mandates. To meet these targets, manufacturers work towards reducing greenhouse emissions and adopt circular economy practices.</p><p dir="ltr">On top of this, the pace of technological advancement presents another challenge. Staying competitive requires manufacturers to adopt new technologies, which often comes with high upfront costs and can disrupt established workflows. As teams adjust to new workflow, productivity can temporarily dip, which creates strain.</p><p dir="ltr">To overcome these challenges, manufacturers need data-driven strategies to boost accuracy, productivity, and adaptability. Intergrating digital solutions is the way forward as it helps make informed decisions to streamline processes and stay competitive in an every-changing industry.</p><h3 dir="ltr">The Rise of Smart Manufacturing: A Transformation Underway</h3><p dir="ltr">The fourth industrial revolution, or Industry 4.0, is helping manufacturers integrate digital technologies such as automation, AI, cloud computing, and IoT to create smart factories where machinery, sensors, and software are connected. With real-time data collection and intelligent analytics, companies can detect inefficiencies and make informed decisions to optimize processes.</p><p dir="ltr">As a leader in this space, Hexagon offers integrated manufacturing intelligence that spans from design to the final product. By providing tools for design, simulation, and quality management, Hexagon enables manufacturers to adopt processes that drive precision, sustainability, and adaptability.</p><table style="width: 100%;"><tbody><tr><td style="width: 100%; vertical-align: top;"><h2 dir="ltr" id="isPasted">Hexagon Live in Eindhoven: Insights, Innovation, and Networking</h2><p dir="ltr" id="isPasted">On November 27th and 28th Hexagon presents participants the chance to engage first-hand with their manufacturing solutions at Hexagon Live. The event also provides an opportunity to build connections with like-minded professionals, opening doors for future collaborations and growth opportunities.By interacting with thought leaders, visitors can gain valuable knowledge that can help them tackle challenges in their businesses.</p><ul id="isPasted"><li dir="ltr" style="font-weight: bold;"><p dir="ltr"><strong>27 November – Strategic Insights – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></strong></p></li><li dir="ltr" style="font-weight: bold;"><p dir="ltr"><strong>28 November – Technology Deep-Dive – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></strong></p></li></ul></td></tr></tbody></table><h2 dir="ltr">The Need for Advanced Digital Manufacturing Technologies</h2><h3 dir="ltr">Addressing Industry Challenges</h3><p dir="ltr">Manufacturers face a range of challenges that impact every stage of the production cycle. One of the most pressing is supply chain instability, caused by factors such as natural disasters, trade restrictions, and pandemics. These disruptions can delay production in today's globally distributed supply chains.</p><p dir="ltr">Energy and resource efficiency have become critical priorities due to fluctuating energy prices fueled by current geopolitical tensions. High energy costs increase production expenses, trimming already slim margins.</p><p dir="ltr">Equipment downtime poses another key efficiency roadblock. Not only does it require costly repairs but also ends up wasting valuable man-hours. The rising demand for customized products adds to these challenges. Manufacturers are now required to frequently perform time-consuming reconfiguration tasks to accommodate a wider variety of designs.</p><h3 dir="ltr">Solving Challenges with Digital Innovation</h3><p dir="ltr">Digital solutions are addressing core challenges in energy efficiency, downtime reduction, and product customization. While implementing these technologies requires an initial investment, they provide long-term benefits.</p><p dir="ltr">To manage high energy costs, manufacturers are adopting IoT-based energy monitoring and automation systems. These systems utilize sensors and smart controls to optimize energy consumption in real time. For instance, occupancy sensors can detect activity in different areas, adjusting lighting and HVAC systems to minimize energy waste.</p><p dir="ltr">Predictive maintenance has proven effective in minimizing unplanned equipment downtime. The system leverages historical data analysis, real-time machine health monitoring, and machine learning. When an anomaly or potential failure pattern is identified, the system alerts engineers to perform maintenance before a breakdown occurs.</p><p dir="ltr">In response to increasing demand for customized products, manufacturers are turning to digital twins. By creating virtual replicas of production systems, engineers can simulate and test custom designs before production begins, accelerating the design-to-manufacturing cycle. Additionally, companies are deploying flexible manufacturing systems (FMS), which feature modular workstations that can be retooled quickly. This flexibility allows manufacturers to easily switch between different product designs without requiring extensive modifications to the factory setup.</p><h2 dir="ltr">Driving the Manufacturing Intelligence Transformation</h2><p dir="ltr">Hexagon’s intelligence solutions integrate into the manufacturing ecosystem by seamlessly connecting tools, technologies, and data throughout entire production cycles. At the heart of this integration is the use of advanced tools such as digital twins, automation systems, and simulations. This integration allows data collection from each stage of the process allowing teams to monitor progress more effectively.</p><p dir="ltr">Metrology tools help companies ensure that components and products meet exact specifications, maintaining precision throughout production. This minimizes extensive rework and material waste caused by incorrect tolerances. Hexagon enhances this process by providing in-process measurement systems that monitor and measure parts directly on the production line.</p><p dir="ltr">Hexagon's innovative solutions enable real-time collaboration between design and production teams. Through digital simulation, manufacturers can optimize designs before production begins. The ability to check components digitally reduces development time, minimizes material waste, and enhances safety in industries like automotive and electronics.</p><p dir="ltr">The company combines automation technologies with its cutting-edge software to optimize manufacturing workflows. By integrating real-time data, it enhances process efficiency and improves operational outcomes.</p><p dir="ltr">Its predictive maintenance solutions identify potential issues so that engineers can address problems before they cause costly breakdowns. Such practices ensure smooth operations and extend the lifespan of equipment. Hexagon’s IoT-enabled energy monitoring tools further support sustainability efforts. These tools help companies pinpoint inefficiencies, reduce waste, and optimize resource usage.</p><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5Njg0NzkxLUhleGFnb25NSVJRMjAxOFBvZDgwMHg0MjhEZXNpZ25FbmdpbmVlcmluZ0ljb24oMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Through digital simulation, manufacturers can optimize designs before production begins. Source:&nbsp;<a href="https://hexagon.com/company/divisions/manufacturing-intelligence/what-we-do/design-engineering" target="_blank" rel="noopener noreferrer">Hexagon</a>.</span></span></span></h3><h3 dir="ltr">Support and Success</h3><p dir="ltr">Hexagon supports some of the world’s leading organizations in various industries. For example, the iconic Red Bull Racing Formula 1 team relies on Hexagon’s metrology equipment and scanners to ensure the precision needed to build their cutting-edge car.</p><p dir="ltr">Volkswagen Group’s ŠKODA AUTO also uses Hexagon’s automated measurement systems across its manufacturing facilities to enhance production accuracy and capacity.</p><p dir="ltr">Additionally, CERN, the organization dedicated to uncovering the mysteries of the universe, trusts Hexagon’s solutions to monitor its entire technical infrastructure, ensuring seamless operations for groundbreaking research.</p><p dir="ltr">For more success stories, <a href="https://hexagon.com/resources/customer-success-stories">click here</a>.</p><h2 dir="ltr">What to Expect at Hexagon Live in Eindhoven: Insights, Innovation, and Networking</h2><h3 dir="ltr">Gain Exclusive Knowledge from Manufacturing Experts &amp; Network with Industry Innovators</h3><p dir="ltr">On November 27th and 28th Hexagon presents participants the chance to engage first-hand with their manufacturing solutions at Hexagon Live. The event also provides an opportunity to build connections with like-minded professionals, opening doors for future collaborations and growth opportunities.By interacting with thought leaders, visitors can gain valuable knowledge that can help them tackle challenges in their businesses.</p><h3 dir="ltr">Content Tailored to Your Needs: Innovation and Problem-Solving</h3><p dir="ltr">The event offers a range of sessions designed to tackle real-world challenges within the manufacturing sector.</p><p dir="ltr">Hear from companies that have successfully navigated manufacturing challenges with the help of digital innovations. These case studies highlight what's possible and serve as a framework for your strategic planning.</p><h3 dir="ltr">Hands-On Exploration of Digital Reality Solutions</h3><p dir="ltr">The event offers a chance to experience how Hexagon's digital reality tools improve operational efficiency. Visitors get an understanding of how to leverage real-time data, machine learning, and automated workflows to optimize every stage of their operations, from design to delivery.</p><h2 dir="ltr">Explore the Manufacturing of Tomorrow at The Experience Center</h2><p dir="ltr">Hexagon's new Experience Centre in Eindhoven brings the future of manufacturing to life, offering visitors a chance to see how cutting-edge technologies are reshaping the industry. Being one of the first of its kind in Europe, the center promises an immersive experience where you can explore&nbsp;emerging trends, solutions, and new products first-hand.&nbsp;From reimagining production lines to real-time energy monitoring, the center showcases how facilities are evolving to meet the demands of next-generation aircraft and electric vehicles.</p><blockquote><p dir="ltr">“It’s about creating a memorable “wow” factor, leaving visitors inspired by a company offering robust solutions to today’s challenges and a visionary partnership for the future. Experience Centres have the potential to be game-changers.”</p></blockquote><p dir="ltr"><em>Marcel Brand, Senior Director Global Events &amp; Experience Centres<br>Hexagon, Manufacturing Intelligence division</em></p><p dir="ltr">In addition to theory, attendees can get hands-on with the PRESTO system and discover how automation is transforming quality control by improving precision and drastically reducing inspection times.</p><p dir="ltr">Explore the HxGN Machine Trainer, a digital twin simulator used by industry leaders like Safran to train CAM programmers and machine tool operators quickly and safely. Visitors can also experience CMM machines and 3D scanners up close, gaining insights into the latest technologies driving innovation in aerospace, automotive, and electronics manufacturing.</p><h2 dir="ltr">Hexagon Live Day 1: 27 November – Strategic Insights</h2><h2 dir="ltr"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" class="link"></a></h2><h3 dir="ltr" id="isPasted">Practical Innovation Workshops</h3><p dir="ltr">The workshops at the event are designed to address challenges in managing complex semiconductor supply chains. Experts will help attendees understand how to streamline operations to manage global disruptions and enhance supply chain resilience to ensure material availability.</p><p dir="ltr">Visitors can discover how to utilize data and automation to optimize processes in the energy industry. From increasing efficiency to reducing waste, these strategies can improve operations at every level.</p><p dir="ltr">The event touches also upon the latest technologies in energy production and distribution, with a focus on how AI and machine learning are helping in energy forecasting and demand management. You'll learn practical approaches for integrating renewable energy sources into existing infrastructure.</p><p dir="ltr" id="isPasted"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" class="button-main-action">Register Now</a></p><h3 dir="ltr">Insightful panel discussions</h3><p dir="ltr">The company will also host panel discussions featuring industry leaders and experts who will share their perspectives on industry advancements.</p><p dir="ltr">These discussions will explore how technologies digital twins and simulation are accelerating design and product development cycles in both aerospace and automotive manufacturing.</p><h3 dir="ltr">An F1 Engineering Marvel Up Close&nbsp;</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5ODc0ODg0LU9yYWNsZS1SZWQtQnVsbC1SYWNpbmctY2FzZXN0dWR5LWJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The Hexagon Live event will also feature a keynote session from the Oracle Red Bull giving insight into how they leverage Hexagon's technology for success. Source:&nbsp;<a href="https://hexagon.com/resources/resource-library/hexagon-measurement-keeps-productivity-track" target="_blank" rel="noopener noreferrer">Hexagon</a>.</span></span></span></p><p dir="ltr">Who better to offer insights on staying ahead of the competition than Oracle Red Bull Racing? This legendary team has secured 6 Constructors' Championships and 7 Drivers' Championships.</p><p dir="ltr">Competing against the best in the world leaves Red Bull Racing with no margin for error. Don’t miss Red Bull’s keynote to learn how Hexagon helps the team achieve unparalleled accuracy, efficiency, and speed in a sport where just one-tenth of a second can make all the difference.</p><h2 dir="ltr">Hexagon Live Day 2: 28 November – Technology Deep-Dive</h2><h3 dir="ltr">In-Depth Exploration of Technical Breakthroughs</h3><p dir="ltr">On the second day of the event, attendees will get to discover the latest metrology solutions, including in-process measurement that integrates metrology directly into the production phase. The session will also cover the impact of these innovations on quality control processes.</p><p dir="ltr">Next, visitors can explore finite element analysis (FEA) simulation techniques, which utilize digital models to simulate how objects behave under forces to predict real-world results. It will be followed by a deep dive into advanced design, feasibility, and cost optimization for sheet metal components.</p><p dir="ltr"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" id="isPasted" class="button-main-action">Register Now</a></p><h3 dir="ltr">Gain Innovative Perspectives</h3><p dir="ltr">The event will highlight how non-contact reality capture offers real-world analysis with precise 3D representations of environments. Attendees will learn how this technology enables engineers, builders, and forensic teams to ensure no critical details are overlooked. With edge computing, they can validate data accuracy directly on-site, streamlining the process and improving outcomes.</p><h2 dir="ltr">Ready to Be a Part of the Future? Register Now for Hexagon Live!</h2><p dir="ltr">Hexagon Live offers a unique opportunity to explore the latest in manufacturing innovation and gain valuable insights to stay ahead in this ever-changing industry.</p><p dir="ltr">Discover advanced solutions like automation and digital twins, designed to boost efficiency and improve quality. Attend discussion panels and workshops to connect with leading professionals and gather expert knowledge.</p><p dir="ltr">Best of all, general admission is completely free. What are you waiting for? Use the following links to reserve your spot today!</p><ul><li dir="ltr"><p dir="ltr">27 November – Strategic Insights – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></p></li><li dir="ltr"><p dir="ltr">28 November – Technology Deep-Dive – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></p></li></ul><p dir="ltr"><strong>Unable to attend? Wevolver will be livestreaming the event on our&nbsp;</strong><a href="https://www.linkedin.com/company/wevolver/"><strong>Linkedin</strong></a><strong>&nbsp;and </strong><a href="https://x.com/WevolverApp?ref_src=twsrc%5Egoogle%7Ctwcamp%5Eserp%7Ctwgr%5Eauthor" target="_blank" rel="noopener noreferrer"><strong>Twitter</strong></a><strong> page on November 27th.&nbsp;</strong><a href="https://www.linkedin.com/company/wevolver/mycompany/#:~:text=Message-,Following,-Home" target="_blank" rel="noopener noreferrer"><strong>Follow us</strong></a><strong>&nbsp;to get a notification on the day so you don't miss a moment!</strong></p>

Learn how manufacturers are leveraging IoT, AI, and automation to tackle global competition, meet sustainability goals, and enhance customization at Hexagon Live on November 27th-28th.

Step into the Center of Future Manufacturing: Experience Intelligent Manufacturing Solutions at Hexagon Live

In the first chapter of our new report, we examine the dominant methods of metal 3D printing—metal laser powder bed fusion (LPBF), directed energy deposition (DED), metal extrusion, and binder jetting—as well as other still-emerging or more niche processes.  

The Metal 3D Printing Technology Report: Chapter 1: Core Metal 3D Printing Technologies

<p>From November 12 to 15, Munich became the epicenter of the global electronics industry as <strong>Electronica 2024</strong> brought together 3,480 exhibitors and nearly 80,000 visitors from across the world. Renowned as the industry’s leading trade fair, this year’s event was more international than ever, offering a glimpse into how digital technologies are shaping the path to a carbon-neutral future. Spanning 18 exhibition halls, the event highlighted groundbreaking advancements in <strong>artificial intelligence (AI)</strong>, <strong>sustainability</strong>, and the <strong>future of mobility</strong>, alongside the critical need to foster young talent in electronics.</p><h2>Key Topics Shaping the Electronics Landscape</h2><h3><strong>Sustainability: Electronics Driving the Green Revolution</strong></h3><p>At the heart of this year’s event was the drive to achieve carbon neutrality, with many exhibitors showcasing how electronics play a crucial role in environmental sustainability. From energy-efficient semiconductor solutions to IoT technologies that enable smarter energy management, it was clear that the industry is stepping up to address climate challenges.</p><p>Sustainability discussions centered on:</p><ul><li><strong>Smart Grids and Renewable Energy:</strong> Innovations in optimizing energy systems for greater efficiency.</li><li><strong>Circular Economy:</strong> Efforts to design electronics for recyclability and longevity.</li><li><strong>Green Electronics Manufacturing:</strong> Reducing the environmental footprint of production processes.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732193109394-electronica-infineon.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Smart and sustainable mobility was one of the main topics at this year's Electronica.</span></span></span></p><h3><strong>Artificial Intelligence: Powering the Industry</strong></h3><p>AI continued to dominate conversations, underscoring its influence across sectors. At Electronica 2024, AI’s transformative power was evident in:</p><ul><li><strong>Smart Manufacturing:</strong> Machine learning-driven solutions to optimize production lines and reduce waste.</li><li><strong>AI-powered Sensors:</strong> New sensor technologies with AI integration for predictive analytics in industrial and healthcare applications.</li><li><strong>Autonomous Mobility:</strong> The role of AI in enhancing vehicle safety and energy efficiency.</li></ul><h3><strong>Future of Mobility: Shifting Gears with Electronics</strong></h3><p>The push toward sustainable transportation took center stage, with electronics enabling electric vehicles (EVs), autonomous systems, and advanced battery technologies. Key themes included:</p><ul><li><strong>Electrification:</strong> Efficient power management and battery advancements for EVs.</li><li><strong>Connectivity:</strong> V2X (vehicle-to-everything) communication for smarter traffic ecosystems.</li><li><strong>Safety Systems:</strong> Innovations in sensor fusion and AI-enhanced driver-assistance technologies.</li></ul><h3><strong>Fostering Talent: Investing in the Future</strong></h3><p>With the global electronics industry facing a talent shortage, Electronica 2024 placed special emphasis on nurturing the next generation of engineers and innovators. Events, workshops, and mentorship programs were tailored to inspire students and young professionals to take up roles in this rapidly evolving field.</p><h2>Exhibitor Highlights: Innovations to Watch</h2><h3><strong>Infineon Technologies: AI and Sustainability at the Core</strong></h3><p><a href="https://www.infineon.com/cms/en/product/promopages/electronica/" target="_blank" rel="noopener noreferrer">Infineon</a> stole the spotlight with its dual focus on <strong>sustainability and digitalization</strong>. Showcasing AI-enabled semiconductor solutions, the company emphasized its commitment to green energy and smart mobility. Their technologies are pivotal in advancing applications such as solar energy systems, electric drives, and secure IoT solutions.</p><h3><strong>Altium: Transforming Electronics Design</strong></h3><p><a href="https://www.messe.tv/en/2024/electronica/altium-life-cycle-electronics-development" target="_blank" rel="noopener noreferrer">Altium</a>, a multinational software company specializing in electronic design automation, unveiled a trifecta of solutions—<strong>Altium</strong> <strong>Discover</strong>, <strong id="isPasted">Altium&nbsp;</strong><strong>Develop</strong>, and <strong id="isPasted">Altium</strong> <strong>Lifecycle</strong>—aimed at streamlining the electronics design process. From conceptualization to product lifecycle management, these tools empower engineers to innovate faster and with greater efficiency.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732192928529-novelties_altium_booth_electronica_2024_fair_munich-large.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Altium presented their three new solutions for solutions for the entire electronics development life cycle: Discover, Develop and Lifecycle. Source:&nbsp;<a href="https://www.messe.tv/en/2024/electronica/altium-life-cycle-electronics-development" target="_blank" rel="noopener noreferrer">Altium</a></span></span></span></p><h3><strong>Nordic Semiconductor: The New Standard in Bluetooth LE</strong></h3><p>Nordic Semiconductor introduced the <a href="https://www.nordicsemi.com/Nordic-news/2023/10/Nordic-announces-nRF54L-Series-expanding-industrys-most-efficient-Bluetooth-LE-portfolio" target="_blank" rel="noopener noreferrer"><strong>nRF54L Series</strong>,</a> expanding the world’s most energy-efficient Bluetooth Low Energy (LE) portfolio. With a focus on ultra-low power consumption, this series is ideal for applications like wearables, medical devices, and IoT solutions, pushing the boundaries of connectivity.</p><h3><strong>Analog Devices: Agile Manufacturing Robotics</strong></h3><p><a href="https://www.analog.com/en/lp/001/electronica.html" target="_blank" rel="noopener noreferrer">Analog Devices</a> showcased robotics innovations for agile manufacturing, demonstrating how precision sensors and edge computing can revolutionize production lines. Their solutions highlighted the growing importance of flexibility and efficiency in Industry 4.0 environments.</p><h3><strong>Ignion: IoT Innovation</strong></h3><p>Ignion focused on smart antenna solutions designed to improve IoT device performance, showcasing their new <a href="https://ignion.io/landing-page/discover-omnia-mxtend/" target="_blank" rel="noopener noreferrer">OMNIA mXTEND™</a>, a one-of-a-kind three-port Virtual Antenna® component designed to simplify RF connectivity for IoT applications.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732194027984-ignion-omnia-mxtend-antenna.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Ignion unveiled their new OMNIA mXTEND™ Virtual Antenna.&nbsp;</span></span></span></p><h2>From Carbon Goals to Connectivity: Electronica’s Blueprint for the Future</h2><p>Electronica 2024 left attendees with a clear message: the future of electronics is deeply intertwined with global efforts to create a sustainable, connected, and intelligent world. Innovations showcased at the event demonstrated the industry’s resilience and ability to address pressing challenges, from climate change to supply chain disruptions.</p><p>As we look ahead, several trends stand out:</p><ol><li><strong>AI as the Catalyst:</strong> Expect deeper integration of AI across all electronics applications, driving efficiency and unlocking new capabilities.</li><li><strong>Sustainability as a Mandate:</strong> Green manufacturing and circular design will become non-negotiable for businesses aiming to stay competitive.</li><li><strong>Talent Development:</strong> The need for a robust talent pipeline will see continued investment in education and mentorship.</li></ol><p>For engineers, technologists, and industry stakeholders, Electronica 2024 served as both a showcase of current advancements and a roadmap for the exciting developments yet to come. As the industry evolves, platforms like Electronica will remain indispensable for fostering collaboration, innovation, and progress.</p>

Over 80,000 visitors and 3,400 exhibitors attended this year's Electronica in Munich. Image source: Electronica.

From AI-powered manufacturing to sustainable mobility solutions, Electronica 2024 revealed how electronics are paving the way to a carbon-neutral world. This year’s record-breaking event featured game-changing technologies and fostered collaboration across the global industry.

Electronica 2024: Key Insights and Innovations Driving the Electronics Industry Forward

<p id="isPasted">As the world struggles to reduce greenhouse gas emissions, researchers are seeking practical, economical ways to capture carbon dioxide and convert it into useful products, such as transportation fuels, chemical feedstocks, or even building materials. But so far, such attempts have struggled to reach economic viability.</p><p>New research by engineers at MIT could lead to rapid improvements in a variety of electrochemical systems that are under development to convert carbon dioxide into a valuable commodity. The team developed a new design for the electrodes used in these systems, which increases the efficiency of the conversion process.</p><p>The findings are reported today in the journal&nbsp;<em>Nature Communications</em>, in a paper by MIT doctoral student Simon Rufer, professor of mechanical engineering Kripa Varanasi, and three others.</p><p>“The CO2 problem is a big challenge for our times, and we are using all kinds of levers to solve and address this problem,” Varanasi says. It will be essential to find practical ways of removing the gas, he says, either from sources such as power plant emissions, or straight out of the air or the oceans. But then, once the CO2 has been removed, it has to go somewhere.</p><p>A wide variety of systems have been developed for converting that captured gas into a useful chemical product, Varanasi says. “It’s not that we can’t do it — we can do it. But the question is how can we make this efficient? How can we make this cost-effective?”</p><p>In the new study, the team focused on the electrochemical conversion of CO2 to ethylene, a widely used chemical that can be made into a variety of plastics as well as fuels, and which today is made from petroleum. But the approach they developed could also be applied to producing other high-value chemical products as well, including methane, methanol, carbon monoxide, and others, the researchers say.</p><p>Currently, ethylene sells for about $1,000 per ton, so the goal is to be able to meet or beat that price. The electrochemical process that converts CO2 into ethylene involves a water-based solution and a catalyst material, which come into contact along with an electric current in a device called a gas diffusion electrode.</p><p>There are two competing characteristics of the gas diffusion electrode materials that affect their performance: They must be good electrical conductors so that the current that drives the process doesn’t get wasted through resistance heating, but they must also be “hydrophobic,” or water repelling, so the water-based electrolyte solution doesn’t leak through and interfere with the reactions taking place at the electrode surface.</p><p>Unfortunately, it’s a tradeoff. Improving the conductivity reduces the hydrophobicity, and vice versa. Varanasi and his team set out to see if they could find a way around that conflict, and after many months of work, they did just that.</p><p>The solution, devised by Rufer and Varanasi, is elegant in its simplicity. They used a plastic material, PTFE (essentially Teflon), that has been known to have good hydrophobic properties. However, PTFE’s lack of conductivity means that electrons must travel through a very thin catalyst layer, leading to significant voltage drop with distance. To overcome this limitation, the researchers wove a series of conductive copper wires through the very thin sheet of the PTFE.</p><p>“This work really addressed this challenge, as we can now get both conductivity and hydrophobicity,” Varanasi says.</p><p>Research on potential carbon conversion systems tends to be done on very small, lab-scale samples, typically less than 1-inch (2.5-centimeter) squares. To demonstrate the potential for scaling up, Varanasi’s team produced a sheet 10 times larger in area and demonstrated its effective performance.</p><p>To get to that point, they had to do some basic tests that had apparently never been done before, running tests under identical conditions but using electrodes of different sizes to analyze the relationship between conductivity and electrode size. They found that conductivity dropped off dramatically with size, which would mean much more energy, and thus cost, would be needed to drive the reaction.</p><p>“That’s exactly what we would expect, but it was something that nobody had really dedicatedly investigated before,” Rufer says. In addition, the larger sizes produced more unwanted chemical byproducts besides the intended ethylene.</p><p>Real-world industrial applications would require electrodes that are perhaps 100 times larger than the lab versions, so adding the conductive wires will be necessary for making such systems practical, the researchers say. They also developed a model which captures the spatial variability in voltage and product distribution on electrodes due to ohmic losses. The model along with the experimental data they collected enabled them to calculate the optimal spacing for conductive wires to counteract the drop off in conductivity.</p><p>In effect, by weaving the wire through the material, the material is divided into smaller subsections determined by the spacing of the wires. “We split it into a bunch of little subsegments, each of which is effectively a smaller electrode,” Rufer says. “And as we’ve seen, small electrodes can work really well.”</p><p>Because the copper wire is so much more conductive than the PTFE material, it acts as a kind of superhighway for electrons passing through, bridging the areas where they are confined to the substrate and face greater resistance.</p><p>To demonstrate that their system is robust, the researchers ran a test electrode for 75 hours continuously, with little change in performance. Overall, Rufer says, their system “is the first PTFE-based electrode which has gone beyond the lab scale on the order of 5 centimeters or smaller. It’s the first work that has progressed into a much larger scale and has done so without sacrificing efficiency.”</p><p>The weaving process for incorporating the wire can be easily integrated into existing manufacturing processes, even in a large-scale roll-to-roll process, he adds.</p><p>“Our approach is very powerful because it doesn’t have anything to do with the actual catalyst being used,” Rufer says. “You can sew this micrometric copper wire into any gas diffusion electrode you want, independent of catalyst morphology or chemistry. So, this approach can be used to scale anybody’s electrode.”</p><p>“Given that we will need to process gigatons of CO2 annually to combat the CO2 challenge, we really need to think about solutions that can scale,” Varanasi says. “Starting with this mindset enables us to identify critical bottlenecks and develop innovative approaches that can make a meaningful impact in solving the problem. Our hierarchically conductive electrode is a result of such thinking.”</p><p>The research team included MIT graduate students Michael Nitzsche and Sanjay Garimella, &nbsp;as well as Jack Lake PhD ’23. The work was supported by Shell, through the MIT Energy Initiative.</p><p>This work was carried out, in part, through the use of MIT.nano facilities.</p>

A conceptual schematic of the new woven electrode design. Researchers wove a series of conductive copper wires (the brown-orange pipe) through a very thin membrane to reach the catalyst. Image: Courtesy of the researchers, edited by MIT News

A new electrode design boosts the efficiency of electrochemical reactions that turn carbon dioxide into ethylene and other products.

Engineers make converting CO2 into useful products more practical

<p id="isPasted"><a href="https://www.fcmore.cl/">FC More Integral</a> is a leading engineering firm based in Chile that specializes in comprehensive solutions for the mining industry. The company manufactures, offers maintenance and repairs components of mining equipment. FC More Integral provides its services to major mining businesses, including Cerro Colorado, Collahuasi, Lomas Bayas (a Glencore company), Finning-CAT, and Komatsu, Minera Escondida, Minera Centinela and Sierra Gorda.</p><p>With a strong commitment to quality, FC More Integral has established itself as a trusted partner for complex projects across Latin America. The company’s team brings together multidisciplinary expertise, enabling it to deliver tailored solutions that meet each client’s unique challenges.</p><h2>Legacy inspection techniques are no longer effective for Latin America’s booming mining sector</h2><p>In the mining industry, maintaining and repairing large-scale equipment is a critical challenge, especially when it comes to the integrity of components and assemblies. Traditional visual inspections and manual 3D measurement techniques can be prone to human error, resulting in overlooked issues that lead to costly component failures and fleet downtimes.</p><p>According to Robert Valenzuela, Manager of Engineering, Administration and Quality at FC More Integral, there was—and still is—a growing need in the Latin American mining sector for more accurate and reliable methods to evaluate, repair, and improve parts to ensure equipment performance and operational efficiency.</p><p>The team at FC More Integral wanted to find a better approach, using the latest metrology technologies, to improve component inspections, designs, redesigns, manufacturing and quality control.</p><h2>Transforming 3D measurement challenges into market opportunities</h2><p>The FC More Integral started exploring different 3D scanning solutions. They settled on two Creaform solutions: the&nbsp;<a href="https://www.creaform3d.com/en/handyscan-3d-silver-series-professional-3d?aw_campaign=20.90.1.0-%5bBRANDED%5d-Search-Canada-EN%5bCB%5d&network=g&aw_device=c&keyword=handyscan%20silver&creative=696797456081&matchtype=p&gad_source=1&gclid=CjwKCAjwxY-3BhAuEiwAu7Y6s_kTPWwwT3s0CI-LbT6HZZSJivU99BqPjkgRqaJwqO1UZs21Z8OMIxoCJLoQAvD_BwE">HandySCAN 3D|SILVER metrology-grade 3D scanner</a> and the&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/optical-measuring-systems-maxshot-3d">MaxSHOT 3D optical coordinate measuring system</a>.</p><p>“Our customers use HandySCAN 3D|SILVER to carry out 3D measurements on smaller components and the MaxSHOT 3D to scan large components over 5 meters—and up to 30 meters,” explained Ismael Mandiola at Talentum Digital. “The results are always accurate, reliable and repeatable.”</p><p>The ultimate goal was to set up a brand-new and patented service, FC Scan, using Creaform’s technologies. In addition to improving the company’s in-house workflows, the HandySCAN 3D|SILVER and MaxSHOT 3D are now leveraged to provide FC More Integral’s customers with on-site assessments.</p><p>“With FC Scan, customers can obtain a range of possibilities, from a simple initial structural diagnosis to deformation or failure identification to an entire inspection cycle, which generates a real three-dimensional image of how the component is today,” Robert said. That data makes carrying out maintenance and repair work easier and more precise. FC Scan customers appreciate the higher quality of repairs, reduced lead times and minimized downtimes.</p><p>Another bonus is part archiving for future reference. “We can provide customers with complete models of various components and assemblies—information that was previously unavailable to many mining companies,” he mentioned.</p><p>FC More Integral’s experts are thrilled with the MaxSHOT 3D and HandySCAN 3D|SILVER. They have had a tremendously positive impact on the company’s processes and customer inspections.</p>

The FC More Integral started exploring different 3D scanning solutions. They settled on two Creaform solutions: the HandySCAN 3D|SILVER metrology-grade 3D scanner and the MaxSHOT 3D optical coordinate measuring system.

Mining engineering firm opens new service segment thanks to 3D scanners

<p id="isPasted">The Royal Netherlands Navy has a rich history and a modern edge. With a vast fleet of ships, helicopters, boats, and submarines, they are a global presence, often stationed far from home on challenging missions. Their commitment to excellence and innovation keeps them at the forefront of maritime defense.</p><h2>Spare part and logistical challenges</h2><p>The Royal Netherlands Navy faces the significant challenge of maintaining their fleet, wherever they are. Their assets often require spare parts, presenting a logistical dilemma. Carrying large quantities of unused spares consumes valuable space, adds weight, and incurs high costs. Transporting these spares, especially via helicopters, can take weeks and is extremely expensive, if it’s possible at all. Additionally, suppliers sometimes cease production of essential spares, complicating operations.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/gkNm7Sl7aew?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-24="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">3D printing as a solution</h2><p>To tackle this major challenge, the Royal Netherlands Navy has adopted 3D printing. This allows them to produce spare parts locally and on-demand. Each ship is equipped with UltiMaker 3D printers and a variety of materials, enabling them to print a wide range of applications.</p><p>Parts are designed and tested at their headquarters in Den Helder. Once approved, they are added to a digital catalog. Crew members simply need to select and print the necessary parts directly on board. The Navy also prints optimized parts for better performance, which can be distributed digitally, and produced locally.</p><p>The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards. Cura is the most popular slicing software used to prepare 3D models for printing, while UltiMaker's Digital Factory platform enables users to manage and monitor their 3D printers and print jobs remotely, enhancing workflow efficiency. Even with large teams, Digital Factory prioritizes security and ensures that data remains protected throughout the process without compromising accessibility.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087595130-the-royal-netherlands-navy-fleet-of-printers.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p>The Royal Netherlands Navy uses a range of filaments, including ABS, PETG, and composite carbon fiber. For instance, PETG is selected for applications that require resistance to extreme temperature, wear, chemicals, and water and moisture absorption. In this instance, the Navy needed a material that would be resistant to saltwater. Using PETG, they 3D printed a new water filter to replace an old brass one</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087624501-1732087624501.png" class="fr-fic fr-dib"></p><p id="isPasted">Composite carbon fiber filaments are used when parts need to be both strong and lightweight, such as a landing boat antenna bracket printed by the Royal Netherlands Navy. Marine antennas are essential for communications and safety. These mounts ensure they are securely in place and allow for the safe lowering and raising of the antenna. Carbon fiber is especially valuable as it allows traditionally heavy parts to be printed with a light material, reducing weight on the carrier as well as the need to transport heavy items across the globe.</p><p>This variety of materials allows the Navy to create parts suitable for any environment or condition. Parts on ships primarily require strength and wear resistance, while parts for land or air troops often need to withstand extreme heat or cold. For example, brackets mounted on land vehicles must endure prolonged sun exposure. With the Royal Netherlands Navy's global presence, these parts must be prepared for a variety of demanding conditions.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087646194-the-royal-netherlands-navy-cura.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Thanks to Cura software's capabilities, UltiMaker 3D printers can seamlessly use both UltiMaker’s and third-party filaments, providing greater flexibility for users. Cura provides a streamlined experience with UltiMaker printers, offering optimized print profiles and faster printing, while maintaining compatibility with third-party products. UltiMaker is committed to regular security updates and providing new feature updates to its Cura users.</p><p>The Royal Netherlands Navy is a classic example where local manufacturing excels over traditional spare part solutions. Having printers on their ships prevents the need for large stocks of spares on the ships. Furthermore, many parts don't have to travel to remote locations, saving time and extremely high cost. These benefits also apply to many other industries. Factories can benefit from local part production, ensuring uptime of production processes, saving on industrial space and preventing parts to be flown in.</p>

The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards.

On-Demand Spare Parts: The Royal Netherlands Navy's 3D Printing Solution

<p id="isPasted">Every year, roughly 1.2 million patients experience adverse outcomes associated with injectable medications, and these errors are estimated to cost about $5 billion. A team including a researcher from Carnegie Mellon University has developed the first wearable camera that uses artificial intelligence to help prevent such errors.</p><p>“The goal of our system is to catch these drug administration errors in real-time, before the injection, and provide an alert so the clinician has a chance to intervene before any patient harm,” said Justin Chan, an assistant professor in the School of Computer Science’s <a href="https://s3d.cmu.edu/" rel="noopener" target="_blank">Software and Societal Systems DepartmentOpens in new window</a> and the College of Engineering’s <a href="https://ece.cmu.edu/" rel="noopener" target="_blank">Department of&nbsp;Electrical and Computer EngineeringOpens in new window</a>.</p><p>In addition to Chan, the team included researchers from the University of Washington, Makerere University and the Toyota Research Institute.</p><p>The error rate for all drugs given in a hospital is about 5 to 10 percent, and they can happen at all levels of care. To design the wearable camera system, researchers focused on training deep learning algorithms that could detect errors when a clinician transfers a drug from a vial into a syringe. These could be vial swap errors, which occur when the wrong vial is used or the drug label on the syringe is incorrect; or syringe swaps, when the label is correct but the clinician administers the wrong drug. To prevent errors, hospitals use safeguards like requiring barcode scanning for syringes, but in high-pressure situations, clinicians can forget to scan the drug’s barcode or manually record its contents.</p><blockquote><p>The goal of our system is to catch these drug administration errors in real-time, before the injection, and provide an alert so the clinician has a chance to intervene before any patient harm.</p><cite><strong>Justin Chan, Assistant Professor, Electrical and Computer Engineering</strong></cite></blockquote><p>In their study, <a href="https://www.nature.com/articles/s41746-024-01295-2" rel="noopener" target="_blank">published in <em>npj Digital Medicine</em>Opens in new window</a>, researchers demonstrated how the AI-enabled wearable camera system could detect vial swap errors with a sensitivity of 99.6 percent and a specificity of 98.8 percent.</p><p>Chan said creating the deep learning system to detect errors as they happen was challenging because syringes, vials and drug labels are small and clinicians can inadvertently obscure them when handling them. Researchers collected a large training dataset from different operating room environments with different backgrounds and lighting conditions. They collected footage using a small head-mounted camera strapped to physicians’ foreheads, and the camera was tilted down to film the providers’ hands. Over 55 days, they collected 4K video footage of drug preparation events from 13 anesthesiology providers and 17 operating rooms in two hospitals.</p><p>“We designed the algorithm so that instead of reading the label text, which can be obscured, it only needs to catch a glimpse of visual cues like vial and syringe shape, label color, and font size for a short period of time to classify what the drug is,” Chan said.</p><p>Now that researchers have shown the accuracy of the system, their next step is incorporating the system into smart eyewear that can provide visual or auditory warnings to clinicians before a drug is delivered to a patient.</p><p>“This work demonstrates how AI-enabled systems can serve as a second set of ‘eyes’ to improve healthcare practices and patient safety,” Chan said. “When integrated into an electronic medical system, our system also opens up opportunities for automatic documentation of drug information and can reduce the overhead of manual record-keeping.”</p>

Researchers develop the first wearable camera that uses artificial intelligence to help prevent medical administration errors.

A new set of eyes

WayKen Rapid Manufacturing Limited-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

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Introduction

The Blueprint for a Modern Smart Factory

Technology Enablers of Manufacturing Automation and Future Factories 

Applications of the Factory of the Future 

The Human Factor: Trustworthy Technologies and Workforce Upskilling 

Cybersecurity and Regulatory Compliance in Manufacturing Automation

Measuring ROI and Sustainability

Report Conclusion

A Comprehensive Guide to Manufacturing Automation

Building the Factory of Tomorrow

Manufacturing

<p dir="ltr" id="isPasted">3D printing technologies give us the ability to design and bring any number of objects into existence, from missing hardware parts, to toys and models, to household items. But while the design freedom and capabilities of 3D printing may make it seem like you can make just about anything from the comfort of your home, it is important to understand what materials you are working with, especially if you are printing objects for your kitchen or parts that will come into contact with food.</p><p dir="ltr">PLA (polylactic acid) is a bioplastic material and is one of the most common 3D printing filaments available today. The plastic is derived from plants—like corn, maize, or sugarcane—and is popular for its low cost and easy processing. Some of PLA filament’s benefits include that it prints at a lower temperature than many 3D printing materials, such as ABS, and it does not require a heated print bed. Because the material is made from natural materials, like corn starch and sugarcane, <a href="https://www.wevolver.com/article/is-pla-biodegradable-what-to-do-with-scrap-filament" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">it is biodegradable</a> and many assume it is also food-safe. This can be true, but not in all cases. In this article, we answer the question “is PLA food-safe?” by looking at what influences the material’s food safety, when to avoid food contact, and how to ensure your 3D prints are safe to use.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/pla-bed-temperature" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">PLA bed temperature &amp; print temperature settings</a></strong></p><h2 dir="ltr">What are the food-safe risks of PLA?</h2><p dir="ltr">As a thermoplastic material, PLA is generally safe for food contact. In fact, a study from 1995 that put PLA material through several tests to determine how it breaks down found that it was “Generally Recognized As Safe (GRAS)” for food contact.[1] More specifically, the researchers conducted migration studies on several samples of (non-printed) PLA to understand which chemical compounds were released from the material when in contact with food. The results showed that the main migrants were lactic acid based, which itself is food-safe.&nbsp;</p><p dir="ltr">The study states: “Potential migrants from PLA include lactic acid, lactide (the monomer), and lactoyllactic acid (the linear dimer of lactic acid). The studies were designed to model reasonable ‘worst’ case extraction situations when the polymer is used (a) in houseware articles for short and intermediate time periods at various temperatures and (b) in food-packaging materials. The limited migration observed during the trials represents no significant risk since migrating species are expected to convert to lactic acid, a safe food substance.”</p><p dir="ltr">When it comes to 3D printing, however, there are many other factors that can affect whether PLA material is actually safe to use in contact with food, such as additives and dyes in the PLA filament, the type of printhead being used, porous structures and more.</p><h3 dir="ltr">Food-safe risk #1: PLA additives</h3><p dir="ltr">In its purest form, PLA is food safe. However, if you are 3D printing with colored PLA filament, you should know that the additives used to dye the material may not be food safe. If you are 3D printing an object that will come into contact with food, like a mold or cookie cutter, it is safest to use natural (undyed) PLA filament. You can also consult the material information and safety data sheet for a particular filament brand to determine whether it contains any non-food-grade additives.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/is-pla-biodegradable-what-to-do-with-scrap-filament" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">Is PLA Biodegradable? What To Do With Scrap Filament</a></strong></p><h3 dir="ltr">Food-safe risk #2: Non-food-safe printheads</h3><p dir="ltr">Another element that can affect PLA’s food safety is the 3D printing process itself. In many cases, the metal hotend of the 3D printer is made from a non-food-grade material. That metal is also continually coming into contact with the filament as it is extruded, which can lead to potentially dangerous contaminating traces in your 3D printed part. &nbsp;Brass nozzles, for instance, can contain lead and potentially leach toxic particles into 3D prints. If you are concerned about whether your hotend will affect the safety of your 3D print, you can always opt to use a stainless steel nozzle, which is considered food-safe.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 626px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU1MTg1MDk2ODM1LTNkX2ZpbGFtZW50LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" width="624" height="415" class="fr-fic fr-dii" alt="Purple filament spool on 3D printer"><span class="fr-inner">Dyes and additives in PLA filament can influence whether the material is food-safe.</span></span></span></p><h3 dir="ltr" id="isPasted">Food-safe risk #3: Bacteria contamination</h3><p dir="ltr">Something else to be aware of is the fact that bacteria and germs can get stuck in and grow in 3D printed parts. While they may look solid, FDM 3D printed parts have tiny pores in them that can trap moisture and provide a breeding ground for bacteria. If you do use a fresh 3D printed part to serve a snack or beverage, the pores can trap tiny particles of food, which can lead to potentially harmful bacteria growth. In terms of cleaning, it is difficult if not impossible to ensure that a PLA part has been properly sanitized for food contact once it has already come into contact with food. (The material is not very resistant to high temperatures and cannot be boiled or put in the dishwasher). This means it is safer to use a PLA utensil or plate once and then dispose of it.</p><h3 dir="ltr">Food-safe risk #4: Filament contamination</h3><p dir="ltr">Finally, it is worth mentioning that your 3D printer should be thoroughly cleaned if you are printing objects for use with food. If you have previously 3D printed non-food-safe filaments such as ABS, there may be traces of the material in the 3D printer that can contaminate a PLA print and make it hazardous. This includes the print bed as well as internal 3D printer components, like extruders and hotends. Ideally, you would use a dedicated 3D printer to print food-safe PLA parts.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/pla-recycling" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect" rel="noopener noreferrer">PLA Recycling: Can PLA 3D Printer Filament be Recycled?</a></strong></p><p dir="ltr"><strong><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyNTM4OTI1MzQ0LXN0YWNrZWRfcGFwZXJfY3Vwc19jbG9zZXVwLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="PLA 3D print porous layer lines"><span class="fr-inner">The porosity of PLA 3D prints can be a challenge for food-safe applications, since food particles can get trapped and lead to bacterial growth.&nbsp;</span></span></span></strong></p><h2 dir="ltr">Making PLA 3D Prints Safe for Food Contact&nbsp;</h2><p dir="ltr">When 3D printing items that need to be food-safe, it is always a good idea to err on the side of caution. One way to ensure that your PLA print is safe to use as kitchenware is to apply a food-safe coating or sealant. When it comes to coatings, there are a couple good options at your disposal. Let’s take a look.&nbsp;</p><h3 dir="ltr">Epoxy resins</h3><p dir="ltr">Epoxy resins are a common coating for 3D prints that will seal the surface. However, it is important that you find an epoxy resin that has been FDA certified as food-safe. You should also note that in liquid form epoxy resins contain toxic materials and must be handled with care (i.e. with gloves and mask). They are only safe when <a href="https://www.wevolver.com/article/knowing-how-long-to-cure-resin-prints" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">properly cured and hardened</a>.&nbsp;</p><p dir="ltr">For example, in tests comparing non-coated PLA 3D prints and epoxy-coated prints, the epoxy-coated prints performed far better, showcasing no bacterial growth after 14 days of regular usage (i.e. food contact and washing), while the untreated PLA model did have significant bacterial growth.[4]</p><h3 dir="ltr">Silicone coating and casting</h3><p dir="ltr">Another option is to use silicone as a food-safe coating. Silicone will seal the pores in the 3D print and result in a watertight surface finish. It is also less hazardous to use than epoxy resins. If you are aiming to make food-safe products that can be used safely over prolonged use, it is also possible to 3D print a mold and cast it with food-grade silicone. There are also many examples of people 3D printing masters to make food-safe silicone molds. This is a great option if you want to make custom ice cubes, candies, or chocolates.[3]</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 627px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU1MTg1MTUwOTY2LTNkX3ByaW50ZXIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="407" class="fr-fic fr-dii" alt="3D printer hotend extruding yellow filament."><span class="fr-inner">3D printer hotends can also leach potentially toxic chemicals into 3D printed PLA parts.</span></span></span></p><p dir="ltr" id="isPasted">One disclaimer: a food-safe coating might wear down and degrade over time, so you should be wary of using your 3D printed kitchenware or food containers over the long-term. You should also read the fine print on the coating you are using: some are dishwasher safe and others are not and some are not suitable for use with hot foods or liquids.[2]</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/pla-vs-abs" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">PLA vs ABS: Which filament should one use?</a></strong></p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Ultimately, as a pure material PLA is generally considered food-safe, as there are no toxic chemicals in the polymer itself. That being said, dyes or additives found in spools of PLA filament may not be food-safe. Other factors, like the 3D printer hotend material can also influence if a printed PLA part is safe to be used with food. Porosity in 3D printed objects can also lead to bacterial growth that can contaminate food.&nbsp;</p><p dir="ltr">It is therefore generally safest to apply a food-safe coating to 3D printed kitchenware to avoid any potential health hazards or to use PLA prints as single use items. Other filaments, <a href="https://www.wevolver.com/article/is-petg-food-safe" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">such as PETG, may also be considered safe</a> for printing food containers. Ceramics are another category of food-safe material if treated properly.</p><h2 dir="ltr">Frequently Asked Questions (FAQs)</h2><p dir="ltr"><strong>Q: Is PLA food-safe?</strong></p><p dir="ltr">A: PLA is generally considered food-safe in its pure form. However, factors such as additives, the 3D printing process, and bacteria growth need to be considered before using PLA 3D prints for food-contact applications.</p><p dir="ltr"><strong>Q: Does the color of PLA affect food safety?</strong></p><p dir="ltr">A: Yes, colored PLA filaments may contain dyes or additives that are not food-safe. For food-related objects, it's generally &nbsp;recommended to use undyed PLA to avoid potential risks. And always check the material's safety data sheet for specific information on types of dye or food safety.</p><p dir="ltr"><strong>Q: Are all 3D printer nozzles safe for food?</strong></p><p dir="ltr">A: Not all 3D printer nozzles are food-safe. Some hotends, like brass nozzles, may contain trace amounts of lead, which can leach into PLA prints. Using stainless steel nozzles is a safer option for food-related prints, as the material is considered food-safe. Additionally, if you have used a hotend with a non-food-safe material like ABS, contamination is also a risk.</p><p dir="ltr"><strong>Q: Can bacteria grow on PLA prints?</strong></p><p dir="ltr">A: Yes, PLA 3D prints often have a porous surface that can trap moisture, creating a breeding ground for bacteria. Moreover, due to PLA’s low temperature resistance, it is difficult to fully clean PLA prints for repeated food contact.</p><p dir="ltr"><strong>Q: How can I ensure my PLA print is safe for food?</strong></p><p dir="ltr">A: One way to make PLA prints safer for food use is to apply a food-safe coating, such as epoxy resin or food-grade silicone. These coatings seal the surface and reduce the risk of contamination.&nbsp;</p><p dir="ltr"><strong>Q: Are food-safe coatings durable for long-term use?</strong></p><p dir="ltr">A: Food-safe coatings, like food-grade epoxy or silicone, can wear down over time, particularly with frequent use, washing, or exposure to high temperatures. Be mindful of the longevity and limitations of these coatings when using them on food-related items.</p><p dir="ltr"><strong>Q: Can I 3D print molds for food use?</strong></p><p dir="ltr">A: Yes, 3D printing can be used to create molds for food items. For example, you can 3D print a mold and then cast it with food-grade silicone to make custom items like chocolates, ice cubes, or candies. You can also 3D print a master model to create food-safe silicone molds. This is a great option for creating food-safe products without direct food contact with PLA.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Conn RE, Kolstad JJ, Borzelleca JF, Dixler DS, Filer Jr LJ, LaDu Jr BN, Pariza MW. Safety assessment of polylactide (PLA) for use as a food-contact polymer. Food and Chemical Toxicology. 1995 Apr 1;33(4):273-83. <a href="https://www.sciencedirect.com/science/article/abs/pii/027869159400145E" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://www.sciencedirect.com/science/article/abs/pii/027869159400145E</a>&nbsp;</p><p dir="ltr">[2] The Essential Guide to Food Safe 3D Printing: Regulations, Technologies, Materials, and More [Internet]. Formlabs, 2024. Available from: <a href="https://formlabs.com/blog/guide-to-food-safe-3d-printing/" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://formlabs.com/blog/guide-to-food-safe-3d-printing/</a>&nbsp;</p><p dir="ltr">[3] Engineering After Hours. 3D Printed Molds with Silicone Rubber from Smooth On [Internet]. Youtube, June 24, 2020. Available from: &nbsp;<a href="https://www.youtube.com/watch?v=LBnUZ-AEuWw" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://www.youtube.com/watch?v=LBnUZ-AEuWw</a>&nbsp;</p><p dir="ltr">[4] Kočí, Jakub. How to make food-grade 3D printed models [Internet]. Prusa Research, December 4, 2020. Available from: <a href="https://blog.prusa3d.com/how-to-make-food-grade-3d-printed-models_40666/" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://blog.prusa3d.com/how-to-make-food-grade-3d-printed-models_40666/</a>&nbsp;</p>

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Introduction

1. The Blueprint for a Modern Smart Factory

2. Technology Enablers of Manufacturing Automation and Future Factories

3. Applications of the Factory of the Future

4. The Human Factor: Trustworthy Technologies and Workforce Upskilling

5. Cybersecurity and Regulatory Compliance in Manufacturing Automation

6. Measuring ROI and Sustainability

7. Report Conclusion

Profiles