No one wants to spend more money than necessary on parts development. Customers often think their choice of material has the biggest effect on cost, but while material does have some influence, the main cost drivers for additive parts are build time and finishing time.&nbsp;There are several design factors that affect build time, finishing time, or both. By factoring these considerations into your design, you can minimise the cost of your parts and improve overall part quality.<img width="458" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1MTUzMDg3MTkzLTE3MTUxNTMwODcxOTMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">A variety of factors can affect the cost of your parts and should be considered carefully in the design phase.&nbsp;What is Build Time?For all of Protolabs’ <a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=wevolver-factors-to-consider-3dp-cost-0524" target="_blank" rel="noopener noreferrer">additive manufacturing</a> technologies, build time is split into two categories: draw time and recoat time. Draw time is the time it takes to sinter, melt, or cure the <a href="https://www.protolabs.com/en-gb/materials/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=wevolver-factors-to-consider-3dp-cost-0524" target="_blank" rel="noopener noreferrer">material</a>. It covers how long it takes for the laser to draw the cross section of each layer and is driven by the total volume of the build, including supports if applicable.After the draw is done, the recoater blade travels across the build to distribute the next layer of raw material. The time it takes for the recoater blade to travel across the platform and back is typically a matter of seconds and will vary based on the size of the machine. The amount of recoat time is directly related to the height of the part in its optimal orientation. However, those seconds add up when you’re talking hundreds of layers-worth of recoat for every inch of build height.If you were designing parts for machining, you would want to avoid removing material unless absolutely necessary because more cuts mean more cost. When designing for 3D printing, the mindset is the opposite; you only want to add material for the model if the material is critical, because more material means more cost.Draw: Part VolumePart volume is a common factor that can drive the price up unnecessarily. The consideration should be your overall part volume and how much of that volume is critical to fit, form, or function. Below is a 127mm x 50.8mm x 76.2mm block where the critical features are channels. The ends of the part are also important because they help align the part in the assembly. This part is very high volume, but not all of that volume is critical to the function of the part. On the revised version, the channels are maintained as well as either end of the part. However, the rest of the material boxing in the channels has been removed, leaving about 2.54mm. of wall thickness for the channels. This reduces the part volume by 80% and can reduce the cost of the part by 50-60% depending on technology.<img border="0" width="390" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1MTUzMDg3MjAyLTE3MTUxNTMwODcyMDIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Part Rendering" class="fr-fic fr-dii">During the design phase, removing material that isn't necessary can often maintain strength, but it's also likely to speed up your build times.&nbsp;Another way to reduce material volume is to shell the part. This is best suited to <a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-selective-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=wevolver-factors-to-consider-3dp-cost-0524" title="Designing for Selective Laser Sintering" target="_blank" rel="noopener noreferrer">selective laser sintering (SLS)</a> and <a href="https://www.protolabs.com/en-gb/resources/design-tips/how-to-use-multi-jet-fusion-for-functional-3d-printed-parts/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=wevolver-factors-to-consider-3dp-cost-0524" title="How to Use Multi Jet Fusion for Functional 3D-Printed Parts" target="_blank" rel="noopener noreferrer">Multi Jet Fusion (MJF)</a> since these do not require support structures. Additionally, since these processes see more heat than the other additive technologies, reducing volume will result in a higher quality part, because it avoids dimensional inaccuracies caused by material shrinkage. Below is an example of a 101.6mm x 101.6mm x 50.8mm organiser tray. The original model is very high-volume. The other two versions show different ways to reduce material.The first method is to use ribs or honeycombs to maintain the structure and rigidity of the part, but also to remove any excess material. This method reduces the volume by 30% and reduces the cost by 20%.If the rigidity of the part is less critical, you can hollow out the part instead. For this example part in the third column, hollowing reduces the volume by 36% and reduces the cost by 26%. Note that material should be reduced in a way that keeps the geometry open, to allow for complete removal of unsintered/unfused powder after the build. Sealed off cavities should be avoided.&nbsp;&nbsp;<img border="0" width="426" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1MTUzMDg3MjE1LTE3MTUxNTMwODcyMTUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">As noted above, hollowing out your part, as indicated in the third column images, can speed production times and also offer a way to remove unused metal or plastic powder.&nbsp;Recoat: Part OrientationRecoat time is the second factor that drives build time and therefore cost. The recoat time is driven by the height of the build, but this isn’t necessarily based on the extents of the part. The build height is based on the height of the part in its optimal orientation. The optimal orientation will vary based on geometry, but generally, if the part can be designed to build in a shorter orientation it will be less expensive. You see this especially with stereolithography (SLA) and <a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-direct-metal-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=wevolver-factors-to-consider-3dp-cost-0524" title="How to Design and Manufacture Metal 3D-Printed Parts" target="_blank" rel="noopener noreferrer">direct metal laser sintering (DMLS)</a> since these technologies use support structure, which plays a significant role in choosing build orientation.Here's a part that needs to be built in metal using DMLS. The first design iteration has channels that are too wide to build horizontally without requiring internal supports that will be trapped inside. However, changing the cross section of the channels to a self-supporting tear drop shape allows the part to build in the shorter, second orientation below. This small change reduces the cost by 18%.&nbsp;<img border="0" width="419" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1MTUzMDg3MjI1LTE3MTUxNTMwODcyMjUuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="part rendering" class="fr-fic fr-dii">Changes in print orientation can help you choose alternative channel shapes, potentially speeding build times.&nbsp;Finishing Time and Strategies to Reduce ItWhen it comes to SLA and DMLS—the technologies requiring supports—finishing time is all about reducing the number of supports. This consideration goes hand-in-hand with build time because fewer supports means less time spent drawing, and later, removing them. Cutting down on finishing time is another way to shave off cost. Both technologies use supports that are made of the same material as the parts themselves.For SLA, supports are removed easily; they can simply be plucked off by hand. After removing the supports, small braille-like bumps remain that get sanded down by our finishing team. Because support removal is relatively simple, having more of them doesn’t drive cost up as much when compared to metal supports with DMLS. However, if you’re looking at hundreds of parts, a few extra minutes of finishing time per part can add up.On the other hand, supports on DMLS parts are more robust and can’t be removed by hand. These supports are cut off using rotary tools. For larger parts, we’ll even use a manual mill to help with the bulk removal of supports. Once the supports are cut off, the remaining burrs get ground and sanded down. Since the support removal process for DMLS is much more involved than SLA, reducing the number of supports will have the biggest effect on DMLS parts.&nbsp;<img border="0" width="430" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1MTUzMDg3MjM1LTE3MTUxNTMwODcyMzUuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="part rendering" class="fr-fic fr-dii">Designing support structures that are more consistent with additive manufacturing best practices can save you considerable time and money&nbsp;This 127mm tall pipe with flanges is a great example of a part that will have a large support volume because supports need to grow from the bottom flange all the way to the top flange to ensure it forms correctly. However, if the application for this part allows, it could be redesigned by reducing unnecessary material from the flange and adding some material so that the flanges grow in at a self-supporting 45-degree angle from the build plate.Making this small change reduces the finishing time required from 3 hours per part to just 30 minutes and results in a 50% cost reduction! The image above shows both versions of the part, as well as the extent of supports that the first version requires versus the second version that was designed for additive manufacturing.&nbsp;Final ThoughtsAdditive manufacturing is a highly geometry-dependent process and strategies that work for one part or technology may not work for another part or technology. This article provides general guidelines on reducing cost and the examples featured were specifically created to demonstrate these guidelines. When it comes to applying these concepts, we’re more than happy to help. You can call our application engineering team at +44 (0) 1952 683047 and we will discuss your specific project with you and provide part-specific suggestions for reducing cost.<a href="https://explore.protolabs.com/design-tips-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=wevolver-design-tip-subscribe-banner-0524" target="_blank" rel="noopener noreferrer">Subscribe for monthly design tips!</a><a href="https://explore.protolabs.com/design-tips-registration/?utm_source=eureka&utm_medium=referral&utm_campaign=uk-design-tip-0524&utm_content=eureka-knowledge-design-tip-subscribe-banner-0524" target="_blank"><img border="0" width="602" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1MTUzMDg3MjUzLTE3MTUxNTMwODcyNTMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="A close-up of a subscribeDescription automatically generated" class="fr-fic fr-dii"></a>&nbsp;

Build time, finishing time, supports, and part volume are all a variety of factors that can affect the pricing of a part. By factoring these considerations into your design, you can minimise the cost of your parts and improve overall part quality. 

How Much Does 3D Printing Cost? Key Factors to Consider

Explore the distinct differences and applications of hot rolled and cold rolled steel in engineering, highlighting how each method impacts material properties and project outcomes.


Hot Rolled vs Cold Rolled Steel: A Comparative Analysis

You might think that Industry 4.0 only applies to large-scale industries, but many benefits also apply to SMEs, including increased efficiency and productivity, giving you greater business flexibility. This leads to enhanced profitability and better customer satisfaction.&nbsp;Industry 4.0 technologies provide you with more and better information to improve decision-making in your business. You'll find out how to optimise your organisational processes so that you'll save time and resources. In doing so, you'll deliver more services or products quickly and cost-effectively. It's a win-win situation.<h2 dir="ltr">Principal Technologies&nbsp;</h2>There are nine main technological advances driving Industry 4.0:<h3 dir="ltr">1. THE IIOT</h3>Industry 4.0 provides more excellent connectivity across more devices with embedded computing capacity. This means that all kinds of devices can communicate and interact with each other. They can do this with centralised control systems. Analytics and decision-making thus become decentralised, enabling real-time reactions and responses.<h3 dir="ltr">2. SYSTEM INTEGRATION</h3>Industry 4.0 allows both vertical and horizontal integration of complex systems. It can bind functions, capabilities, departments and companies together more cohesively. Even in small businesses, universal data-integration networks can advance customer satisfaction and enable automated value chains.<h3 dir="ltr">3. BIG DATA AND ANALYTICS</h3>Big data allows even the smallest business to collect and evaluate data from multiple sources. These include production systems, equipment, enterprise management systems, and customer feedback information. Larger data sets and comprehensive information allow you to make more focused business decisions.<h3 dir="ltr">4. CLOUD COMPUTING</h3>Cloud technologies are getting faster and more powerful. You may need to share valuable data across sites when your company performs more production-related activities. You can upload your machine data and analytics to the cloud to benefit from sharing information. You'll also be able to take advantage of data-driven services in your production systems.<h3 dir="ltr">5. ROBOTS</h3>Autonomous or collaborative robots can undertake many more tasks. These machines can work safely alongside or instead of humans and interact with each other. They're helpful in small production environments and are more cost-effective than human labour. Over time, their range of capabilities will increase.<h3 dir="ltr">6. ADDITIVE MANUFACTURING</h3>Additive manufacturing is more commonly known as 3D printing. It has significant advantages for SMEs in terms of <a title="How Does 3D Printing Lower The Cost Of Product Development?" href="https://www.rowse.co.uk/blog/post/how-does-3d-printing-lowers-the-cost-of-product-development" target="_blank">reducing production costs</a>. Companies no longer need to undergo lengthy prototyping procedures but can quickly produce customised products in small batches. Even complex designs can be made quickly using a combination of CAD modelling and an in-house 3D printer.&nbsp;<h3 dir="ltr">7. AUGMENTED REALITY (AR)</h3><a title="The Future of Manufacturing" href="https://www.rowse.co.uk/blog/post/the-future-of-manufacturing" target="_blank">Augmented reality systems</a> use IIoT devices to support a variety of services. Using AR, you can provide employees with real-time information over remote devices. Capabilities include sending detailed repair instructions or picking parts in a warehouse. AR helps companies to streamline work procedures and improve decision-making.<h3 dir="ltr">8. SIMULATION</h3>The next step with AR and VR is computer simulation, sometimes called <a title="An Introduction To Digital Twins" href="https://www.rowse.co.uk/blog/post/an-introduction-to-digital-twins" target="_blank">digital twins</a>. They're used a lot in large-scale industrial operations like automotive manufacturing and shipyards but can equally be helpful for small business operations. This system represents the physical world digitally, together with real-time data. You can test and optimise multiple iterations of a new product, increasing quality and significantly reducing machine setup times.<h3 dir="ltr">9. CYBERSECURITY</h3>Cybersecurity is one of the significant drawbacks to Industry 4.0. Although you'll benefit from increased connectivity and cross-platform communications protocols, you'll also be at increased risk from cybercrime. Protecting your critical systems and sensitive information from cybersecurity threats is essential. The digital world advances exponentially, and sadly, cybercriminals are constantly finding new ways to attack your system. Secure, reliable communications will become part and parcel of your digital transformation. You'll install sophisticated access management to business systems, production machinery, and user identity verification protocols.<h2 dir="ltr">Expected Benefits Of Digital Transformation</h2>Many business owners, especially owners of SMEs, are put off adopting Industry 4.0 tech because of the capital outlay involved. You might have higher priorities for expenditure or cybersecurity concerns. You might not see how digitalisation can help your business or lack the necessary skills to manage complex IIoT systems. If you don't have the appropriate infrastructure, digitalisation can be a daunting prospect for an SME.&nbsp;However, at this stage in our technological journey, most businesses will perceive that digital transformation is inevitable. You'll want to take advantage of better production speeds and product quality, increased outputs and profitability. In the long run, you'll achieve considerable cost savings in reduced downtime. Techniques like additive manufacturing and <a title="What Is Predictive Maintenance?" href="https://www.rowse.co.uk/blog/post/what-is-predictive-maintenance" target="_blank">predictive maintenance</a> will help you reduce costly defects, errors, waste and delays.You'll use big data and cloud computing to speed up and improve decision-making. Real-time forecasting and systems monitoring will help improve your customer experience, as you'll be better able to anticipate market demands. Your services and delivery performance will improve, and you'll enhance your supply chain relationships. You'll enjoy greater collaboration and knowledge sharing, increase your capacity for innovation and become more competitive.As a knock-on benefit from these factors, you'll be better positioned for talent acquisition. You'll have better organisational security and an enhanced ability to combat risk and fraud. Also, compliance with regulations will become easier. &nbsp;&nbsp;<h2 dir="ltr">Embracing The Change</h2>Industry 4.0 technologies evolve rapidly, so you must recognise and embrace the changes. Fully comprehending the digital revolution will allow your business to get "smart". Your organisational processes will get more efficient and your business more competitive. To do this, you must adopt new business models, install new equipment and upskill your employees.&nbsp;This might seem an insurmountable barrier to embracing digital transformation, but today's SMEs are better positioned to take advantage of the benefits. If you're a small business that hasn't yet invested in digitalisation, you'll find plenty of online resources and tools to help you. Or you can contact our specialist advisers at Rowse, who'll always be happy to help.

You might think that Industry 4.0 only applies to large-scale industries, but many benefits also apply to SMEs, including increased efficiency and productivity, giving you greater business flexibility.

How Can Small Businesses Benefit From Industry 4.0?

The market for additive printed circuit boards (PCBs) and flexible electronics is full of possibilities, with applications including IoT-connected skin patches, environmental sensing devices, flexible electronic displays, and much more. However, making such devices requires a carefully developed selection of materials (not all of which are electrically conductive). This article provides an overview of three key groups of materials required for additive PCBs and flexible electronics: conductive inks, substrates, and solder pastes. Throughout the article, we look at the most important materials within each group and see how additive PCB pioneer <a href="https://hubs.ly/Q02hPg450" target="_blank">Voltera</a> is pushing electronics material possibilities to the limit.<h1 dir="ltr">Conductive Inks in Additive Manufacturing: Making Prints Electronic</h1>A conductive ink is a type of functional ink that can conduct electricity after it has been printed and processed. Printing involves depositing the ink in a computer-specified pattern with a dedicated machine, and processing typically involves applying heat to the printed pattern. Once processed, the ink can carry electrons from one place to another.Conductive inks are made up of several components. The conductive element or filler must be a conductive material like silver, copper, or graphene particles. However, for the ink to flow freely and be accurately printable, it needs to contain many other components too, components collectively known as the vehicle. These ingredients may include binders to give the ink its polymeric backbone, solvents to dissolve the other components, and dispersants to help the ink flow and cure.<h2 dir="ltr">Types of Conductive Inks</h2><ul><li dir="ltr">Silver: Perhaps the most important type of conductive ink for additive PCBs and flexible electronics is silver ink. This is partly due to the good conductive properties of silver and partly because of its ubiquity: silver inks are widely available and inexpensive, allowing for low-cost printed electronics like sensors and antennae.</li><li dir="ltr">Copper: An alternative to silver ink is copper ink. Copper is also a conductive metal and is consequently used in traditional PCB production techniques like etching. However, because it oxidizes when cured in air, it requires extra processing which can increase the overall cost of printing.</li><li dir="ltr">Carbon: Materials like carbon black, carbon nanotubes, and graphene — a carbon allotrope with a very high level of conductivity — can also be used as fillers in conductive inks, with almost limitless potential uses. Electronics applications include sensors, resistors, and heating elements.</li><li dir="ltr">Conductive Polymers: Certain polymers such as polythiophene can be used as conductive printable inks. These polymers become conductive when they are oxidized due to the delocalization of their electrons.</li></ul><h2 dir="ltr">Innovative Materials and Future Trends</h2>Inks used in printed electronics are not just limited to conductivity. Other applications include the use of electroluminescent inks such as those developed by <a href="https://www.saralon.com/en/" target="_blank">Saralon</a>, which emit light when an electrical current passes through them.&nbsp;<iframe width="640" height="360" src="https://www.youtube.com/embed/Yc8nEoVnpDY?&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">&nbsp;&nbsp;&nbsp;</iframe>By printing with these inks, it is possible to create an Electroluminescent Displays (ELD) on a substrate. Another exciting area of printed electronics is the creation of bioelectronic medical devices. Researchers have had some success developing biocompatible inks that are both conductive and harmless to cells.<h2 dir="ltr" id="isPasted">Popular Conductive Inks</h2><div dir="ltr" align="center"><table><tbody><tr><td>Manufacturer</td><td>Conductive Ink</td><td>Filler</td><td>Advantages</td></tr><tr><td>Voltera</td><td>Conductor 3</td><td>Silver</td><td>Rapid curing, no burnishing</td></tr><tr><td>ACI Materials</td><td>SS1109</td><td>Silver</td><td>Stretchable for elastomeric substrates</td></tr><tr><td>Copprint</td><td>LF-360</td><td>Copper</td><td>Patented sintering agent that prevents oxidation</td></tr><tr><td>Celanese</td><td>Micromax 7082</td><td>Carbon</td><td>Custom resistance blends</td></tr><tr><td>Saralon</td><td>Saral BluePhosphorL 800</td><td>Silver</td><td>Electroluminescent blue light</td></tr><tr><td>Henkel Adhesives</td><td>LOCTITE EDAG 7019 E&amp;C</td><td>Silver and Silver Chloride</td><td>Non-toxic and suitable for medical applications</td></tr><tr><td>Creative Materials</td><td>128-24</td><td>Gold</td><td>Highly conductive</td></tr></tbody></table></div><h2>Substrates: The Foundation of Flexible Electronics</h2>Conductive inks open up a world of opportunities in additive PCBs and electronics. But electronics printing works differently compared to ordinary additive manufacturing: you cannot print an entire device out of conductive ink. Instead, the ink needs to be printed onto something. The durable material required here is known as the substrate, and it forms the foundation of flexible electronics and other devices.As with conductive inks, there are several options to choose from when it comes to the substrate. Established types of rigid substrates include FR4, a glass-reinforced epoxy laminate, and FR1, a low-cost alternative made of paper and phenolic resin.While rigid substrates are incredibly useful, one of the most exciting applications of printed electronics is the use of flexible substrates for devices like wearables. Flexible substrates can endure bending and various motions while maintaining functionality. They include films, foils, and even paper (electronic RFID tags are regularly printed on paper transit tickets, for example). Flexible substrates require specially developed conductive inks that will not crack or deform when the substrate bends.Some flexible substrates can also be classified as stretchable substrates. Unlike papers and foils, these materials have good tensile strength and can have additional uses in printed electronics. However, it can be slightly harder to match stretchable substrates with a suitable ink; this is because the ink must stretch congruently with the substrate to avoid circuit breakage and separation from the underlying substrate or layer. When choosing a stretchable substrate like TPU, the ink must be carefully selected to accommodate its stretchability.<h2 dir="ltr">Types of Flexible Substrates</h2><ul><li dir="ltr">PI (Kapton): Polyimide films possess excellent thermal stability, electrical insulation, and flexibility, making them a good choice for applications like flexible displays and flexible batteries. Though polyimide is its scientific name, the material is referred to as Kapton, a brand name owned by DuPont.</li><li dir="ltr">PET: Polyethylene terephthalate, the most widely used material in the polyester family, is commonly used to make items like single-use water bottles. However, it also makes an excellent flexible substrate for flexible electronics like force-sensitive resistors. It is recyclable and more affordable than polyimide but less thermally stable.</li><li dir="ltr">TPU: Thermoplastic polyurethane makes a very good substrate for flexible and stretchable electronics due to its elasticity and resistance to abrasion and oil. Its rubber-like consistency makes it suitable for wearable electronics like smart watches and even textile-based smart clothing.</li></ul><h2 dir="ltr" id="isPasted">Popular Substrates</h2><div dir="ltr" align="center"><table><tbody><tr><td style="width: 21.6511%;">Manufacturer</td><td style="width: 21.6511%;">Substrate</td><td style="width: 16.3551%;">Material</td><td style="width: 40.3427%;">Advantages</td></tr><tr><td style="width: 21.6511%;">DuPont</td><td style="width: 21.6511%;">Kapton FPC</td><td style="width: 16.3551%;">Polyimide</td><td style="width: 40.3427%;">Excellent dimensional stability and adhesion</td></tr><tr><td style="width: 21.6511%;">Polyonics</td><td style="width: 21.6511%;">XF102</td><td style="width: 16.3551%;">Polyimide</td><td style="width: 40.3427%;">High level flexibility and temperature resistance</td></tr><tr><td style="width: 21.6511%;">BEYOLEX (Panasonic)</td><td style="width: 21.6511%;">MUAS13111AA</td><td style="width: 16.3551%;">Thermoset film</td><td style="width: 40.3427%;">Suitable for stretchable electronics</td></tr><tr><td style="width: 21.6511%;">Insulectro</td><td style="width: 21.6511%;">Intexar TE-11C</td><td style="width: 16.3551%;">TPU</td><td style="width: 40.3427%;">Suitable for smart clothing</td></tr></tbody></table></div><h2>Solder Paste: The Secret Sauce for Printed Electronics</h2>We have so far looked at two very important groups of materials in PCBs and flexible electronics: the conductive inks that allow for the transfer of electrons and the substrates upon which these inks can be deposited in a specific pattern (and which can sometimes bend and stretch for added functionality). A third material, less glamorous but no less important, is solder paste. This critical substance allows PCB designers to add pre-existing electronic components onto their boards.Solder is a metal alloy that can be fused to bond two pieces of metal. In many industries, a solder bar or wire is used in conjunction with a tool like a soldering iron or gun and a separate wetting agent called flux. In printed electronics, things are done a little differently. Here, solder paste — containing powdered solder and flux (which acts as a cleaning, flowing, and purifying agent) already mixed together — is deposited alongside conductive inks onto the substrate. After its application alongside conductive inks on the substrate, the solder paste undergoes a reflow process. During reflow, the assembly is heated, causing the solder paste to melt and flow — forming solid, electrically conductive connections upon cooling. The solder itself typically contains tin and other metals.<h1 dir="ltr">Voltera’s Approach to PCBs and Flexible Electronics</h1>Additive electronics expert <a href="https://hubs.ly/Q02hPg450" target="_blank">Voltera</a>, based in Canada, develops printers that dispense conductive inks for PCBs and functional electronic devices. Its <a href="https://www.voltera.io/v-one?utm_campaign=Wevolver&utm_source=Blog&utm_content=V-One" target="_blank">V-One PCB printer</a> lets users prototype printed circuit boards in less than an hour, while its <a href="https://www.voltera.io/nova?utm_campaign=Wevolver&utm_source=Blog&utm_content=NOVA" target="_blank">NOVA materials dispensing system</a> can print a wide array of conductive materials onto a range of substrates, including flexible, stretchable, and porous materials. Both machines also deposit solder paste, allowing for the creation of functional electronics.In terms of the specific inks, substrates, and solder pastes that the V-One and NOVA use to make PCBs and flexible electronics, perhaps the most important material of all is <a href="https://store.voltera.io/products/conductor-3-ink-cartridge-2ml?_pos=1&_sid=92a745f26&_ss=r" target="_blank">Conductor 3</a>. Voltera’s own silver-based conductive ink formulation boasts a 30-minute curing time, a low soldering temperature of 180°C, and compatibility with rigid and flexible substrates. Importantly, however, NOVA is also compatible with other screen-printable inks.Voltera also brings a new level of substrate flexibility to flexible substrates. NOVA’s vacuum table creates uniform suction which keeps flexible and soft substrates in place, enabling high-precision printing upon the chosen material, while a Smart Probe maps the height of the substrate. There is also a threaded mounting grid to secure custom rigid substrates of different shapes and sizes.&nbsp;Finally, both Voltera systems offer precision solder paste deposition, with the company offering tin-lead eutectic alloy and a tin-bismuth-silver alloy in T4 or T5 particle sizes, so users can solder components to their boards with precision.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0OTk5NzU3MDM2LWludGVybmFsIHZvbHRlcmEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="351" class="fr-fic fr-dii">Voltera enables the streamlining of research and development with direct-ink-write dispensing. Credit: Voltera<h2 dir="ltr">Conclusion</h2>The PCB and flexible electronics industry moves at a fast pace. Material scientists are constantly seeking solutions to current challenges in order to evolve the technology and create electronics with greater functionality, longevity, and sustainability. And with interest rising in products like flexible displays, wearable technology, and flexible photovoltaics, the demand for printed electronics materials — inks, substrates, and pastes alike — will continue to grow.

PCBs printed onto flexible substrates demonstrate huge potential across a range of industries. But what are the materials used to make these printed devices?

The Building Blocks of Innovation: Inks, Substrates, and Solder Pastes for Additive PCBs and Flexible Electronics

Companies are always seeking to streamline processes, enhance precision, and reduce the risk of human error. So much so that more manufacturers are turning to 3D printing to create custom jigs and fixtures, making them one of the most powerful applications for additive technology.But beyond the buzz of innovation, how can 3D printers directly address your production challenges?To answer that question, we caught up with Jesse Ippel, an Application Engineer at ERIKS. And what was his best advice for finding new, useful 3D printing applications?<h3>To socialize 3D printing within your company and to be a good listener.</h3><blockquote>Our production team often comes up to me with issues and challenges they face. They know that we can 3D print tools and so they ask if we can 3D print something like this.</blockquote>When you consider that these operators are working on production day in and day out, this makes perfect sense. Ultimately, they will figure out what works best for them.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714988956502-eriks-3d-printing-application-deep-dive-ultimaker-jesse.jpg" style="width: 100%px;" class="fr-fic fr-dib">Jesse (left) advises that 3D printing useful jigs and fixtures depends on listening well to the ERIKS production teamJesse explains, “Whenever I just walk onto the production floor, the operators always ask, ‘can we do this, can we do that?’ There are more things that they notice that I will never notice, and that's where the power of 3D printing really lies.”Let’s look at two 3D printing applications that were created from this collaboration between ERIK’s application engineers and production team.<h2>Examples of time-saving 3D printing applications</h2>As a multi-product specialist, ERIKS offers a wide range of mechanical engineering components and technical services to all sections of industry. And the company has embraced 3D printing to enhance their production efficiency.By integrating custom jigs and fixtures into their workflow, they have streamlined their processes and reduced manual labor. To get a comprehensive view of how ERIKS is making the most of 3D printing, be sure to read&nbsp;<a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/" target="_blank">their customer success story</a>. <h2>Box drilling jig</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/84xiq3R_Dlc?&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>The production team at ERIKS needed to drill four precise holes in each corner of a small plastic box. This task used to take up to two minutes to measure by hand.To accelerate this process, Jesse designed a custom 3D printed jig, reducing the hole preparation to just seconds. The design included openings to reduce material use and to make it easy for operators to see that the jig was flush against the box. UltiMaker PLA in the company's brand color provided the durability needed for frequent use while maintaining a professional appearance consistent with ERIKS' branding.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714988994315-eriks-3d-printing-application-deep-dive-ultimaker-drill-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">The blue 3D printed drilling jig allows operators to drill accurate holes in the black boxes in seconds rather than minutes<blockquote id="isPasted">We like to use PLA because it's super convenient. We just throw it in the 3D printer. And it always works.</blockquote>Jesse then went into more detail about the process of creating the box drilling jig.“So we had a couple of iterations of the design. The first one didn't quite fit snugly enough on the box. So we adjusted it slightly. Then we also added the small metal tube as a press-fit insert.”This allows ERIKS operators to drill without worrying that jig’s guide holes will become larger, affecting their accurate positioning. Jesse also added magnetic inserts into a holder for the box and jig. This then snaps onto a metal vice on the workbench, providing a stable platform for the assembly while drilling. <h2>Motor support jig</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/K-UGeihfxQw?&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>To more easily fix a motor to a metal plate and add an electronic component to the motor, ERIKS developed a support jig to aid the process. Before the creation of this jig, the production team would balance the motor and plate on a roll of duct tape to keep the motor axle off the work surface. The 3D printed jig offers a far superior solution.It features a hole which fits the motor axle perfectly, keeping the motor stable off the work surface and not allowing it to turn. The 3D printed side column supports the addition of an electric component without the assembly tipping over. This simplifies the process for operators and minimizes the chance of assembly errors.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714989091911-eriks-3d-printing-application-deep-dive-ultimaker-motor-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">A custom 3D printed jig perfectly supports adding an electrical component to a motor. Before, operators balanced the assembly on a roll of duct tapeThe jig was also easy to design using Trinckle software. This allowed an ERIKS engineer with less CAD experience to load a model of the motor into Trinckle and easily create a mesh for the 3D printed part around it.The result? This jig has cut assembly time from two to three minutes down to one, making the job significantly easier for the production staff.For both applications, the 3D printing team at ERIKS always adds unique reference code to the 3D printed design. This helps engineers and operators to easily identify the correct and most recent jig iteration to be used on the production floor. <h2>Why ERIKS chose UltiMaker S7 for manufacturing aids</h2>The decision to use the UltiMaker S7 for creating these manufacturing aids was rooted in the printer's versatility, ease of use, and material compatibility. The printer's reliability and consistent performance ensure that these jigs can be created quickly and withstand the rigors of a fast-paced production environment.<blockquote>For us the primary benefit of 3D printing is speed. How quickly can we get something? And that is where 3D printers are the fastest option you can get. I can turn on a print job at 2 pm one day, and the next morning I come into the office and now I have the tools ready. So that is the main factor why we choose 3D printing over conventional methods, whenever we can. Cost is a side benefit for us.</blockquote><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714989112975-eriks-3d-printing-application-deep-dive-ultimaker-ecosystem.jpg" style="width: 100%px;" class="fr-fic fr-dib">The reliability of the UltiMaker ecosystem allows the ERIKS application engineers to start a print job in the afternoon and it’s ready the next morning<h2 id="isPasted">Conclusion</h2>The use of custom 3D printed jigs and fixtures is transforming manufacturing workflows by improving efficiency, consistency, and quality. The examples from ERIKS illustrate the significant benefits that can be realized by adopting these practices. Other companies can look to these success stories as inspiration for optimizing their own production processes, leveraging the power of 3D printing with tools like&nbsp;<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s7/" target="_blank">UltiMaker S7</a> or&nbsp;<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank">UltiMaker Factor 4</a>.

Companies are always seeking to streamline processes, enhance precision, and reduce the risk of human error. So much so that more manufacturers are turning to 3D printing to create custom jigs and fixtures, making them one of the most powerful applications for additive technology.

Application deep-dive: Maximizing production efficiency with custom jigs at ERIKS

The globalization of supply chains is being formed on production lines that are able to supply only the required quantity of products at the time required. This means that an obstacle arising in one place in the production line may strike a major blow to the entire supply chain.The causes of production delays and stoppages include conflicts, disasters, raw material shortages, and equipment and device failures. In particular, production stoppages and the outflow of defective products due to equipment and device failures may lead to major problems for manufacturers. These problems include the expense required to recover those defective products and opportunity losses due to product supply stoppages. Therefore, equipment maintenance, which bears responsibility for the stable operation of the production line, is an important issue that holds the key to the life of manufacturers.The importance of equipment maintenance has been strongly expressed up to now. The techniques of equipment maintenance have also been advancing from breakdown maintenance to preventive maintenance and then onto predictive maintenance as well in recent years.We introduce in an easy-to-understand manner equipment maintenance that is continuing to evolve in this way—from basic knowledge such as the types of equipment maintenance and their advantages and disadvantages to the technologies to realize the predictive maintenance that is considered the ideal form of equipment maintenance.<h2>What Is Equipment Maintenance?</h2>Equipment maintenance refers to the activities to keep various production equipment in factories functioning normally. It is also called “machine maintenance.” The purposes of equipment maintenance are cited as being, for example, to prolong the life of machine components used in equipment, to shorten machine and device downtime, and to prevent unexpected failures in addition to repairing equipment that has failed.Moreover, equipment maintenance up to now has mainly focused on machines and devices. Now, the focus is also on the software that controls the Programmable Logic Controllers (PLCs) and machines and devices with the conversion of regular factories into smart factories using industrial robots, machine vision, and other technologies.There are other terms similar to maintenance such as “upkeep” and “care,” but these are the same as equipment maintenance. The reason is that they all involve inspecting equipment and then servicing or repairing it as necessary so that it does not fail.<h2>Types of Equipment Maintenance and Their Advantages and Disadvantages</h2>Equipment maintenance includes breakdown maintenance and preventive maintenance. Preventive maintenance is further broken down into time-based maintenance and condition-based maintenance (Figure 1). We explain here the features and the advantages and disadvantages of each type.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714985901545-predictive-maintenance-img0001_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 1: Types of Equipment Maintenance<h3 id="isPasted">What Is Breakdown Maintenance?</h3>This is maintenance that is performed after a piece of equipment’s functions have declined or after it has stopped functioning (Fig. 2).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714985917150-predictive-maintenance-img0002_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 2: Breakdown MaintenanceAdvantages: The advantages of breakdown maintenance include the fact that the burden on maintenance work is low because the condition of the equipment is not checked until it fails or a malfunction is discovered. Another advantage is that it keeps the costs involved in maintenance low in the case of minor failures. Disadvantages: Failures and malfunctions occur unexpectedly. Therefore, there may be delays in obtaining repair components, and so it may take some time to carry out repairs. In addition, there are risks such as major disruptions to production plans if the failure or malfunction occurs in a core piece of equipment. Furthermore, if there is a delay in discovering the failure or malfunction in the equipment, it may lead to defective products and their flowing out of the factory. Dealing with such issues may require a considerable amount of expense and time.<h3>What is Preventive Maintenance?</h3>This is maintenance that is performed based on a piece of equipment’s service life, the number of times it is used, its condition, or other factors. It is also called “time-based maintenance” (Fig. 3).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714985934940-predictive-maintenance-img0003_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 3: Preventive MaintenanceAdvantages: The maintenance work is performed once a certain period has been reached. Therefore, it is possible to prevent failures and malfunctions from occurring in equipment. It is an effective maintenance method when the service life of each component used in equipment or the number of times those components are used can be grasped accurately. Disadvantages: It is necessary to establish criteria to ascertain as accurately as possible the life of components. Maintenance may be performed after a failure if the criteria is not accurate. Conversely, component and time losses may arise such as from the replacement of components that can still be used.<h3>What Is Predictive Maintenance?</h3>This is maintenance that is performed in line with extent of a piece of equipment’s deterioration by constantly monitoring its condition. It is also called “condition-based maintenance” (Fig. 4).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714985956264-predictive-maintenance-img0004_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 4: Predictive MaintenanceAdvantages: The maintenance work is performed when the equipment deteriorates. Therefore, it is possible to reduce component and time losses such as from the periodic stoppage of equipment for maintenance and the replacement of components that can still be used. Of course, it is also possible to prevent failures and malfunctions that would lead to the equipment stopping unexpectedly. Disadvantages: It is essential to have equipment to constantly monitor the condition of equipment and to store the collected data. Specifically, the constant monitoring of equipment requires a large number of various types of sensors. In addition, data loggers and similar recording devices are needed to store data. Furthermore, it is necessary to have equipment and other technologies to connect to those recording devices to communicate the data.<h2>Four Technologies to Turn Preventive Maintenance into Predictive Maintenance</h2>The most common method of maintenance currently is preventive maintenance whereby equipment is periodically maintained by determining the inspection timing based on the service life of each component used in equipment or the number of times those components can be used. Furthermore, there are an increasing number of cases in which semi-predictive maintenance is being adopted. This is when a large number of sensors that measure vibrations, temperature, current, voltage, and other elements are attached to equipment and thresholds are then set for each of them with maintenance being performed when those upper or lower limits are exceeded. In fact, a survey conducted on companies engaged in converting regular factories into smart factories produced results showing that over 96% of them cited “equipment maintenance utilizing sensors and AI” as the reason they are continuing to convert their factories into smart factories (Fig. 5).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714985974057-predictive-maintenance-img0005_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 5: Reasons Why Companies Want to Continue Converting Regular Factories into Smart Factories* About the survey:&nbsp; Surveying entity: Murata Manufacturing Co., Ltd. Survey focus: 11,084 workers in the manufacturing industry in Japan (screening survey) / 500 workers in the manufacturing industry involved in converting their company’s regular factories into smart factories (main survey) Survey method: Internet survey Survey period: 3 days from January 25 (Wed.) to 27 (Fri.), 2023 * The total values may not necessarily match due to rounding.In this way, equipment maintenance is currently undergoing a switch from preventive maintenance to predictive maintenance. We explain here the four technologies that can help with this switch from preventive maintenance to predictive maintenance.<h3>1. Introduction of Sensors into Equipment Maintenance</h3>Predictive maintenance begins with constant monitoring of the condition of equipment. There are individual differences in judgment when this monitoring is performed with the eyes and touch of people. This means it is not possible to respond accurately. We can quantify the condition of equipment by introducing sensors. Visualizing and analyzing the data collected from those sensors then enables us to respond more accurately. However, this requires installing many types and a large number of sensors in large factories. Accordingly, routing and connecting the sensor wiring requires many man-hours when changing the setup. Therefore, it is best to have noise-resistant sensors capable of wireless communication with a long transmission distance.Moreover, devices have been developed that can keep a log of the actions taken by workers on manufacturing lines in recent years. It is also possible to record how those workers respond when trouble occurs. Utilizing these records allows various matters to be saved as data, including the deterioration of equipment that occurs on the manufacturing line and the actions taken by workers in response. This data can be used to give hints to improving processes in addition to maintenance.<h3>2. Visualization of the Condition of Complex Equipment: Sensor Fusion</h3>Sensor fusion is a technology that realizes cognitive functions that cannot be obtained with a single sensor on an engineering basis. Specifically, sensor fusion has already been introduced into Advanced Driving Assistant Systems (ADAS). For instance, examples include reading the shapes of people, obstacles, and other objects with an image sensor and temperature sensor and then measuring the distance with a radar sensor utilizing milliwaves and microwaves to grasp the situation in the direction in which those objects are moving. It has also become possible to display warning messages on monitors in vehicles and to apply brakes automatically. This utilizes sensor fusion as a technology to, for example, automatically determine the situation with data collected from multiple sensors such as image sensors and radars and to then convey those results to the driver. When we use this technology in equipment maintenance, we can analyze the measurement data from vibration sensors, temperature sensors, current sensors, and voltage sensors on an integrated basis. For example, if a current or voltage value is abnormal despite the motor vibrations and temperature being normal, we can determine that there has been a problematic change to the load on the part where the motor is operating. In addition, if an abnormal value is seen only in a vibration sensor, it is likely to be bearing wear, shaft deformation, level abnormality, or similar (Fig. 6).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714986016706-predictive-maintenance-img0006_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 6: Introduction of Sensor Fusion into Equipment MaintenanceConventionally, such abnormalities were grasped and determined by workers reading each sensor value and then comparing those values with their past experiences.&nbsp; However, if we use the technology of sensor fusion, we can aggregate data collected by many sensors and display it on monitors or other devices as results that indicate the condition of equipment. This allows even inexperienced workers to accurately grasp the condition of equipment.<h3>3. Introduction of AI into Equipment Maintenance</h3>Sensor fusion is an outstanding technology. However, as the number of sensors increases and measurements become more precise, the amount of data increases. This leads to calculations becoming complex. It also becomes difficult to output data that indicates accurate results. Accordingly, the introduction of deep learning into equipment maintenance has come to be seen as important. Introducing the AI technology of deep learning into equipment maintenance enables data collected from multiple sensors to be integrated and analyzed by AI. If there is an error in the output results, it is corrected through machine learning. Furthermore, accurate results are produced. When we utilize AI in equipment maintenance, we become able to respond correctly to the condition of equipment that is constantly changing with self-learning such as by comparing the data collected during normal times and data collected from sensors to extract the difference in addition to simply detecting abnormalities that are determined by establishing a threshold (Fig. 7).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714986035251-predictive-maintenance-img0007_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 7: Introduction of AI into Equipment MaintenanceIn this way, introducing AI into equipment maintenance doesn’t just reduce the differences in judgments due to differences in the proficiency level of the workers; we can also solve issues in conventional maintenance activities that rely on manpower, which involves investing a lot of personnel and hours in work, including monitoring and inspections.&nbsp;<h3>4. Introduction of Edge AI Cameras and Other Edge AI Devices</h3>Edge AI is a technology that applies edge computing to AI. In edge AI, AI processing is performed with various sensors, cameras, mobile terminals, and other edge devices at the end of networks (Fig. 8). On the other hand, in contrast to edge AI, there is a technology called “cloud AI.” This is a technology that applies cloud computing to AI. This means AI processing is performed on the cloud server connected to the network and the results are then returned to the edge devices. If we compare edge AI and cloud AI, we find that there are advantages to edge AI. These advantages include outstanding response speed and data confidentiality because the AI processing is performed on edge devices without involving a network. This also means edge AI is not impacted by the quality of the network. High data confidentiality is an absolute requirement especially for equipment maintenance that handles data in factories. Moreover, a high response speed is sought in vibration and acceleration calculations, which require data collection at high sampling cycles. Therefore, we can say that edge AI is an attractive technology for predictive maintenance involving the handling of large volumes of data.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714986052981-predictive-maintenance-img0008_en.png" style="width: 100%px;" class="fr-fic fr-dib">Fig. 8: Introduction to Edge AI DevicesHowever, edge devices equipped with edge AI are small. This means they have disadvantages such as inferior memory size and calculating capacity compared to cloud AI. Accordingly, it is necessary to select either cloud AI, edge AI, or to use both together according to your purpose.<h2>Summary</h2>The importance of equipment maintenance for the stable operation of manufacturing lines has long been recognized. Nevertheless, on the other hand, it is also true that too much emphasis on production has led to daily maintenance activities being neglected. Nowadays, with the globalization of manufacturing having long since progressed, manufacturing lines are continuing to constantly supply products to supply chains. In particular, supply chain management has been built based on production output during normal operations in regular factories that are being converted into smart factories. Under these circumstances, unexpected equipment failures on the manufacturing line can deal a major blow to the supply chain and cause damage to a company’s image. Moreover, the introduction of sensor fusion, AI, and other technologies into equipment management is not just about optimizing equipment maintenance, reducing personnel expenses, and solving labor shortages. It is a cutting-edge approach with many advantages including the continuing maintenance of high productivity, the optimization of energy usage, and the effective utilization of personnel. It is no exaggeration to say that realizing predictive maintenance by introducing sensor fusion, AI, and other technologies into equipment maintenance is the key to future corporate management for the manufacturing industry, which is surrounded by a complex economic environment such as the widening of supply chains.&nbsp;<hr><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714986081243-1714986081243.png" class="fr-fic fr-dii">If you have any questions based on this article that you would like to discuss with an expert at Murata, don't hesitate to reach out. There's an entire team ready to support you with your question.<a href="https://www.murata.com/en-eu/contactform?&Detail=Wevolver%20request" target="_blank" rel="nofollow" class="button-main-action">GET IN TOUCH</a>

The importance of equipment maintenance is clear. In recent years, equipment maintenance techniques have also advanced from breakdown maintenance to preventive maintenance and now focus on predictive maintenance.

The Technology That Realizes Predictive Maintenance

BGAs&nbsp;(Ball Grid Array)&nbsp;are&nbsp;a type of&nbsp;lead-less&nbsp;surface mount&nbsp;semiconductor package&nbsp;that, as the name suggests,&nbsp;features an array of spherical solder balls on the underside of the package.Many motherboard control chips utilize this packaging technology.&nbsp;Memory chips&nbsp;utilizing this package technology&nbsp;can double or triple their capacity without increasing in size&nbsp;and compared to&nbsp;other packages, BGA offer&nbsp;higher pin counts,&nbsp;superior heat dissipation&nbsp;and enhanced electrical performance&nbsp;in a smaller volume.The technological success of&nbsp;compact packages including&nbsp;BGA packages allow us to have&nbsp;supercomputers that fit in the palm of our hands. Microprocessors, FPGAs, and memory chips are increasingly being offered in BGA type packages as general PCB assembly capabilities catch-up and the demand for small and powerful electronics continues to increase. However, their utilization poses challenges for PCB layout and manufacture.Small-pitch BGA packages and packages with higher pin counts encroach on the limits of many modern assembly houses’&nbsp;capabilities and call for complex PCB stack-ups and via technologies, not to mention the power and heat dissipation and signal integrity of the overall design must be considered.Designing with BGAs require significant investment and preparation in terms of researching manufacturing and design techniques, and money as the techniques required to fully route-out fine-pitch and larger BGA packages are advanced and costly, and poor design decisions could increase the manufacturing costs by several factors.Before choosing to design with BGA packages, designers should acquaint themselves with the capabilities of their PCB manufacturer and assembly house and familiarize themselves with the design techniques needed to achieve a reliable design at the best price possible. Failure to do so could result in unexpected expenses or wasted time reworking or restarting a design.In this article, we summarize a few BGA design considerations designers should be aware of before beginning a BGA design, especially fine-pitch BGAs (0.5mm pitch and below BGAs).<h3>Routing&nbsp;Traces&nbsp;Between BGA Pads</h3>The number of traces that can be routed between BGA pads is determined by the BGA pitch (center-to-center spacing) and the PCB fabricators capabilities. Typically traces can be routed between pads for 0.5mm and above pitch BGAs. Two can be squeezed in between 0.8mm pitch and above pitch BGAs. For 0.4mm pitch and below BGAs, routing between them is not feasible due to trace width and spacing limitations. Many PCB manufacturers can produce 4mil (0.1mm) traces reliably and 3-3.5mil is not uncommon if used for limited to necking. Necking of traces is where the trace thickness is reduced in select areas. Necking can allow for routing between 0.5mm pitch BGAs pads and routing of more than one trace between pads of larger pitch BGAs.<h3>BGA Pad Size</h3>To route traces, BGA pads should be sized accordingly to ensure adequate spacing between pads. Manufacturers will modify production files to fit their processes and if the spacings are not adequate, excess copper may be shaved off. If the BGA pads are cut into irregular shapes, the quality of the solder joints could be affected.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0ODM3ODc0MDI1LUJHQSBiZWZvcmUgYW5kIGFmdGVyIHByb2Nlc3NpbmcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Gerber file design before and after post-processing<h3>Via-in-Pad via filling and capping</h3>When pad spacing is tight and routing between pads is not possible (such as for 0.4mm pitch BGAs), vias can be placed directly on top of BGA pads (via-on-pad), allowing for signal transfer to the inner or bottom layers. However, it is important that these vias are filled and capped. If not, solder joint defects are almost certain to occur due to the non-planar surface and solder leaking through the vias.The via filling and capping process involves using specialized equipment to fill the vias with a non-conductive epoxy then capping them by plating over the via, essentially adding a pad on top of the via. The plated over vias are visually indistinguishable from regular BGA pads to the naked eye.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0ODM4MDUxODczLUJHQSB2aWEtb24tcGFkIHdpdGhvdXQgZmlsbGluZyBhbmQgY2FwcGluZy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="Via-on-pads on BGA pads without filling and capping">Via-on-pads on the pads of a BGA land without filling and capping <h3>Tenting of Regular BGA Vias</h3>Regular vias between BGA pads should be covered to prevent the solder ball and molten solder paste wicking away from the BGA pads, short circuits and to protect the via from environmental contaminants. Various methods are available for different quality levels.The most basic is to simply cover the vias with solder mask i.e. tent the vias. The solder mask offers a fine layer of protection from contaminants and electrical shorts, however, the level of coverage depends on the viscosity of the solder mask oil and via size. The holes of larger vias may not be fully covered and there is the risk of the via popping during reflow if there is moisture inside the via.Solder mask plugging is another option which adds an extra production step to press solder mask oil into the vias before the general solder mask covering. This ensures that the via barrel is blocked with solder mask but is not guaranteed to be fully filled.&nbsp;The optimal solution is to have all vias filled with epoxy but since this an expensive process, this is usually reserved for high demand applications where via reliability and lifetime is important.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0ODM4OTUwMzQ4LUJHQSBDQU0gdmlldy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">BGA land pattern on a PCB with the vias closed (no solder mask openings) as indicated by the lack of yellow circles on the vias<h3>Via-In-Pad and HDI Design</h3>For fine-pitch BGA chips where traces cannot be routed between pads, it is advisable to utilize a HDI (high-density-interconnect) design with blind and buried vias. For example, mobile phone boards typically have small BGA chips that do not allow for routing between pads.&nbsp;A HDI design with blind and buried vias can be used to make maximum use of the available space in all layers however, the specific stack-up, types of blind/buried vias and total number of layers can have a significant impact on the PCB manufacture cost. It is recommended to consider all possible options on a cost-benefit basis before beginning a design and choosing the types of blind buried vias to use.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0ODQwMTcwODA2LUhESSBQQ0IgQkdBIERlc2lnbi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Tools for Improving BGA PCB Design</h2>Many considerations go into designing a PCB based on a BGA device beyond the scope of this article. HQDFM is a free software developed by HQ NextPCB (HQ Electronics) that inspects Gerber files or OBD++ files for common design for manufacture errors that may affect reliability, cost or manufacturability.<h3>Via-In-Pad Design</h3>HQDFM can detect via-in-pads and reminds designers that via-in-pads should be filled and plated to prevent solder defects and that this increases production costs significantly. If these can be moved away from the pad and converted to regular vias, this will remove the need for via filling and capping.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0ODQwNzExODgxLVAgVmlhLWluLXBhZC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><h3>Pad-to-Pin Size&nbsp;Ratio</h3>HQDFM can compare the solder pad size to the size of the BGA ball. A pad diameter less than 20% smaller than the BGA pin size could lead to insufficient space for routing, while more than 25% might result in poor solder joints. In such cases, design engineers need to adjust the ratio of pad diameter to BGA pin diameter.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0ODQwNzg4Mzg1LVAgQkdBIFBhZCBzaXplLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">HQDFM can also detect areas where trace widths and spacings are inadequate, opened vias, poor component placement and spacing and more not just related to BGA design.&nbsp;HQDFM is a free PCB design analysis software covering bare board and populated PCB analysis. With over 200 inspection items under 30 DFM and DFA categories including trace, solder mask and drill clearances, pads dimensions, shorts/opens, drill hole sizes and solder mask dams. HQDFM also provides tools for the designing and manufacturing PCBs including an impedance calculator, panelization tool, footprint, BOM and centroid file checker.Transform your workflow and swiftly integrate DFM methodologies into your product development with the <a href="https://www.nextpcb.com/free-online-gerber-viewer.html" target="_blank" rel="nofollow">HQDFM</a> desktop suite from <a href="http://www.nextpcb.com" target="_blank" rel="noopener noreferrer">HQ Electronics (NextPCB)</a>.

The miniaturization of electronics is widely attributed to advances in semiconductor technology as observed by Moore’s Law, but many overlook the design and manufacturing challenges involved in utilizing small device packages such as ball grid arrays.

Design for Manufacture Considerations for Ball Grid Array (BGA) Packages

Lean manufacturing is a powerful methodology to optimize processes and eliminate waste in production processes. It originated from the Toyota Production System (TPS) and has since been widely adopted by manufacturers worldwide. 3D printing, also known as additive manufacturing, is a game-changing technology, that offers new opportunities to fulfill the goals of lean manufacturing. This article will explore the ways additive manufacturing supports lean manufacturing by eliminating waste and increasing efficiency in the manufacturing process.<h2>What is lean manufacturing?</h2>At its core, lean manufacturing is about creating value by minimizing waste and using production resources efficiently. Waste, in the context of lean manufacturing, refers to any activity or process that does not add value to the end product or service, increase costs and decrease efficiency. Toyota’s Chief Engineer Taiichi Ohno has developed seven types of wastes, commonly known as the “7 Wastes” or “Muda” in Japanese.<ul><li>Overproduction: Producing more than what is needed</li><li>Waiting: Parts, materials or information are not available, when needed, resulting in delays and inefficiency</li><li>Transportation:&nbsp;Unnecessary movement or transportation of goods</li><li>Excess inventory: Holding more inventory than necessary ties up capital, increases storage costs and can result in obsolete or wasted inventory</li><li>Motion: Unnecessary movement or motion of people, equipment or materials</li><li>Over-processing: Doing more work than necessary can lead to unnecessary costs, time, and effort</li><li>Defects: Products or parts that do not meet quality standards, resulting in rework, scrap, or customer returns</li></ul><figure><img width="1024" height="1024" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0NzE5Mzg5NjA0LTE3MTQ3MTkzODk2MDQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" srcset="https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-1024x1024.png 1024w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-300x300.png 300w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-150x150.png 150w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-768x768.png 768w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-1600x1600.png 1600w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-1536x1536.png 1536w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-2048x2048.png 2048w, https://replique.io/wp-content/uploads/2023/12/Principles-of-lean-manufacturing-660x660.png 660w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">The 5 principles of lean manufacturing according to Womack and Jones (1990) in their book "The Machine That Changed the World"</figure><h2>How 3D printing supports lean manufacturing</h2>3D printing in combination with decentral manufacturing, offers unique capabilities that can help eliminate or reduce many of these wastes. Following the 5 principles of lean manufacturing described below, additive manufacturing is an approach which definitely increases efficiency of value chains.<h3>1. Identify Value: Focusing on customer needs</h3>The first principle of lean manufacturing is value, which focuses on understanding and delivering what the customer truly values. 3D printing offers a unique advantage in the development and introduction of new products. Companies can use additive manufacturing to quickly prototype and test new designs without huge ramp-up costs to find out what the customer values. 3D printing further enables the production of customized and personalized parts that fulfill individual customer needs. This flexibility allows manufacturers to widen their product portfolio with niche products that provide significant benefits to specific customer segments, leading to a more customer-centric approach.<figure><img width="1024" height="732" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0NzE5Mzg5NjUxLTE3MTQ3MTkzODk2NTEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Miele Accessories on Replique Platform" class="fr-fic fr-dii">Miele can offer new accessories in their webshop to their customers, produced on-demand upon customer order via the digital inventory platform of&nbsp;<a href="http://www.replique.io" target="_blank" rel="noopener noreferrer">Replique</a></figure><h3>2. Map Value Stream: Reduce complexity with additive manufacturing</h3>The second principle of lean manufacturing involves identifying and mapping the entire value stream from raw materials to the end customer. Traditional manufacturing methods often require multiple suppliers, transportation, and assembly steps, resulting in a complex and lengthy value stream. In contrast, 3D printing allows for the direct production of parts with minimal intermediaries, reducing assembly costs, and shortening the value stream. In combination with decentral manufacturing, additive manufacturing further eliminates the need for physical movement of parts between different locations. Parts can be produced directly at the point of use, reducing lead times, and leading to faster and more responsive manufacturing processes.<figure><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0NzE5NzA2OTkyLXRyYWRpdGlvbmFsIHZzIDNkIHByaW50aW5nLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 708px;" class="fr-fic fr-dib">Traditional complex supply chains (left) vs simplified decentral 3D printing supply chains (right)</figure><h3>3. Create Smooth Workflow: Eliminate unnecessary production steps</h3>The third principle of lean manufacturing is flow, which emphasizes the smooth and uninterrupted flow of materials and information throughout the production process. While traditional manufacturing methods often require time-consuming tooling changes and setup adjustments to produce different parts, 3D printing, enables a continuous and uninterrupted flow of production as there is nearly no set-up included other than material change. This greatly minimizes waiting times and reduces unnecessary motion, leading to a seamless flow of production.<h3>4. Pull Principle: Producing only what is needed</h3>The fourth principle of lean manufacturing is pull, which focuses on limiting inventory while ensuring that all materials and information are available for a smooth workflow. Traditional manufacturing typically requires large production runs to be cost efficient, leading to overproduction and excess inventory. One of the key benefits of 3D printing however is the ability to produce parts on-demand, per customer order and based on actual demand. This pull-based production approach helps manufacturers to minimize waste in inventories and optimize production, ensuring that resources are used efficiently and effectively.<figure><img width="1024" height="717" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0NzE5Mzg5NDU3LTE3MTQ3MTkzODk0NTcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" srcset="https://replique.io/wp-content/uploads/2023/03/Rehamedpower-1024x717.jpg 1024w, https://replique.io/wp-content/uploads/2023/03/Rehamedpower-300x210.jpg 300w, https://replique.io/wp-content/uploads/2023/03/Rehamedpower-768x538.jpg 768w, https://replique.io/wp-content/uploads/2023/03/Rehamedpower.jpg 1090w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">Small series can be produced more cost-efficiently and upon customer request</figure><h3>5. Continuous improvement: Faster design iterations</h3>The last key principle of lean manufacturing lies in continuous improvement. As the technology continues to evolve rapidly, more and more parts can be produced using additive manufacturing. This presents companies with the opportunity to constantly seek out ways to improve their products and production processes. The speed and flexibility of 3D printing allow for easy and quick design iterations and enables manufacturers to swiftly implement improvements.<h2>How platforms leverage the full benefits of 3D printing</h2>While 3D printing alone already improves production efficiency, a decentral manufacturing approach increases those benefits even more. Additive manufacturing platforms such as <a href="http://www.replique.io/" target="_blank">Replique</a> provide a streamlined and efficient way for manufacturers to connect with 3D printing service providers and access additive manufacturing capabilities on-demand. By combining on-demand 3D printing with a digital inventory, companies can easily get their parts produced in a safe and efficient manner.With a digital inventory, companies can upload their 3D models with qualified production parameters that are locked for all future orders. In the digital inventory they have a comprehensive overview of all their 3D printable parts and past orders. Whenever a part is needed, either for their own use or by their customers, the order can be quickly processed through the digital inventory and printed by a partner located close to the end user. This approach eliminates the need for manufacturers to invest in expensive 3D printers and related equipment and allows them to leverage the expertise and capabilities of additive manufacturing service providers. Additionally, the reordering process becomes much smoother as all parts and associated production information are securely stored in a digital inventory. Paperwork and email transfer is not needed, reducing time and the risk of errors.<figure><img width="1024" height="683" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE0NzE5Mzg5NzA0LTE3MTQ3MTkzODk3MDQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" srcset="https://replique.io/wp-content/uploads/2023/12/Digital-Inventory_Replique-1024x683.png 1024w, https://replique.io/wp-content/uploads/2023/12/Digital-Inventory_Replique-300x200.png 300w, https://replique.io/wp-content/uploads/2023/12/Digital-Inventory_Replique-768x512.png 768w, https://replique.io/wp-content/uploads/2023/12/Digital-Inventory_Replique.png 1170w" sizes="(max-width: 1024px) 100vw, 1024px" class="fr-fic fr-dii">A digital inventory platform, such as Replique, enables companies to provide parts anytime, anywhere in the right amount</figure><hr>

Learn how additive manufacturing supports lean manufacturing by eliminating waste and increasing efficiency in the manufacturing process.

5 Ways 3D Printing is Enhancing the Principles of Lean Manufacturing

Explore the intricate technical details of overmolding and insert molding, the manufacturing processes that are revolutionizing the production of composite materials. This article unpacks the complexities and engineering expertise required to master these techniques.

Overmolding and Insert Molding: Engineering Precision in Hybrid Components

Pipe crawler conducting an inspection inside a wind turbine blade.

Inspecting turbine blades is critical to plan maintenance and avoid downtime. Empower your team to conduct quick, safe, detailed inspections without contracting.

Performing Remote Visual Inspections of Wind Turbine Blades

<section id="isPasted">One concern about AI is that it can imitate voices, a practice called voice spoofing. Deepfakes are a prominent type of voice spoofing facilitated by deep learning, a process in which AI modeled after neural networks in the human brain analyzes data and draws connections. Criminals can use voice spoofing to impersonate someone’s family member and ask for money. Voice spoofing is also a concern in manufacturing settings where verbal commands are widely used to control machinery. Criminals can engineer voices to manipulate and disrupt the machinery or steal data.&nbsp;Machines and manufacturing personnel need a way to verify that verbal commands are legitimate. Such protections do exist but cannot stop skilled attacks like deepfakes, requiring additional safeguards.&nbsp;Dr. Nitesh Saxena, a professor in the Department of Computer Science and Engineering at Texas A&amp;M University, and Yingying (Jennifer) Chen, professor and department chair of Electrical and Computer Engineering at Rutgers University, are working to protect voice control technology against manipulation. Smartwatches may be part of their solution.</section><blockquote>Improving the security of voice authentication is critical in many applications, especially in manufacturing domains.<cite>Dr. Nitesh Saxena</cite></blockquote><section>Wearable devices like smartwatches are already equipped with microphones and accelerometers, which measure vibrations. Saxena and Chen plan to develop software that can be installed on smartwatches or other wearable devices to help authenticate commands in manufacturing settings.&nbsp;Voice control technologies are susceptible to attack because existing defenses only assess a voice sample’s acoustic properties. Saxena and Chen hope to enhance security by requiring verification of both the acoustic properties and the vibration signals of voice samples. They believe this will improve security because it will be harder for criminals to fake both measures simultaneously.&nbsp;“Improving the security of voice authentication is critical in many applications, especially in manufacturing domains. Thanks to the support from our sponsor, this project will allow us to explore this important line of research,” Saxena said. His&nbsp;<a href="https://spies.engr.tamu.edu/" rel="noopener" target="_blank">lab</a> has pioneered work in voice-based security.&nbsp;</section>

Dr. Nitesh Saxena is teaming up with the Texas A&M Engineering Experiment Station and Rutgers University to create software that could stop voice-control mischief in manufacturing settings.

Fighting Deepfakes with Smartwatches

PCB or small components on flexible ribbon cables

This article delves into the innovative world of flexible printed circuit boards, uncovering their design, advancements, and transformative role in modern engineering applications.

Flexible PCBs in Modern Engineering

Unlock the potential of aluminium die casting in modern engineering applications through advanced techniques and innovative solutions.


Aluminium Die Casting: Essential Insights for Engineers

Many businesses changed their working methods after the pandemic, with technological advances allowing more dispersed work sites. Businesses have become more agile, as the IIoT (Industrial Internet of Things) allows constant and instant responses to real-time situations.&nbsp;Here at Rowse, we see the following manufacturing trends influencing the global industry landscape in 2024:<h2 dir="ltr">1. Increased Automation</h2><a title="What Is IIoT?" href="https://www.rowse.co.uk/blog/post/what-is-iiot" target="_blank">The IIoT</a> is the leading technological factor in Industry 4.0, which also deploys artificial intelligence (AI), machine learning (ML), big data and advanced analytics. At the beginning of 2020, only about 10% of manufacturers had implemented it, but this has advanced considerably since the pandemic. Some reports suggest that the adoption rate may now be as high as 85%, which will only get higher.&nbsp;Virtually any sensor or device can now be connected to a network, offering high-speed manufacturing environments unprecedented flexibility. These systems generate vast amounts of data, spurring developments in communications technology. 5G wireless connectivity can achieve speeds up to 10 Gbps and near-zero latency, allowing more excellent, faster and more efficient connectivity.&nbsp;<h2 dir="ltr">2. Increased Efficiency With AI, ML And Advanced Analytics</h2>The IIoT enables remote monitoring and focused manufacturing, producing and collecting vast data. For example, a typical oil rig may deploy over 80,000 sensors, providing a constant data flow. Information can be gathered from machinery and equipment status to real-time monitoring of process parameters (pressures, temperatures, flow rates, etc.). This data amounts to about two terabytes a day of information, hence its usual title of Big Data. This is far beyond the capacity of conventional data analysis methods, leading to the increased use of AI and ML in advanced analytics.&nbsp;The automotive industry has adopted AI-based applications, with electronics, heavy machinery, metals and chemical industries not far behind. AI-based decision-making is applied in many areas, including production line checks, quality inspection, inventory control and supply chain management. ML and advanced analytics adoption is even more widespread since many manufacturing companies now recognise their contribution to&nbsp;<a title="How To Use AI/ML To Optimise Manufacturing Costs" href="https://www.rowse.co.uk/blog/post/how-to-use-ai-ml-to-optimise-manufacturing-costs" target="_blank">significant revenue savings</a>.<h2 dir="ltr">3. Reduced Errors With Digital Twins</h2>Survey data suggests that almost 75% of companies in the advanced industrial sector have already begun using&nbsp;<a title="An Introduction To Digital Twins" href="https://www.rowse.co.uk/blog/post/an-introduction-to-digital-twins" target="_blank">digital twins</a> to aid decision-making. The leading sectors are aerospace and defence, but the energy, infrastructure and logistics sectors are also starting to explore it. Digital twins use scans and computer-aided design (CAD) to construct a 3D representation of almost any object, combined with virtual and augmented reality systems. This means designers and engineers can troubleshoot without requiring a physical model. Its applications include simulating and fixing potential design faults and predicting a product's viable lifespan based on a particular design. Companies like Siemens are already committing to an industrial metaverse that uses<a title="Siemens Digital Twin" href="https://www.siemens-advanta.com/insights/digital-twin-and-industrial-metaverse" target="_blank" rel="nofollow noopener">&nbsp;digital twins</a> to optimise the operations and management of entire factories. &nbsp;<h2 dir="ltr">4. Reduced Downtime With Predictive Maintenance</h2>We've often talked about the value of&nbsp;<a title="What Is Predictive Maintenance?" href="https://www.rowse.co.uk/blog/post/what-is-predictive-maintenance" target="_blank">predictive maintenance</a>, and the message is finally getting through. Equipment failures in the manufacturing environment can be extremely costly. Unplanned downtime can set manufacturers back up to £1.3 trillion a year. Predictive maintenance can help address this problem, reducing downtime by 30%-50%. Big Data analytics and the IIoT allow sophisticated algorithms to accurately predict equipment failures, increasing machine life by 20%-40%. More companies now recognise this, accelerating implementation by large-scale manufacturers.<h2 dir="ltr">5. Widespread Adoption of 3D Printing</h2>3D printing or additive manufacturing has been a rapid growth industry. What started as an experimental bonus for manufacturers has become a legitimate, cost-effective and time-saving way to carry out&nbsp;<a title="How Does 3D Printing Lower Production Costs" href="https://www.rowse.co.uk/blog/post/how-does-3d-printing-lowers-the-cost-of-product-development" target="_blank">various tasks</a>. Large-scale 3D printing, short-run production, metal casting, and moulding are now feasible. For example, The new steel toolmaking process typically reduces costs by 50% and lead times by 80%.&nbsp;Additive manufacturing is also highly prized for its capacity to produce one-off products like customised bike helmets and artificial limbs. There's a greater use of materials like thermoplastic polymers and carbon fibre. More companies are recognising the value of installing in-house 3D printers.<h2 dir="ltr">6. Emergence of Micro-Factories&nbsp;</h2>The pandemic caused many manufacturers to change their production methods. Micro-factories are small, highly modular setups that use all the technological capacity of the IIoT to enable highly autonomous manufacturing. As a self-contained smart factory, these plants are incredibly flexible and resilient. They can affect small part runs, switch production lines rapidly to accommodate new designs and manage restructured supply chains. Micro-factories are a fraction of the size of traditional premises, cost much less and can be situated almost anywhere. Moving closer to the point of sale, time to market is reduced, and the entire system, from design to product despatch, is efficient and agile.<h2 dir="ltr">7. Increased Efficiency With Supply Chain Restructuring</h2>The post-pandemic demand for resilience drives dramatic supply chain management and logistics shifts. Several factors have seriously affected the sourcing of raw materials and siting of production facilities. These include rising shipping costs, higher labour costs in previously cheap offshore countries, and increased social and regulatory pressures on sustainable sourcing. More companies are re-shoring as places like India, China, and Mexico have become more expensive manufacturing bases.New strategies are also being used to source raw materials and components – sometimes described as local, near, or multi-sourcing. Again, 3D printing and AI-assisted supply chain and inventory management have helped manufacturers reduce their reliance on offshore sources. This has been underscored by shifts towards a <a title="What Is A Circular Economy?" href="https://www.rowse.co.uk/blog/post/manufacturing-a-circular-economy" target="_blank">circular economy</a> and efforts to achieve net-zero emissions.<h2 dir="ltr">8. The Push Towards Carbon Neutrality</h2>According to the latest available statistics, the manufacturing industry in the UK was responsible for producing almost 80 million metric tons of greenhouse gas emissions in 2021. This is 40% less than in 1990 but still accounts for around 17% of the UK's total GHG emissions. Globally, the manufacturing industry is responsible for 20% of all carbon emissions.A worldwide push for sustainability has led to many countries adopting a net-zero emissions policy. There's a growing trend towards achieving carbon neutrality, reducing waste and adopting more sustainable practices. Companies are investing in renewable energies and transitioning to electric vehicles. Governments are offering funding incentives to the manufacturing sector to promote decarbonisation, like the UK's £1 billion Net Zero Innovation Portfolio.<h2 dir="ltr">9. Increased Threat of Cyber Attacks&nbsp;</h2>Increased digitisation offers manufacturers great benefits, but it increases cybersecurity risks. Since 2022, the manufacturing sector has ranked above finance as the most targeted for ransomware attacks. It's suggested that at least half of the world's manufacturers consider cyber attacks as posing the biggest threat to their business. According to IT experts, this is due to the industry's low downtime tolerance, making it especially attractive to hackers.Manufacturers must build cybersecurity into their systems when implementing digital transformation projects to prevent the potential exposure of sensitive and proprietary data. It's becoming an equal, if not greater, priority than the potential benefits of new technologies and ROI to protect systems and data against cyber threats. The cybersecurity preparedness of third-party supply chain participants is also critical to prevent disruption from a cyberattack.&nbsp;<h2 dir="ltr">10. Strategising to Combat Labour Shortages</h2>Figures&nbsp;<a title="Labour Shortages" href="https://researchbriefings.files.parliament.uk/documents/CDP-2023-0001/CDP-2023-0001.pdf" target="_blank" rel="nofollow noopener" data-lf-fd-inspected-laxoeak5koo7oygd="true" data-lf-fd-inspected-kn9eq4roawkarlvp="true">published by the UK government</a> in November 2022 show that 13.3% of all surveyed businesses reported a labour shortage. Of these, manufacturing reported shortages of 12%. There were 1.19 million vacancies reported for September-November 2022, of which 84,000 were in manufacturing. Reasons for this include a post-pandemic change in attitude and engagement, changes in immigration and work policies after Brexit, declining birth rates and an ageing workforce.&nbsp;This does not even touch on the subject of digitalisation. According to recent research, 36% or so of manufacturing vacancies are due to applicants not having the necessary skills, experience or qualifications to deal with the demands of new technology. This figure is about 12% higher than the average rate across all industries. One of 2024's most essential manufacturing trends will be finding a way to resolve this situation.<h2 dir="ltr">2024 And The Industrial Metaverse</h2>Two thousand twenty-four manufacturing trends are all leaning towards intelligent automation and the IIOT, expanding predictive maintenance, 3D printing and AI-based decision-making with tools like big data analytics and digital twins. This adds up to the industrial metaverse of bright and micro-factories but carries increased threats of cyber attacks and labour shortages.<hr>This article was originally published at: <a href="https://www.rowse.co.uk/blog/post/2024-manufacturing-trends" target="_blank" rel="noopener noreferrer">https://www.rowse.co.uk/blog/post/2024-manufacturing-trends</a>

Many of last year's trends are still prominent in manufacturing, especially regarding automation. Predictive maintenance and additive manufacturing (3D printing) continue to expand, while robots and digital twins are proving their worth in many industry sectors.

2024 Manufacturing Trends

Wire Electrical Discharge Machining (Wire EDM) has revolutionized precision machining, empowering manufacturers to tackle with intricacies in aerospace, medical devices, and electronics. This latest technology pushes boundaries with its ability to create complex shapes and achieve point accuracy.

Wire EDM: Precision of Modern Engineering

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Manufacturing

Isolated capacitor, used in electronic devices

This guide explores the crucial factors in capacitor polarity, its mathematical analysis, identification, and advanced practices for improved circuit performance.

Capacitor Polarity: Ensuring Proper Orientation for Optimal Performance

Manufacturing

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