A comprehensive look at the science behind anodizing aluminum, exploring the challenges inherent in the process and its various industrial applications.


How to Anodize Aluminum: Mastering the Process and Its Applications

<h2 id="isPasted">Understanding Rapid Prototyping</h2><p>Rapid prototyping spearheads a shift in manufacturing, enabling the quick transformation of ideas into tangible products. This approach leverages cutting-edge technologies such as 3D printing, CNC machining, and additive manufacturing to facilitate fast-paced development cycles, crucial for staying competitive in today's market.</p><p>At the forefront of this transformation is <a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN</a>, a company that's integrating advanced rapid prototyping techniques to offer flexible, cost-effective, and time-efficient solutions. Their services cater to a wide range of businesses, from startups dreaming big to global corporations looking for innovative manufacturing strategies. By reducing the time and cost associated with traditional manufacturing methods, BOEN empowers companies to experiment more freely with their designs, iterate faster, and bring products to market more quickly.</p><p>This shift toward rapid prototyping is not just about speed and efficiency; it's also about the democratization of manufacturing. By lowering the barrier to entry, rapid prototyping enables more creators to bring their visions to life, fostering a new era of innovation in manufacturing.</p><h2>The BOEN Difference</h2><p>BOEN distinguishes itself in the rapid prototyping industry through a blend of proprietary techniques and state-of-the-art technology. Their advanced approach combines:</p><p><strong>Innovative Workflows:</strong> Streamlining the design-to-production cycle, BOEN employs agile methodologies that significantly reduce development time. Their seamless integration of client feedback loops ensures that prototypes meet or exceed expectations with minimal iteration.</p><p><strong>Advanced Hardware:&nbsp;</strong>BOEN's investment in cutting-edge hardware, from 3D printers capable of producing complex geometries to sophisticated CNC machines for high-precision machining, sets a new standard for rapid prototyping. This hardware allows for a wide array of materials to be used, each selected through a rigorous materials science approach that matches the right medium to the project's specific requirements.</p><p>The synergy of these elements positions BOEN as a leader in rapid prototyping, providing unique technical benefits such as reduced lead times, increased precision, and greater flexibility in material selection. Their dedication to pushing the boundaries of what's possible in rapid prototyping not only accelerates product development cycles but also empowers innovation, making them a sought-after partner in the manufacturing sector.</p><h2>Practical Impacts on the Industry</h2><h3>Streamlining the Design to Manufacturing Pipeline</h3><p>Rapid prototyping significantly streamlines the journey from design to production, offering a profound impact on manufacturing efficiency and product quality. By enabling quicker iterations and faster validation of designs, organizations can drastically reduce development cycles and associated costs. BOEN plays a pivotal role in this transformation through its advanced prototyping solutions.</p><p>Leveraging state-of-the-art technologies, BOEN helps industries accelerate their design processes. For instance, the use of 3D printing allows for complex geometries to be created directly from digital models within hours, bypassing the lengthy traditional manufacturing setups. Similarly, CNC machining services offer precision in creating parts from a wide range of materials, further refining the prototype's fidelity to the intended final product.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713185375967-5-Axis-CNC-machining-aluminium-p.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">5-axis CNC machines allow BOEN to deliver rapid prototyping at low volume. Credit: BOEN.</span></span></span></p><p>Moreover, BOEN's emphasis on materials science ensures that each prototype not only meets design specifications but also simulates the functional and aesthetic properties of final products. This holistic approach to prototyping encompasses not just the physical creation of parts but also a rigorous assessment of how materials react under real-world conditions, leading to higher quality outcomes.</p><p>Significantly, BOEN's methodologies foster greater innovation. With reduced time and cost implications, companies are encouraged to explore more ambitious designs, test new concepts, and iterate more frequently. This democratization of high-quality prototyping serves as a catalyst for breakthroughs across numerous sectors, from automotive to medical devices, where the precision and speed of prototyping can mean quicker market entry and competitive advantage.</p><p>In essence, the services provided by BOEN underscore the practical benefits of rapid prototyping in today's fast-paced industry, emphasizing efficiency, quality, and innovation.</p><h3>Opening Doors for Startups and Innovators</h3><p>Rapid prototyping is a game-changer for startups and innovative companies, easing the path from ideation to realization with its cost-efficiency and flexibility. For ambitious projects on tight budgets, this methodology is a beacon, illuminating the route to successful product development without the hefty investment traditionally associated with manufacturing.</p><p>BOEN, understanding the unique landscape startups navigate, offers specialized services that align with the agile, innovative ethos of these ventures. Their approach demystifies the prototyping process, granting access to high-quality resources and expertise that were once the exclusive domain of industry giants.</p><p>The technical benefits provided by rapid prototyping, such as improved design accuracy, the possibility of iterative testing, and the capability to quickly adapt to feedback, are crucial for startups. These benefits enable a swift response to market demands or design challenges, enhancing market responsiveness.</p><p>Furthermore, BOEN’s solutions are not one-size-fits-all but are carefully tailored to meet the distinct needs of innovators. Whether it's selecting the right material for a prototype to test its durability or employing the most suitable prototyping technique to ensure cost-effectiveness, BOEN’s expertise proves invaluable.</p><p>This support empowers startups to tread boldly in competitive markets, making rapid prototyping not just a manufacturing approach, but a strategic asset for driving innovation and securing a foothold in the industry.</p><h2>Beyond Prototyping: The Future with BOEN</h2><h3>From Prototyping to Low-Volume Production</h3><p>The transition from rapid prototyping to low-volume production is a critical phase for any product development process, marking the shift from concept validation to market readiness. This stage involves:</p><p><strong>Detailed Planning:</strong> Establishing a clear roadmap from prototype to production, considering timeframes, budget, and resource allocation.</p><p><strong>Material Selection and Sourcing:</strong> Choosing materials that balance cost, performance, and availability for low-volume runs.</p><p><strong>Manufacturing Technique Adjustment:</strong> Shifting from prototyping methods to those more suitable for small-scale production without compromising quality.</p><p><strong>Quality Control Systems:</strong> Implementing stringent quality control measures adapted for low-volume production to ensure each unit meets the high standards set during prototyping.</p><p><strong>Logistics and Supply Chain Management:</strong> Optimizing logistics to handle the distribution of smaller product quantities, managing supply chain relationships to ensure timely delivery of materials.</p><p>BOEN supports businesses through this transition by leveraging its expertise in both rapid prototyping and small-scale manufacturing. Their support encompasses:</p><p><strong>Consultation and Strategy:&nbsp;</strong>Advising on the best pathways for scaling production in a cost-efficient manner while maintaining product quality.</p><p><strong>Custom Manufacturing Solutions:&nbsp;</strong>Offering tailor-made manufacturing solutions that address the unique challenges of low-volume production.</p><p><strong>Quality Assurance:&nbsp;</strong>Ensuring that the quality established during the prototyping phase is maintained or enhanced as production scales.</p><p><strong>Supply Chain Optimization:&nbsp;</strong>Assisting in creating a responsive and efficient supply chain tailored to the needs of small-scale production.</p><p>Through these services, BOEN helps companies navigate the complexities of scaling their products, enabling a smoother transition from concept prototypes to market-ready products. This comprehensive support is invaluable for businesses looking to capitalize on their innovations with minimal delays and optimal product quality.</p><h2>Empowering Innovation Across Industries</h2><p>Rapid prototyping, especially when leveraged by BOEN's expertise, catalyzes innovation across various industries by providing tailored solutions that meet each sector's unique demands.</p><p>In the aerospace sector, precision and reliability are paramount. Rapid prototyping facilitates the production of lightweight, high-strength components, reducing aircraft weight and improving fuel efficiency. BOEN's adept material selection ensures components withstand extreme conditions, from high temperatures to mechanical stress, crucial for aerospace applications.</p><p>In the medical devices industry, the ability to prototype intricate, biocompatible devices rapidly accelerates the development of lifesaving technologies. BOEN's proficiency in navigating material compatibility and regulatory requirements allows for the swift iteration of designs, from prosthetics to surgical tools, ensuring they meet stringent medical standards. Low-volume manufacturing allows medical device products to be made in small batches, as medical devices, unlike consumer products do not require very large quantities.</p><p>The automotive industry benefits significantly from rapid prototyping by expediting the design process of both functional and aesthetic automotive parts. BOEN's expertise in durable materials and finishing techniques enables the production of prototypes that closely mimic final products, allowing for comprehensive testing and design optimization.</p><p>By overcoming technical challenges through innovative solutions and material expertise, BOEN not only advances product development within these sectors but also empowers companies to push the boundaries of what's possible, leading to groundbreaking innovations that reshape industries.</p><h2>Conclusion</h2><p>The journey through rapid prototyping's capabilities and its transformative impact on various industries has underscored its indispensable role in modern manufacturing. Through the lens of BOEN's innovative practices, we've seen firsthand how technological advancements in rapid prototyping significantly streamline the design-to-manufacturing pipeline, empower startups, and catalyze innovation across sectors like aerospace, automotive, and medical devices.&nbsp;</p><p><a href="https://www.boenrapid.com/" target="_blank" rel="noopener noreferrer">BOEN</a> stands at the forefront of this revolution, offering expertise and solutions that not only meet the current demands of the market but also pave the way for future advancements. The potential for further innovation in manufacturing, driven by rapid prototyping, is boundless. We invite industry professionals to consider how these advancements could be integrated into their operations, ushering in a new era of efficiency and creativity.&nbsp;</p>

Rapid prototyping is significantly contributing to an innovative manufacturing future by enabling swift conversion from conceptual designs to physical models.

Rapid prototyping's transformative role to the future of manufacturing

<p id="isPasted">When it comes to finishing options for aluminium parts, the choices can be baffling. Two standout methods, powder coating and anodizing, often find themselves at the centre of the debate. But what exactly sets them apart?</p><p>Whether in the automotive industry, aviation, or just curious, understanding these methods will equip you with the knowledge to choose your specific needs.</p><h2 data-counter-attr="value0"><strong>What is Powder Coating?</strong></h2><p>Powder coating is a finishing technique where a dry, free-flowing powder is applied to a surface, typically aluminium, with a spray gun. The powder adheres to the metal surface through electrostatic application before being cured under heat, forming a tough, uniform layer.</p><h3 data-counter-attr="value1"><strong>Benefits and Key Features</strong></h3><ul><li><strong>Durability</strong>: A powder coat creates a hard finish that’s more resistant to scratching, chipping, and corrosion than traditional paints</li><li><strong>Variety</strong>: Many colours and textures are available, offering great versatility</li><li><strong>Cost-effective</strong>: Though the initial setup may be expensive, the long-term benefits make it cost-efficient</li><li><strong>Environmentally friendly</strong>: This process emits few <a href="https://www.epa.gov/indoor-air-quality-iaq/what-are-volatile-organic-compounds-vocs#:~:text=Volatile%2520organic%2520compounds%2520are%2520compounds,paints%252C%2520pharmaceuticals%252C%2520and%2520refrigerants." target="_blank" rel="noreferrer noopener">volatile organic compounds (VOCs)</a>, making it a greener choice</li></ul><h3 data-counter-attr="value2"><strong>Common Applications</strong></h3><ul><li>Used for coating wheels, bumpers, and other parts for enhanced aesthetics and protection</li><li>Found in appliances and gadgets for a sleek, durable finish</li><li>It is ideal for coating window frames, railings, and other building elements</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909242472-CNC-machined-and-powder-coated-part-768x513.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CNC machined and powder coated part</span></span></span></p><h2 data-counter-attr="value3" id="isPasted"><strong>What is Anodizing?</strong></h2><p>Anodizing is an electrolytic process that forms a protective oxide layer on the surface of aluminium. A robust, corrosion-resistant layer is created by submerging the aluminium in an acid electrolytic bath and passing an electric current through it. This natural oxide layer is not merely a coating but is integrated with the underlying aluminium, providing a strong bond.</p><h3 data-counter-attr="value4"><strong>Benefits and Key Features</strong></h3><ul><li><strong>Strength and durability</strong>: Unlike other coatings, anodized aluminium doesn’t peel or chip, offering lasting protection</li><li><strong>Aesthetic flexibility</strong>: Anodizing allows for colouring and decorative finishes, providing a broad palette of options</li><li><strong>Enhanced adhesion</strong>: The process allows for better adhesion for paints and glues.</li><li><strong>Non-toxic</strong>: The process uses non-hazardous materials and is generally considered more environmentally friendly</li></ul><h3 data-counter-attr="value5"><strong>Common Applications</strong></h3><ul><li>Anodizing is vital in aviation, where weight and durability are key considerations</li><li>Used in surgical instruments and other medical devices due to its resistance to wear and biological contamination</li><li>Kitchen utensils and cookware often utilise anodizing for a smooth, non-reactive surface</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909260643-Sheet-Metal-Aluminium-anodising-768x512.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Sheet metal aluminium anodizing</span></span></span></p><h2 data-counter-attr="value6" id="isPasted"><strong>Powder Coating and Anodizing Comparison</strong></h2><h3 data-counter-attr="value7"><strong>Cost</strong></h3><p>When evaluating cost, several factors come into play. Powder coating often has higher initial equipment and setup costs. Still, it can be more cost-effective in the long run, particularly for large-scale projects.</p><p>On the other hand, anodizing typically has lower entry costs but may be more expensive for custom colours and finishes. Ultimately, the price will depend on the specific requirements and scale of the project.</p><h3 data-counter-attr="value8"><strong>Durability</strong></h3><p>Durability is a vital consideration in choosing a surface treatment. Powder coating provides a robust surface that’s resistant to chipping and scratching. Its uniform coating ensures all-around protection.</p><p>Anodizing, however, takes it further by integrating the protective layer into the aluminium. This results in a finish that doesn’t peel or chip, offering long-term resilience. Both methods are highly durable, but anodizing may provide a slight edge regarding wear resistance.</p><h3 data-counter-attr="value9"><strong>Corrosion Resistance</strong></h3><p>Both powder coating and anodizing offer substantial protection in terms of corrosion resistance. A powder coat forms a sealed, continuous layer that prevents oxidation and corrosion.</p><p>By creating a thick oxide layer, anodizing also offers robust corrosion resistance. While both methods are highly effective, anodizing’s integrated oxide layer might provide more consistent and long-lasting protection against corrosion, especially in aggressive environments.</p><h3 data-counter-attr="value10"><strong>Comparison Table</strong></h3><table id="isPasted"><thead><tr><th>Characteristics</th><th>Anodizing</th><th>Powder Coating</th></tr></thead><tbody><tr><td>Type</td><td>Electrochemical process</td><td>Electrostatic process</td></tr><tr><td>Cost</td><td>High</td><td>Moderate</td></tr><tr><td>Durability</td><td>Excellent</td><td>Good</td></tr><tr><td>Corrosion Resistance</td><td>Excellent</td><td>Good</td></tr><tr><td>Colour Options</td><td>Limited colours</td><td>Wide range of colours</td></tr><tr><td>Surface Finish</td><td>Matte or satin texture</td><td>Glossy, matt, or satin textures</td></tr><tr><td>Colour Fading Resistance</td><td>Poor</td><td>Excellent</td></tr><tr><td>Eco-friendliness</td><td>Good</td><td>Excellent</td></tr></tbody></table><h2 data-counter-attr="value11" id="isPasted"><strong>Application-Specific Considerations</strong></h2><h3 data-counter-attr="value12"><strong>Architectural Applications</strong></h3><p>When it comes to architectural applications, both powder coating and anodizing have their merits. Powder coating’s wide range of colours and textures makes it versatile for adding an aesthetic touch to window frames, railings, and other architectural elements.&nbsp;</p><p>On the other hand, anodizing offers a unique advantage with its corrosion-resistant properties. This makes it particularly suitable for structures in coastal areas where the salty air can accelerate corrosion.&nbsp;</p><p>Anodizing might lead in this context, providing enhanced protection against the elements.</p><h3 data-counter-attr="value13"><strong>Consumer Electronics</strong></h3><p>In the realm of consumer electronics, the coating process shines. Its sleek and attractive finish enhances the aesthetics of gadgets. At the same time, its scratch-resistant nature ensures that everyday wear and tear don’t mar its appearance.</p><p>The versatility in colours and textures allows manufacturers to match the finish with the product’s design. While robust, anodizing might not offer the same array of customisation options as powder coating, making powder coating the preferred choice for consumer electronics.</p><h3 data-counter-attr="value14"><strong>Automotive Industry</strong></h3><p>In the automotive industry, both powder coating and anodizing find their niches. Powder coating’s durability makes it popular for coating wheels, bumpers, and other metal products that withstand harsh road conditions.&nbsp;</p><p>On the other hand, anodizing’s corrosion resistance makes it valuable in areas where vehicles might be exposed to corrosive elements, such as road salt. The choice here might depend on whether durability or corrosion resistance is the higher priority.</p><h3 data-counter-attr="value15"><strong>Aviation and Aerospace Applications</strong></h3><p>For aviation and aerospace applications, the corrosion-resistant properties of anodized aluminium shine. In an industry where weight, durability, and corrosion resistance are paramount, anodizing’s ability to provide all three qualities makes it a top choice.&nbsp;</p><p>The protective oxide layer helps extend the lifespan of crucial components, ensuring the safety and performance of aircraft.&nbsp;</p><p>The unique demands of aviation and aerospace applications often make anodizing the preferred option.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909300406-Powder-coating-vs-anodising-1-768x513.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Powder coating (left) vs anodizing (right)</span></span></span></p><h2 data-counter-attr="value16" id="isPasted"><strong>How to Choose Between Powder Coating and Anodizing?</strong></h2><p>A thoughtful evaluation of multiple factors becomes crucial when deciding whether to opt for powder coating or anodizing for aluminium finishing. In this intricate selection process, aesthetics, environment, and function are pivotal considerations.</p><h3 data-counter-attr="value17"><strong>Aesthetics</strong></h3><p>One must assess the desired visual appeal of the finished product. A powder coat can have various colours and textures, catering to diverse design preferences.&nbsp;</p><p>On the other hand, anodizing’s colour options, though limited, provide a more lasting and integrated appearance. The choice hinges on balancing immediate visual impact and long-term colour retention.</p><h3 data-counter-attr="value18"><strong>Environment</strong></h3><p>The surrounding environment significantly impacts the durability and longevity of the chosen finish. Suppose the aluminium parts are expected to endure corrosive atmospheres or extreme weather conditions. In that case, anodizing’s inherent corrosion resistance offers a distinct advantage.</p><p>Powder coating’s robustness remains undeniable, yet its vulnerability to chipping might necessitate an extra layer of protection in harsh environments.</p><h3 data-counter-attr="value19"><strong>Function</strong></h3><p>The function of the aluminium component must dictate the choice of finish. If the part is exposed to mechanical stresses or potential abrasion, powder coating’s scratch-resistant nature could be instrumental.&nbsp;</p><p>Meanwhile, if corrosion prevention is paramount, anodizing’s integrated oxide layer becomes indispensable.</p><h3 data-counter-attr="value20"><strong>Expert Opinion</strong></h3><p>In this intricate decision-making process, the role of experts cannot be overstated. Engaging with professionals who possess comprehensive knowledge of both finishing methods is essential.&nbsp;</p><p>These experts can evaluate the unique demands of each project, ensuring that the selected finish aligns optimally with its intended application.</p><h2 data-counter-attr="value21"><strong>Conclusion</strong></h2><p>The choice between powder coating and anodizing in aluminium finishes transcends mere aesthetics. It’s a decision that directly impacts durability, corrosion resistance, and overall functionality.</p><p>As we’ve navigated the intricacies of these processes, the significance of informed decision-making has become clear. Powder coatings and anodizing present distinct advantages, each catering to specific requirements.</p><p>Powder coating offers a broad spectrum of colours and robust protection against scratching, making it a strong contender. On the other hand, anodizing embeds corrosion resistance into the very structure of the aluminium, ensuring a longer lifespan.</p><p>In the dynamic landscape of surface treatment, Xometry emerges as a versatile and reliable service provider, offering powder coating and anodizing solutions. With a commitment to precision and excellence, Xometry caters to a diverse range of industries, fulfilling the nuanced requirements of each project.</p>

In a world where quality and durability are paramount, selecting the right finish for an aluminium surface is more than a mere aesthetic choice. This article aims to clear the fog by providing a head-to-head comparison of powder coating and anodising processes.

Powder Coating vs. Anodizing for Aluminium

<h2 id="isPasted">Iconic PepsiCo Brand Finds Best Alternative to Expensive, Time-Consuming Conventional Metal Tooling</h2><p><a href="https://www.pepsico.com/" target="_blank">PepsiCo products</a> are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo generated more than $79 billion in net revenue in 2021, driven by a complementary beverage and convenient foods portfolio that includes Lay’s, Doritos, Cheetos, Gatorade, Pepsi-Cola, Mountain Dew, Quaker, and SodaStream. PepsiCo’s product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.</p><h2 id="isPasted">The challenge</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MTU1MjQ1LWV6Z2lmLTEtNGZiZjE1OTIxMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Speed to market has never been more important in the consumer goods sector, as brand owners aim to develop new bottle and package designs to address ever-shifting customer desires. But creating conventional metal tooling for the blow molding of bottles is an expensive and time-consuming proposition. Once a CAD file of the package design is created, it can take up to four weeks to machine a metal tool, and then an additional two weeks to get a trial unit to do the actual blow molding. It also could easily cost up to $10,000 to produce a single metal tool set depending on its complexity, according to Max Rodriguez, senior manager of Global Packaging R&amp;D, Advanced Engineering and Design, at PepsiCo’s Valhalla research center.</p><p>This has led many to try to apply 3D printing to shorten this process, but previous rapid tooling approaches also had their shortcomings. It would take two to three days to 3D print a single blow molding tool from Digital ABS (an expensive material) on a $250,000 PolyJet 3D printing machine. Even so, the resulting tool lacked durability and could produce only about 100 bottles before the mold began to fail. This prompted Rodriguez and his team to explore using a hybrid approach, combining parts of a conventional metal mold with 3D printed inserts.</p><blockquote id="isPasted"><p>“Time and cost are obviously important, but more important is to have the ability to have the flexibility to run through a number of different design iterations at a record pace so that we can evaluate performance in all of the downstream activities. That really is what helps us accelerate packaging design and development.”<strong>Max Rodriguez, Senior Manager of Global Packaging<br id="isPasted">R&amp;D, Advanced Engineering and Design, PepsiCo</strong></p></blockquote><h3 id="isPasted"><strong>The application</strong><strong><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjI2NDE3LVBlcHNpQ28tUGF0ZW50ZWQtM0QtUHJpbnRlZC1IeWJyaWQtTW9sZC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></strong><br></h3><p>Applying its patented technology and a hybrid approach, PepsiCo is using additive manufacturing as an enabler in various aspects of bottle development – accelerating and enhancing performance simulation, advanced system analysis and the production of high-quality, functional prototypes.</p><h3><strong>The advantages</strong></h3><ul><li>Compress prototype tooling development time from 4 weeks to 48 hours</li><li>Slash prototype tooling costs from $10,000 to $350 per mold set</li><li>Create durable tooling that can produce more than 10,000 bottles per mold</li><li>Enable multiple design iterations to allow for timely verification of downstream activities</li></ul><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/k7OiPJ9xfps?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">More Than 10,000 Bottles at 96% Reduction in Cost</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyODE5MjY2OTM4LVBlcHNpQ28tUGF0ZW50ZWQtTW9sZC0zRC1QcmludGVkLU5leGEzRC03Njh4NTg5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p>PepsiCo chose Nexa3D’s xPEEK147 from Henkel Loctite for the 3D printed tool inserts due to the material’s strength and impressive performance factors, including its very high heat-deflection temperature. While this hybrid approach is machine-agnostic, meaning it can use various types of 3D printers, PepsiCo has found the ultrafast, high-throughput <a href="https://nexa3d.com/3d-printers/nxe400/" target="_blank">Nexa3D NXE 400 3D printer</a> and accompanying material performance to be ideal for producing the mold components it needs.</p><p>A complete mold set can be made in 12 hours, with 8 hours of 3D printing time and 4 hours of curing. These hybrid-made molds can then successfully be used for more than 10,000 bottles before failure – at up to a 96% reduction of cost compared to traditional metal tooling.</p>

PepsiCo worked with Nexa3D’s partner Dynamism to validate the NXE 400 and the xPEEK147 material as ideal for their blow molding application requiring speed and durability.

CAD to Part in 48 Hours: PepsiCo Slashes Tooling Costs and Cycle Times with the help of NXE 400

<p>The transition to more environmentally friendly processes and materials promotes sustainability and can lead to significant cost reductions in various industries. Finally, the ability to innovate is a key competitive factor in opening up new markets. These challenges can often not be met alone, but only hand in hand with a strong partner who understands the requirements. And offers the right solutions.</p><h3 id="isPasted"><strong>Customised metal mesh solutions for every industry</strong></h3><p>Located in the heart of Oelde, Germany, Haver &amp; Boecker oHG has stood for outstanding expertise in wire mesh and packaging technology for generations. Both the Wire Weaving and Machinery Division are under the umbrella of this traditional family business, which is characterized by its innovative spirit, engineering know-how and tireless search for tailor-made customer solutions. &nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712813314016-1712813314016.jpeg" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">An average of 70 looms are used in the fine weaving department. Mass production is also possible.</span></span></span></p><p id="isPasted">Haver &amp; Boecker's Wire Weaving Division has established itself as a leading global manufacturer – a testament to the company's expertise and commitment. The brand stands for an impressive variety of product solutions that go far beyond the limits of conventional wire cloth applications. From filters and moulded parts for the various industries to filtration media for the chemical and pharmaceutical industries, to innovative architectural mesh – the applications are as diverse as the needs of the customers.&nbsp;</p><p>Haver &amp; Boecker uses specially designed fine weaving machines and looms to produce products that often exceed specific requirements in terms of functionality and form.</p><h3><strong>Vertical integration and processes: A look behind the scenes</strong></h3><p>Haver &amp; Boecker's exceptional vertical integration enables it to meet customer requirements precisely and efficiently – from the construction of the looms to the processing of the finest wires. Wire mesh of exceptional quality is produced on a production area of more than 30,000 m² in Oelde and other locations in Belgium and Canada. The ability to respond to almost any customer request underlines the flexibility and future security of the company.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712813343123-1712813343123.jpeg" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Wire mesh is highly flexible, robust and, depending on the application, has excellent filtering properties and EMC compliance.</span></span></span></p><h3 id="isPasted"><strong>Wide range of materials &nbsp;</strong></h3><p>The ability to work with all woven materials, from stainless steel to highly specialised materials such as titanium and hastelloy, enables Haver &amp; Boecker to meet the most demanding customer requirements. Combined with the company's technical expertise, solutions can be developed that are perfectly tailored to the process. &nbsp;</p><h3><strong>Shaping the future with wire mesh</strong></h3><p>"The world of tomorrow needs our wire mesh" – this is the conviction and commitment of Haver &amp; Boecker, a manufacturer that contributes to overcoming global challenges with pioneering solutions and products. Take electromobility, for example: flat and round wire mesh is already being used successfully to shield components in modern vehicles, including sensors and infotainment systems, from alternating fields that impair functionality. In addition to its excellent shielding attenuation, the material's flexibility and light weight are advantages.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712813376457-1712813376457.jpeg" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">State-of-the-art machinery ensures precision in the processing of high-quality materials.</span></span></span></p><p id="isPasted">The combination of decades of experience, technological innovation and customer proximity makes Haver &amp; Boecker a unique partner for modern industry, whose products and solutions are indispensable today and in the future. Please browse the website for more information on applications and custom solutions. Haver &amp; Boecker contacts are also available for a personal, no-obligation discussion. &nbsp;</p><p>Find out more about the Wire Weaving Division <a href="https://www.haverboecker.com/en/company/old-about-us/wire-weaving-division/?lso=wewolver-brand-beitrag" target="_blank" rel="noopener noreferrer">here</a>.</p>

Resource scarcity and climate change are major challenges for today's (and tomorrow's) industries: More efficient processes and reduced emissions are needed to keep pace in a globalised world. Cutting-edge technologies like AI and renewable energies are making a valuable contribution. 

Tradition meets innovation: wire mesh solutions for industry

<p dir="ltr" id="isPasted">The integration of robotics into manufacturing has radically boosted efficiency and quality and lowered costs. However, large industrial robots also pose a threat to human safety due to their size, weight, and ‘on/off’ programming. In an effort to solve this problem, collaborative robots, or cobots, have been introduced to manufacturing facilities. These lightweight robots are designed to work alongside human workers. However, cobots cannot do the same grunt work as their more industrial cousins, leaving a gap between the small save robots and the caged larger machines.&nbsp;</p><p dir="ltr">Blue Danube Robotics, the company behind <a href="https://www.airskin.io/" target="_blank" rel="noopener noreferrer">AIRSKIN®</a>, aims to solve this industrial automation problem. Their innovative product, AIRSKIN®, is a breakthrough technology designed as a soft, tactile skin for industrial robots, enabling them to work alongside humans safely. This patented solution allows robots to perform a broader range of tasks in close proximity to human workers, revolutionizing how robotic automation integrates into human-centric work environments.&nbsp;</p><h1 dir="ltr">AIRSKIN® enables an open workplace with robots</h1><p dir="ltr">The integration of robots into the industrial workforce presents a unique set of safety challenges. The limitations of traditional safety measures and even the most advanced cobots have made it clear that a new approach is needed to harmonize human-robot collaboration. This is where AIRSKIN® enters the scene, offering a solution that addresses these challenges.</p><p dir="ltr">AIRSKIN® seamlessly integrates with industrial robots and transforms traditional manufacturing setups into collaborative environments. This reduces hazardous collision areas and ensures maximum safety with PLe / Cat. 3 certification.</p><h3 dir="ltr">Upgrade to Collaborative Robots</h3><p dir="ltr">AIRSKIN® transforms standard industrial robots into fenceless, collaborative &nbsp;robots. This transformation allows robots to operate in close proximity to humans and other machinery, enhancing productivity and efficiency while maintaining a safe working environment. By eliminating the need for physical barriers, AIRSKIN® enables seamless collaboration between humans and robots, optimizing workflow and reducing downtime. AIRSKIN® works with all robots, already off-the-shelves products exist for KUKA (Agilus 2, Cybertech 2, Iontec, Quantec 2), Stäubli (TX2touch) and Epson (Scaraflex).&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzM5Mzg3MDk5LXNlY29uZC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">AIRSKIN® transforms standard industrial robots into fenceless, collaborative robots. Credit: AIRSKIN.</span></span></span></p><h3 dir="ltr" id="isPasted">Innovative Design and Functionality</h3><p dir="ltr">AIRSKIN® comprises soft and robust air-filled pads mounted on the robot, with embedded safety electronics that monitor internal air pressure and instantly react to contact anywhere on the robot. Dual-channel pressure sensors detect pressure changes, ensuring precise and rapid response to potential collisions in a maximum of 8ms.</p><p dir="ltr">Equipped with intelligent sensors and real-time monitoring capabilities, AIRSKIN® detects and responds to potential hazards with precision and speed, mitigating the risk of accidents and injuries. Certified according to ISO 13849 with the highest safety performance level PLe / Cat.3, AIRSKIN® meets all industrial requirements, including high durability and IP54 rating.</p><p dir="ltr">AIRSKIN® offers adaptability to various industrial environments and applications, seamlessly integrating into existing workflows. Its space-saving design eliminates the need for physical barriers, optimizing floor space by up to 90% compared to traditional fencing systems, thereby unlocking new possibilities for layout optimization and production line flexibility.</p><h1 dir="ltr">How&nbsp;AIRSKIN® is used</h1><p dir="ltr">AIRSKIN® can be added to industrial robot applications to enable them to have ‘collaborative’ status by effectively covering all hazardous collision areas. The maximum speed for the robot is based on a risk assessment and can reach up to 2m/s in collaborative mode.</p><p dir="ltr">AIRSKIN® can help large payload robots achieve movement speed of beyond 1 m/s, while still maintaining operator safety. The AIRSKIN® Modules help absorb energy and distribute the contact forces associated, helping them avoid serious injury.</p><h3 dir="ltr">Clamping/shearing collisions</h3><p dir="ltr">For clamping/shearing collisions the robot’s stopping distance must be shorter than the thickness of the soft AIRSKIN®. In order to accommodate these stringent application areas, a risk assessment needs to be done to determine the permissible speed. It must be obtained by measuring contact forces occurring in the collision using an ISO/TS 15066 compliant measurement device.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzM5NDIyODQyLXRoaXJkLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Safer workplaces enable more agile and customized workflows. Credit: AIRKSIN.</span></span></span></p><h1 dir="ltr" id="isPasted">Advancing Industry 4.0</h1><p dir="ltr">Robotics is a pivotal component of Industry 4.0. AIRSKIN® enables companies to convert existing robotic setups to collaborative, human-safe zones. This can radically increase efficiency by reducing downtime usually created by safety cage protocols. It also enables more agile and customized workflows, which are integral to meeting industry 4.0 goals.&nbsp;</p><p dir="ltr">Industry 4.0 benefits With AIRSKIN®</p><ul><li dir="ltr"><p dir="ltr">Speed:&nbsp;Up to 6 times faster than applications with cobots, achieving speeds of up to 2 m/s for collaboration.</p></li><li dir="ltr"><p dir="ltr">Flexibility:&nbsp;Safety system mounted on the robot offers flexibility in location and task execution.</p></li><li dir="ltr"><p dir="ltr">Space Optimization:&nbsp;Optimizing installation footprint by up to 90%, maximizing operational efficiency.</p></li><li dir="ltr"><p dir="ltr">Payload &amp; Reach: Supporting a wide range of payloads and reaches for various robotic applications. – like AIRSKIN for KUKA Quantec – up to 300 kg payload&nbsp;</p></li><li dir="ltr"><p dir="ltr">Precision:&nbsp;Offering highest accuracy, repeatability, and path consistency for precise operations.</p></li><li dir="ltr"><p dir="ltr">Risk Assessment: Prepared safety concept simplifies application assessments, ensuring compliance with safety standards.</p></li></ul><h3 dir="ltr">AIRSKIN Safetyflange: Advancing Safety and Efficiency</h3><p dir="ltr">AIRSKIN Safetyflange, a compliant robotic collision sensor, extends the safety benefits of AIRSKIN® technology to protect tools, workpieces, and individuals from potential hazards. Designed for easy mounting with any robot and end-of-arm tool, AIRSKIN Safetyflange ensures compliance with safety standards while maximizing workplace safety without compromising productivity.</p><p dir="ltr">Key Features:</p><ul><li dir="ltr"><p dir="ltr">Finger-Safe Applications:&nbsp;Eliminates crushing and clamping risks, ensuring compliance with safety standards.</p></li><li dir="ltr"><p dir="ltr">Adjustable Break-Away Forces:&nbsp;Absorbs energy and reduces pressure and force during collisions in collaborative applications.</p></li><li dir="ltr"><p dir="ltr">Compliance in All Directions:&nbsp;Adjustable compliance minimizes contact forces, maximizing workplace safety.</p></li><li dir="ltr"><p dir="ltr">Easy Mounting Compatibility:&nbsp;Simplifies integration with any robot and tool using exchangeable ISO 9409-1 adapters.</p></li><li dir="ltr"><p dir="ltr">Safety Certification: Complies with the PLe / Cat. 3 ISO 13849 safety certification, setting a new standard for safe and efficient operations.</p></li></ul><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/5ljMxWZMLvc?&amp;feature=youtu.be&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"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h1 dir="ltr">Versatile Applications</h1><p dir="ltr">AIRSKIN Safetyflange is suitable for a wide range of applications, including palletizing, machine tending, visual inspection, gluing, and more, making it a versatile solution for enhancing safety and efficiency in industrial environments.</p><p dir="ltr">AIRSKIN® marks a pivotal advancement in the sphere of industrial automation, fundamentally transforming how safety and efficiency are perceived and implemented in collaborative workspaces. By integrating AIRSKIN® into your operations, your business can set new benchmarks for what is possible to achieve with human-robot collaboration. There is immense potential for AIRSKIN®-equipped robots to redefine and enrich collaborative workspaces, allowing a future where robots and humans can work side by side with unprecedented efficiency and safety.</p><p dir="ltr">As we move further into the Industry 4.0 era, the impact of <a href="https://www.airskin.io/" target="_blank" rel="noopener noreferrer">AIRSKIN®</a> represents the endless possibilities at the intersection of innovation, safety, and collaboration. It fosters a new period of industrial productivity and human-centric automation.</p>

AIRSKIN® revolutionizes industrial automation by adding air-powered tactile skin for to robots to create safe, collaborative environments, ensuring maximum safety with PLe / Cat. 3 certification.

Bringing Freedom into Factories: How Air-Powered Tech Paves the Way for Human-Robot Harmony

<p dir="ltr" id="isPasted">Machine vision represents a fascinating fusion of hardware and software designed to empower machines to 'see' and interpret the world around them. This technology, critical in manufacturing, automates tasks that require visual understanding, enhancing efficiency, accuracy, and safety on production lines. From guiding robots to inspecting products for defects, machine vision systems translate visual inputs into actionable information, fundamentally transforming industrial operations.</p><p dir="ltr">The evolution of machine vision is closely linked with advancements in artificial intelligence (AI). As AI technologies have progressed, they have significantly enhanced the capabilities of machine vision systems, enabling more complex and nuanced interpretation of visual data. This integration has been pivotal in driving Industry 4.0, the ongoing automation of traditional manufacturing and industrial practices using smart technology.&nbsp;</p><p dir="ltr">Augmented with AI, machine vision is an enabler of automation and a key player in creating intelligent, adaptable, and efficient manufacturing environments. The convergence of machine vision and AI pushes the boundaries of what's possible in industrial automation, leading to unprecedented productivity and innovation.</p><h2 dir="ltr">The Core Components of Machine Vision Systems</h2><p dir="ltr">Machine vision systems are intricate setups that combine hardware and software to enable machines to 'see' and make decisions based on visual inputs. These systems play a pivotal role in various applications, including automated inspection, process control, and guiding robots, significantly contributing to industrial automation and robotics advancements.</p><h3 dir="ltr">Hardware: The Observational Components</h3><p dir="ltr">The foundational hardware components of machine vision systems include cameras and sensors, which serve as the 'eyes' of the system. Cameras equipped with image sensors capture visual data from the environment. These cameras range from simple, compact smart cameras for specific applications to more complex multi-camera systems offering greater versatility and data collection capabilities.&nbsp;</p><p dir="ltr">Sensors are crucial for determining the system's specifications, such as resolution, directly impacting the amount of data collected and the system's ability to discern environmental changes. The resolution, defined by the total number of pixels in rows and columns, affects not just image clarity but also processing speed, with monochrome cameras often facilitating faster processing than colour counterparts due to simpler data.</p><h3 dir="ltr">Software: The Analytical Brain</h3><p dir="ltr">On the software side, machine vision systems are powered by image processing algorithms and, increasingly, by deep learning and AI technologies. These software components are tasked with analysing and interpreting the captured visual data. The traditional approach to image processing involves predefined rules for analysing images, which can be rigid and limited in scope.</p><h3 dir="ltr">The Synergy of Hardware and Software</h3><p dir="ltr">The interplay between the hardware's data collection capabilities and the software's processing power defines the effectiveness of a machine vision system. Adequate lighting and lens quality are also essential, ensuring the captured images are clear and detailed enough for accurate analysis. For example, the choice between backlighting and front-lighting setups can significantly affect the system's ability to capture usable data in real-world applications.</p><h2 dir="ltr">Implementing Machine Vision in Manufacturing</h2><p dir="ltr">Implementing machine vision in manufacturing significantly enhances quality control, defect detection, and production efficiency. This technology integration facilitates a transition from manual to intelligent manufacturing, providing high detection accuracy, speed, and improved coordination.</p><p dir="ltr">Machine vision technology is pivotal in collecting information, detecting quality, positioning, automatic sorting, and intelligent monitoring within manufacturing. It addresses the challenges of poor quality, low precision, low efficiency, and high labour intensity traditionally associated with manual operations. Adopting machine vision in manufacturing accelerates production, elevates detection accuracy, and minimises the risk of accidents.</p><h3 dir="ltr">Enabling Algorithms for Object Detection, Identification, and Classification</h3><p dir="ltr">The backbone of machine vision systems in industrial settings is a suite of sophisticated algorithms that enable object detection, identification, and classification. These algorithms leverage optical tools and computer technology to collect and process data, simulating human visual functions.&nbsp;</p><p dir="ltr">With the advancement of AI, machine learning, and deep learning technologies, machine vision systems have achieved higher accuracy and broader application scopes. These technologies encourage traditional manufacturing processes to become more intelligent, requiring expertise across various fields, including optical imaging, signal processing, image processing, and deep learning.</p><h2 dir="ltr">Current Trends and Future Directions</h2><p dir="ltr">The evolution of machine vision technology is rapidly transforming the landscape of industrial automation, robotics, and beyond. At the forefront of this transformation is integrating 3D imaging and point cloud data, offering enhanced spatial analysis and enabling more complex applications. Let's explore the cutting-edge research and predictions for future advancements in this exciting field.</p><h3 dir="ltr">Integrating 3D Imaging and Point Cloud Data</h3><p dir="ltr">In recent years, significant advancements have been made in deep learning techniques for processing 3D point cloud data. This has revolutionised applications in fields such as robotics and autonomous vehicles by allowing for detailed spatial analysis of environments. Techniques exist for various tasks, including 3D object classification, tracking, pose estimation, segmentation, and point cloud completion. Transformative methodologies like Pointr and SnowflakeNet have emerged, highlighting the potential for these technologies to evolve further and impact various domains.</p><h3 dir="ltr">Predictions for Future Advancements</h3><ul><li dir="ltr"><p dir="ltr">Augmented Reality (AR) Applications: AR's immersive experience can benefit greatly from advancements in machine vision by providing more accurate and real-time interaction with the physical world. This could revolutionise medical imaging, retail, and education by offering more intuitive and interactive ways to engage with information and environments.</p></li><li dir="ltr"><p dir="ltr">Further Integration with Robotic Process Automation (RPA): Machine vision technology allows robots to perform more complex tasks more efficiently and accurately. Combining machine vision and RPA could lead to significant productivity boosts from manufacturing to logistics by automating tasks that require understanding and interpreting visual data.</p></li><li dir="ltr"><p dir="ltr">Ease of Use and Accessibility: There's a trend towards making machine vision systems more accessible and easier to use. Efforts are being made to develop "ease-of-use" and "no-code" solutions to democratise the technology, making it more accessible to non-experts.</p></li><li dir="ltr"><p dir="ltr">Growth in 3D Imaging for Vision Guided Robotics: 3D imaging is no longer emerging but becoming a mature automated imaging offering. From bin picking to product palletizing, these solutions promise to expand the use of VGR by making it more user-friendly and applicable to a broader range of use cases.</p></li><li dir="ltr"><p dir="ltr">AI and Deep Learning as Automated Inspection Tools: Deep learning has become a valuable tool for segmentation and classification in automated inspection. It enables the identification of images or features within images more intuitively, akin to human perception.</p></li></ul><h2 dir="ltr">Practical Applications of Machine Vision in Industry</h2><p dir="ltr">Machine vision technology transforms operations across various sectors, particularly in the automotive and electronics industries, by enhancing product quality and operational efficiency.</p><h3 dir="ltr">Automotive Industry</h3><p dir="ltr">Machine vision is essential in inspections and robotic guidance in the automotive sector. Companies like Ford and General Motors (GM) use machine vision to ensure the safety and efficiency of manufacturing processes. Machine vision systems are employed for various applications, including flexible automation, model verification, and quality improvement. The technology offers significant advantages such as adaptable tooling, model verification on flexible lines, and in-station process control for immediate feedback. This enables manufacturers to uphold stringent quality standards and eliminate waste, ultimately contributing to producing a quality product.</p><h3 dir="ltr">Oil and Gas Industry</h3><p dir="ltr">Machine vision is critical in inspections and robotic guidance in the oil and gas sector. Companies like Wipro are leveraging machine vision in several cutting-edge ways, including visual inspections of oil rigs, automated quality inspections, and remote monitoring of safety-critical assets. For instance, machine vision enables magnetic crawlers with cameras to inspect difficult-to-reach areas, such as great heights and remote locations within industrial plants. Robots equipped with machine vision can proactively detect internal cracks in gas pipelines, potentially saving millions of dollars by preventing failures. Moreover, these robots can grade the corrosion of pipes based on drone-captured images and videos, facilitating more preventive and cost-effective operations.</p><h3 dir="ltr">Manufacturing Industry</h3><p dir="ltr">Machine vision systems are employed for various applications, including flexible automation, model verification, and quality improvement. The technology offers significant advantages such as adaptable tooling, model verification on flexible lines, and in-station process control for immediate feedback. This enables manufacturers to uphold stringent quality standards and eliminate waste, ultimately contributing to producing a quality product.</p><h3 dir="ltr">Electronics Industry</h3><p dir="ltr">While the specifics on electronics were not directly covered in the sources, it's evident that the benefits and applications of machine vision in the automotive industry, such as inspection, quality control, and robot guidance, are also pertinent to the electronics sector. High precision and accuracy are essential in electronics manufacturing, where machine vision can identify defects, verify component placement, and ensure product integrity, much like in automotive manufacturing.</p><h3 dir="ltr">Key Benefits</h3><ul><li dir="ltr"><p dir="ltr">Increased Efficiency: Automation of inspection processes and real-time decision-making capabilities speed up production lines and reduce manual intervention.&nbsp;</p></li><li dir="ltr"><p dir="ltr">Reduced Error Rates: High-resolution cameras and sophisticated software in modern machine vision systems enable precise defect detection, minimising the risk of errors.</p></li><li dir="ltr"><p dir="ltr">Enhanced Safety: In the automotive industry, ensuring the proper assembly of over 30,000 parts per vehicle is crucial for driver safety. Machine vision facilitates the flawless fabrication of each component.</p></li><li dir="ltr"><p dir="ltr">Flexibility and Adaptability:&nbsp;Companies highlight the demand for more flexible automation as a driver for increased use of machine vision. The technology's adaptability allows easy integration into existing production lines, supporting model verification and quality improvements without needing hard-tooled custom fixtures.</p></li><li dir="ltr"><p dir="ltr">Improved Quality: The ability of machine vision systems to provide feedback for in-station process control plays a vital role in quality assurance. By enabling the detection of defects at the source, these systems help maintain high-quality standards and reduce the cost and complexity of end-of-line repairs.</p></li></ul><p dir="ltr">Machine vision technology continues to evolve, offering scalable and versatile solutions that cater to the growing demands of industrial automation.</p><h2 dir="ltr">Challenges and Considerations</h2><p dir="ltr">Adopting machine vision technologies has several challenges and considerations that organisations must navigate to leverage their full potential effectively. These challenges include high initial costs, integration complexities, and the need for specialised expertise. By addressing these factors, organisations can better position themselves to take advantage of the numerous benefits that machine vision technologies offer.</p><h3 dir="ltr">High Initial Costs</h3><p dir="ltr">Implementing machine vision technologies often requires a significant initial investment. This includes the cost of hardware such as cameras and sensors, software for image processing and analysis, and the infrastructure needed to support these technologies. While the costs of components and engineering have decreased, making the technology more accessible, the initial setup still represents a substantial financial commitment.</p><h3 dir="ltr">Integration Complexities</h3><p dir="ltr">Integration involves ensuring compatibility between new and existing systems, configuring machine vision technologies to meet specific operational needs, and optimising performance within the current workflow. This complexity is compounded by the rapid pace of technological advancement, which introduces new standards and capabilities that systems must adapt to.</p><h3 dir="ltr">Need for Specialized Expertise</h3><p dir="ltr">Organisations often need professionals skilled in both the technical aspects of machine vision systems and the specific applications within their industry. This expertise is necessary for designing effective solutions, troubleshooting issues, and updating systems to incorporate the latest advancements in the field. The challenge here is finding and retaining talent with the necessary skill set.</p><p dir="ltr">By proactively addressing these challenges, organisations can harness the power of machine vision technologies to drive innovation and competitive advantage in their operations.</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">The transformative impact of machine vision on manufacturing is undeniable. Machine vision has become a cornerstone of modern industrial automation through its ability to automate complex inspection tasks, enhance quality control, and drive efficiencies. Its application spans various sectors, providing unparalleled accuracy and speed in tasks once deemed challenging for automated systems. Machine vision systems minimise downtime, reduce waste, and ensure product quality by enabling more reliable and faster inspections, significantly improving manufacturing.</p><p dir="ltr">The journey of machine vision from a supportive technology to a pivotal component of industrial automation underscores its transformative impact on manufacturing. As we look to the future, continued innovation, coupled with strong partnerships between technology providers and manufacturers, will be key to unlocking the full potential of machine vision. Embracing these advancements will ensure that industries keep pace with modern production demands and set new standards for efficiency, quality, and innovation.</p><h2 dir="ltr">References</h2><ol><li dir="ltr"><p dir="ltr"><a href="https://www.automate.org/vision/industry-insights/trends-and-lessons-from-the-2021-machine-vision-market" target="_blank">https://www.automate.org/vision/industry-insights/trends-and-lessons-from-the-2021-machine-vision-market</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.frontiersin.org/articles/10.3389/frobt.2021.627280/full" target="_blank">https://www.frontiersin.org/articles/10.3389/frobt.2021.627280/full</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.cognex.com/what-is/deep-learning/challenges-to-machine-vision" target="_blank">https://www.cognex.com/what-is/deep-learning/challenges-to-machine-vision</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.automate.org/vision/industry-insights/machine-vision-in-the-automotive-industry" target="_blank">https://www.automate.org/vision/industry-insights/machine-vision-in-the-automotive-industry</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.zebra.com/us/en/blog/posts/2021/why-auto-manufacturers-should-take-a-second-look-at-new-machine-vision-systems.html" target="_blank">https://www.zebra.com/us/en/blog/posts/2021/why-auto-manufacturers-should-take-a-second-look-at-new-machine-vision-systems.html</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.automate.org/vision/industry-insights/machine-vision-in-the-automotive-industry" target="_blank">https://www.automate.org/vision/industry-insights/machine-vision-in-the-automotive-industry</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.vision-systems.com/factory/article/14300295/machine-vision-and-imaging-trends-in-automation-a-view-from-the-trenches-for-2024" target="_blank">https://www.vision-systems.com/factory/article/14300295/machine-vision-and-imaging-trends-in-automation-a-view-from-the-trenches-for-2024</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://news.mit.edu/2019/deep-learning-point-clouds-1021" target="_blank">https://news.mit.edu/2019/deep-learning-point-clouds-1021</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://pubs.aip.org/aip/acp/article-abstract/2788/1/110005/2903916/An-overview-of-machine-vision-based-quality?redirectedFrom=fulltext" target="_blank">https://pubs.aip.org/aip/acp/article-abstract/2788/1/110005/2903916/An-overview-of-machine-vision-based-quality?redirectedFrom=fulltext</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://aimagazine.com/articles/machine-vision-enabling-the-factories-of-the-future" target="_blank">https://aimagazine.com/articles/machine-vision-enabling-the-factories-of-the-future</a></p></li></ol>

Discover the revolutionary impact of machine vision in manufacturing. Learn how integrating AI and machine vision enhances efficiency, quality, and safety in industrial automation, and explore the challenges and future advancements in this cutting-edge technology.

Transforming Manufacturing with Machine Vision Technology

<p dir="ltr" id="isPasted">What’s the extent of impact of electric vehicle on drivetrain system? Electric Vehicle is driving significant change in drivetrain design for electric vehicles, with the use of different kinds of automatic transmissions and integrated units to optimize efficiency. Despite differences in operating principles, there are similarities. Explore the impact and challenges of drivetrain design and find how RPWORLD comes in to accelerate the design iteration.</p><h2 dir="ltr"><strong>What’s the Impact of EV on Drivetrain Design</strong></h2><p dir="ltr">Electric Vehicle is driving significant change in the way manufacturers approach drivetrain design, as compared to the development process for traditional combustion engine vehicles. This change is reflected in the use of different kinds of automatic transmissions, such as 2-stage spur gear drives, integrated stepped planetary gear drives, or continuously variable transmissions (CVT), to optimize efficiency in state-of-the-art electric vehicles, whereas previously 6-speed manual or 8-speed automatic transmissions were standard in the automotive world.</p><p dir="ltr">One notable difference is that electric motors, power electronics, and drivetrains can share a single housing, which reduces the overall number of components in the powertrain and lowers the system's weight. In battery electric vehicles (BEVs), this integrated unit may directly power a combined electric axle drive, while various transmission configurations are possible in hybrid vehicles, depending on how the manufacturer intends the electric motor and combustion engine to interact with each other.</p><h2 dir="ltr">Challenges in Component Design for Electric Vehicle Drivetrains</h2><p dir="ltr">Despite the differences in operating principles between electric vehicle drivetrains and their combustion engine counterparts, there are many similarities in the design and manufacturing processes required at the component level. Key components such as straight gears, helical gears, and housings are common to both types of drivetrains. However, specializing such components for electric vehicle drivetrains presents challenges in dealing with the higher torque and speed of rotations that can be achieved with electric motors.</p><ul><li><h3 dir="ltr">Special considerations for precision manufacturing</h3></li></ul><p dir="ltr">The precision manufacturing of transmission components like straight and helical gears or planetary gear drive systems requires tighter tolerances for electric vehicle components. The surface finish of gears also gains new importance as the noise emission of the drivetrain is critical in electric vehicles due to the silent electric motor.</p><ul><li dir="ltr"><h3>Shift in drivetrain design</h3></li></ul><p dir="ltr">Electric Vehicle is driving a significant shift in drivetrain design for state-of-the-art electric vehicles, leading to the use of different kinds of automatic transmissions and integrated units that reduce the overall number of components and weight of the system. Despite differences in operating principles, there are many similarities in the design and manufacturing processes required at the component level. Specializing components for electric vehicle drivetrains requires dealing with higher torque and speed of rotations and tighter tolerances, as well as placing greater importance on surface finish to reduce noise emission from the silent electric motor.</p><h2 dir="ltr">Customized Drivetrain Components to Meet Your Specific Needs</h2><p dir="ltr">At RPWORLD, we understand that every vehicle's drivetrain requirement is different, and that's why we offer customized drivetrain components with tight tolerance and high efficiency to meet your specific needs. Our 20-years’ experience in manufacturing allows you to turn your design into reality fast and accelerate your iteration and prototyping verification.</p><p>RPWORLD is a customized manufacturing supplier, offering CNC Machining, Injection Molding, Sheet Metal Fabrication, Surface Treatment and more.</p>

Photo by ThisisEngineering RAEng on Unsplash

Explore the impact and challenges of drivetrain design and find how RPWORLD comes in to accelerate the design iteration.

Customized Drivetrain Components: Meeting the Challenges of EV Design

<p id="isPasted">Black anodizing refers to the process of anodizing an aluminium part and then dying it black using a suitable dye. This must not be confused with black oxide coating which is unsuitable for aluminium parts. Anodized aluminium has improved wear and corrosion resistance, while black anodized parts have the additional benefits of being light absorbent as well as being able to effectively radiate heat. This article will describe what black anodizing is, how it works, as well as the various pros and cons.</p><h2 data-counter-attr="value0"><strong>What is Black Anodizing?</strong></h2><p>Black anodizing refers to the electrochemical process of blackening an aluminium part by first performing standard anodizing to create a semi-porous aluminium oxide layer. The oxide layer is then dyed black using one of three dyeing techniques: organic dyes, inorganic dye, or electrolytic dyeing using metal salts.&nbsp;</p><p>The metals that can be black anodized are aluminium, magnesium, and titanium. Aluminium, however, is the most common material used for black anodizing. It must be noted that not all grades of aluminium can be black anodized. Only aluminium series 5, 6, and 7 can be anodized.</p><h2 data-counter-attr="value1"><strong>How Does Black Anodizing Work?</strong></h2><p>Black anodizing works by first anodizing the part using the standard anodizing process with either a type II or type III anodizing process. A minimum anodized coating thickness of 25 microns or more is recommended for optimal colourfastness. Once anodized, the part will have a semi-porous surface structure. These pores are utilised to hold the black dye.&nbsp;</p><p>There are three types of dyeing techniques, as described below:</p><ol><li><strong>Organic pigments</strong>: These dyes are dissolved in warm water and then placed into the dye bath. The part is placed into the dye bath and the dye fills in the semi-porous surface of the anodic layer. Typically, black dyeing requires additional dyeing time compared to lighter colours. Organic-dyed parts are not recommended for outdoor usage.</li><li><strong>Inorganic pigments</strong>: These pigments are not soluble in water. Inorganic pigments produce coatings with excellent light fastness. For black anodizing, parts can be produced with inorganic salts of cobalt sulfide.</li><li><strong>Electrolytic dyeing</strong>: After normal anodizing, parts are placed in another electrolysis bath with a solution containing heavy metal salts. The anodic layer acts as the cathode, and a stainless steel electrode is placed in the acid electrolyte bath. The metal salts are then deposited into the bottom of the pores. Nickel, cobalt, and tin salts are used to produce different colours, a proprietary process that produces parts with exceptional colourfastness.</li></ol><p>After dyeing, the pores on the anodic layer must be sealed to prevent colour leaching. Sealing is typically done via hydration of the coating, which closes the pores off by reaction with the anodic layer. Wherever there is a pore, AI2O3H2O is formed; this is less abrasion-resistant than the normal aluminium oxide surface. Alternatively, chemical sealing can be put into effect, for example by using nickel acetate or dichromate sealing.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/LBLV1CPBRRk?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><p id="isPasted">The time required to black anodize a part depends on the desired anodic layer thickness, the dyeing method, and the post-dye sealing technique. In general, it takes five minutes to anodize 2.5 microns. So to anodize the minimum recommended black anodized thickness of 25 microns will take around an hour. The dyeing process can take up to 20 minutes. However, these time frames also depend on the cleaning and rinsing processes.</p><h2 data-counter-attr="value2"><strong>Applications of Black Anodizing</strong></h2><p>Black anodized aluminium has all the benefits of standard anodized aluminium with the additional benefits afforded by the black colouring. The black anodized aluminium is used in applications where the black coating is beneficial. Here are some applications examples:&nbsp;</p><ul><li>Satellite components that rely on the black anodic coating to&nbsp;</li><li>efficiently radiate heat back into space</li><li>Optical equipment that relies on the ability of black coatings to absorb any stray reflective light</li><li>Architectural trimmings in which the deep black colours are aesthetically pleasing while also having excellent colourfastness, and the surface finish provides improved abrasion resistance.</li></ul><p>An anodized coating can last between 10 and 20 years depending on the application, the thickness of the coating, and whether or not the relevant sealing steps were performed after anodizing. When metal salts are used for dyeing, the colour will not fade. However organic dyes will fade over time.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711444501200-Stack-of-black-anodised-aluminium-extrusion-bars.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Stack of black anodized aluminium extrusion bars</span></span></span></p><h2 data-counter-attr="value3" id="isPasted"><strong>Benefits of Black Anodizing Finish</strong></h2><p>The benefits of black anodizing include increased wear resistance and corrosion resistance. This finish ensures that anodized aluminium parts will not be prone to rust. Rust is typically used to describe the formation of a destructive flaking oxide layer on ferrous metals. When an oxide layer forms on aluminium, it adheres to the metal surface and prevents further oxidation of the base material.</p><p>However, black anodizing has a few additional specific benefits described below:</p><ul><li><strong>Heat emissivity</strong>: Aluminium components are often dyed black to increase their emissivity; applications can include heat sinks as well as satellite components.</li><li><strong>No outgassing</strong>: Black anodized parts, if properly sealed after dyeing, do not undergo outgassing when exposed to a vacuum. This lack of outgassing helps protect sensitive equipment, especially sensitive space-based equipment.&nbsp;</li><li><strong>Colour fastness</strong>: Black anodized parts, especially if dyed with inorganic or metal salts, have excellent colourfastness, which means they will typically maintain their colour when exposed to UV (ultraviolet) light.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711444547421-A-black-anodised-flashlight.jpeg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">A black anodized flashlight</span></span></span></p><h2 data-counter-attr="value4" id="isPasted"><strong>Limitations of Black Anodizing</strong></h2><p>While black anodizing stands as a robust finishing process with notable advantages, it is important to acknowledge its inherent limitations. Navigating beyond its sleek black aesthetic and corrosion-resistant properties, certain constraints shape the boundaries of its applicability.</p><ul><li><strong>Surface cracking</strong>: When exposed to thermal cycling, black anodized parts will form cracks in the anodic coating. These cracks are mainly due to the difference in thermal expansion rates of the substrate and the coating.&nbsp;</li><li><strong>Limited materials</strong>: Not all aluminium series can be black anodized. In general, the most commonly anodized aluminium series are 5, 6, and 7, with series 6 being the most commonly anodized.</li><li><strong>Colour fading</strong>: If organic dyes are used, black anodized parts will lose their colour as these dyes are unsuitable for UV light exposure.</li></ul><h2 data-counter-attr="value5"><strong>Summary</strong></h2><p>In conclusion, black anodizing emerges as a versatile and essential process in the manufacturing landscape. Its dual advantages of enhanced corrosion resistance and an appealing black finish make it a preferred choice in industries ranging from aerospace to robotics.</p><p>Xometry provides a wide range of manufacturing capabilities and other value-added services for all of your prototyping and production needs.</p>

Explore black anodising, a key finish in manufacturing, and gain insights into the detailed process from pre-treatment to sealing. Understand its practical applications in industries such as aerospace and robotics, known for its durability and corrosion resistance in components.

Everything You Need to Know About Black Anodizing

<p id="isPasted">It is easy to take for granted actual scales when zoomed in on modern high-res flat-screens, but in reality, the surfaces of PCB boards are not two-dimensional with precisely defined edges. The layers of copper, solder mask, silkscreen and non-planar surface finishes are raised and allowing for solder mask expansion and dams can reduce space between elements even further.</p><p>Allowing for sufficient component clearances is something PCB designers know all about, but many inexperienced and experienced designers still end up digging their own graves to avoid a little bit of extra rerouting.&nbsp;</p><p>As careful engineer Xiao Peng learned, the perfect layout depends not only on one’s experience but also on one’s toolbox. Various tools are freely available to provide a systematic and automated approach to detecting such issues and improving the layout overall.&nbsp;</p><p>Xiao Peng is a PCB layout engineer with over a decade of industrial experience under his belt from layout to production. But his recent experience caused him to doubt his abilities.</p><p>As per his standard workflow, Xiao Peng’s pre-production checks consist of meticulous design review covering signal integrity, functionality and performance, design for manufacture (DFM) and design for assembly (DFA). However, for this particular batch undergoing wave soldering, the incidence of cold solder joints and insufficient through-hole barrel fill defects was unusually high. Consequently, the batch failed to meet IPC Class 2 standards.</p><p>IPC Class 2 standards define strict requirements for solder joints. For through-hole joints, the barrel must have a minimum solder fill ratio of 75%, with 25% sinking allowed.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE3OTcwNzA3LVdlaXhpbiBJbWFnZV8yMDI0MDMyMTE0MTIyNi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 478px;" class="fr-fic fr-dib"></p><p id="isPasted">Xiao Peng suspected that the nearby surface mount resistor could be the culprit and upon inspection, found that the distance between the pads was only 0.2mm. This spacing was more than enough for solder mask dams to form and prevent solder bridges, however, the effect on the through-hole joint was not clear. After consulting the assembly technicians, it was found that the board was suffering from shadowing effects.&nbsp;</p><p>PCB shadowing is the phenomenon whereby taller parts <em>cast </em><em>shadows</em> on other lower neighboring parts which can have consequences on soldering, thermal management and signal integrity. For wave soldering, the nearby components can physically block molten solder from reaching certain areas of the PCB, in this case, the through-hole barrels.&nbsp;</p><p>To remedy the issue, the technicians recommended a clearance of 3mm to mitigate the effects of shadowing, and even more for taller components.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE4MDY4OTU1LUhRREZNIENvbXBvbmVudCBzcGFjaW5nLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">With wave soldering, components can affect neighboring solder joints even with the presence of a solder mask dam.</span></span></span></p><p id="isPasted">At the same time, HQDFM, the PCB design analysis software from HQ Electronics was recommended to Xiao Peng, which claims to be able to detect PCB shadowing issues and many other DFM issues. HQDFM indeed highlighted the spacing issue among other errors. After following the suggestions, the new design effectively eliminated cold solder and barrel filling defects.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE4MTIxNjM1LUhRREZNIENoaW5lc2UgVmVyc2lvbiBTY3JlZW5zaG90IG9mIGNvbXBvbmVudCBzcGFjaW5nIHZpb2xhdGlvbi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Tight component spacing detected in HQDFM software (Chinese Version)</span></span></span></p><p id="isPasted">As Xiao Peng discovered, even the most experienced engineers could do with extra assistance here and then. Unlike in China, where engineers can freely contact their manufacturers and expertise is common, overseas designers outsourcing overseas will have time differences, language barriers and limited resources to contend with.</p><blockquote><p id="isPasted">“I am deeply aware of the close relationship between quality and design. A good design can not only improve product performance and quality but also reduce production costs and difficulty. Inbuilt DRCs are one way of detecting issues, but they are often limited and are based on black-and-white values you have to feed in yourself. HQDFM on the other hand is powerful, informative and explicit in its goals to reduce manufacturing issues and improve reliability even if you don’t use HQ for production.&nbsp;</p></blockquote><blockquote><p>I especially liked the fact that HQDFM is free yet powerful. HQDFM looks at everything from bare board spacings to component heights and the impact on wave soldering and gives specific recommendations and figures. There aren’t many tools outside of EDA programs that can be considered essential in the designer’s toolbox but HQDFM is one of them and I will be using it extensively from now on.”&nbsp;<em>- Xiao Peng</em></p></blockquote><h2><strong>Common spacing pitfalls and guidelines</strong></h2><p>Knowing what to look out for and the potential impact is the first step for PCB designers to improve their DFM evaluation skills which can then be incorporated at the earliest stage of design. The second is the ability to quickly detect issues, which can be accomplished with tools like HQDFM. HQDFM helps to achieve both of these goals through education and detection. Some of the component spacing issues covered by HQDFM include:</p><h3>Through-hole to Surface Mount Pad Spacing</h3><p>In Xiao Peng’s case, the close proximity of the through-hole and surface mount pads resulted in the through-hole being inadequately filled during wave soldering. For reflow soldering, insufficient spacing between through-holes, opened vias, test points, metallic mounting holes, and surface mount pads can result in solder being pulled away from the surface mount pad, resulting in poor wetting and making solder defects such as tombstones more likely.&nbsp;<br id="isPasted"><br>If spacing is limited, consider putting vias on pads, but these should be plugged and capped to prevent solder from leaking through the via. Be aware that via plugging and capping require specialist machinery and come at an additional cost.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 428px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE4NDk4MTE0LUhRREZNIHZpYS1pbi1wYWQgc3BhY2luZy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 426px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Via on SMD pad illustration - HQDFM</span></span></span></p><h3 id="isPasted">Solder Mask Dams</h3><p>Any two objects that are so close together that they do not leave room for solder mask dams are at risk of solder bridges. Solder mask, or also accurately named solder&nbsp;<em id="isPasted">resist</em>, is your best friend in both SMT and wave soldering as it helps to prevent solder from building up where it is not wanted. For fine-pitch components, especially chips with underside pads, dams can be a lifesaver. For a single reflow, you can probably get away with suitably sized stencil openings, but when it comes to rework and manual soldering, the lack of dams will require greater skill and patienceharder.<br><br><strong>Pro-tip</strong>: most PCB manufacturers have their own solder mask expansion values and will not necessarily follow the lengths in your Gerber files. So a more accurate way of determining if the spacing is large enough for dams to form is to follow pad-to-pad (copper to copper) spacing from manufacturers. Also, remember that values typically vary according to solder mask color. If color is not important, sticking with regular green will produce the best results. If you need to push the limits further, use ENIG plating for a planar pad surface.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 402px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE4NTM2NTYyLUhRREZNIHNvbGRlciBtYXNrIGRhbS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 400px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">SMD Pad Spacing illustration - HQDFM</span></span></span></p><h3 id="isPasted">Solder Mask Opening to Trace Spacing</h3><p>Traces positioned too close to pads may inadvertently be exposed as a result of solder mask expansion and be at risk of shorting. Ensure traces are sufficiently covered to protect the trace and ensure it remains sealed by the solder mask film.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 412px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE4NjIyNDk4LUhRREZNIFNvbGRlciBtYXNrLXRvLXRyYWNlIHNwYWNpbmcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 410px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Solder mask-to-trace spacing illustration - HQDFM</span></span></span></p><h3 id="isPasted">Through-hole Spacing</h3><p id="isPasted">Whether soldered manually or automated, through-hole leads need to be <em>reachable</em>, be it by a soldering iron, wave, lead clippers, etc. Therefore the area around them must be void of obstacles such as tall components and other leads. Insufficient adjacent and overhead clearance could result in tricky soldering positions and accidental melting of other components or oneself.&nbsp;</p><p>Lower on the ground, leads of adjacent through-hole parts should be far enough to prevent solder bridges. For through-hole parts, solder mask dams are a must, which can be achieved by reducing the diameter of pads or shaving material off the edges.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 401px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDE4NjU2MTE0LUhRREZNIFNwYWNpbmctaGVpZ2h0IHJhdGlvLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 399px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Spacing/height ratio - HQDFM</span></span></span></p><h3 id="isPasted">Wave Soldering Considerations</h3><p>Wave soldering’s main advantage is the ability to solder through-hole parts in volume but comes at a cost. Layout engineers have a whole host of extra restrictions to compete with, limiting placement options and possibly ruling out higher-density designs. In addition to leaving extra space between parts, engineers have to constantly consider the direction of the incoming wave, shadowing effects and the use of glue or fixtures for mixed assembly.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzExMDIxNTkxMzU1LVdhdmUgc29sZGVyaW5nIHBhbGxldCBhbmQgYm9hcmQgd2l0aCByZWQgZ2x1ZSBkb3RzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 768px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false">Wave soldering fixture with gaps for through-hole leads and mixed assembly board with red glue dots</span></span></span></p><p id="isPasted">As we have explored, the consequences of something as simple as component spacing can have grave consequences, but as the DFM mantra goes, it’s better to be safe than sorry. Experienced layout engineers and beginners should make it part of their workflow to pay special attention to spacings and use tools such as HQDFM to accelerate mundane tasks and act as a safety net.</p><p>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.</p><p>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="noopener noreferrer">HQDFM</a> desktop suite from HQ Electronics (NextPCB).</p><h2>References</h2><ol><li><a href="https://www.nextpcb.com/blog/consequences-of-insufficient-spacing-between-components-for-surface-mount-assembly" target="_blank" id="isPasted">Consequences of insufficient spacing between components for surface mount assembly (nextpcb.com)</a></li><li><a href="https://www.nextpcb.com/blog/what-is-dfa-in-design-for-manufacturing-and-assembly" target="_blank" id="isPasted">What is DFA in Design for Manufacturing and Assembly? (nextpcb.com)</a></li></ol>

Adequate component spacing is typically not high on the PCB designer's list of priorities, but oversights can be frustrating and could demand substantial re-work. Here we look at an example, give general guidelines and look at how tools can be used to educate designers and save time.

Consequences of Insufficient Component Spacing in PCB Design: A Case Study

<p id="isPasted">Lignin, a complex organic polymer, is one of the main components of wood, providing structural support and rigidity to make trees strong enough to withstand the elements. When transforming wood into paper, lignin is a key ingredient that must be removed and often becomes waste.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1710979930198-240208_naunheim_washu_mckelvey_labs_007-760x507.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Marcus Foston (left) and collaborators are exploring how to use lignin, a common waste product of paper pulping, as a source of renewable alteratives to petroleum-derived chemicals. (Photo: Jerry Naunheim)</span></span></span></p><p>Marcus Foston, associate professor of energy, environmental &amp; chemical engineering in the McKelvey School of Engineering at Washington University in St. Louis, is exploring how to add value to lignin by breaking it down into small molecules that are structurally similar to oxygenated hydrocarbons. These renewable chemicals are key components in many industrial processes and products, but they are traditionally sourced from non-renewable petroleum.</p><p>Foston’s study of lignin disassembly, done in collaboration with Sai Venkatesh Pingali, a neutron scattering scientist at Oak Ridge National Laboratory (ONRL), was published Jan. 17 in <em>Sustainable Chemistry &amp; Engineering</em>.</p><p>“Lignin’s structure actually looks a lot like what we get from petroleum,” said Foston, who is also the director of WashU’s Synthetic Biology Manufacturing of Advanced Materials Research Center (SMARC). “In current manufacturing processes, we spend time making petroleum look like the elements of lignin. Instead, I’m using a catalyst to break lignin down more easily and in such a way that it produces specific chemicals. Once we can produce chemical from lignin in a form we want, then we can make more efficient use of lignin, which is an abundant byproduct of pulping wood into paper.”</p><p>With collaborators at ORNL, Foston used neutron scattering to study how lignin interacts with solvents and catalysts during its disassembly under reaction conditions, including high temperature and pressure. ORNL’s advanced facilities allowed researchers to observe the reaction process in real time to improve their catalyst and further streamline reaction systems for lignin depolymerization. This direct, molecular-level view is critical, Foston said, to figure out how the catalyst and lignin behave in solution and to ensure the lignin doesn’t recondense into a polymer with bonds scientists can’t easily break.</p><p>“In this study, we’re specifically thinking about how we can take the large amount of lignin that gets produced during biofuel or paper production and use it to make renewable chemicals that replace some of the chemicals we currently get from petroleum,” Foston said. “More broadly, the same depolymerization principles we’re exploring with lignin could be used in other applications. For example, the same lessons from this study apply to plastic waste scenarios, where one approach is to deconstruct plastic waste into small molecules that could be used to make plastic or other useful products.”</p><p>“Ultimately, we want to take a bunch of chemicals that are coming from petroleum and figure out how we can make those renewably,” Foston added. “Everything we’re learning about lignin will apply to other spaces as well.”</p><hr><p>Zhang J, Yang Z, Ponukumati A, Senanayake M, Pingali SV, and Foston M. Structural evolution of lignin using in situ small-angle neutron scattering during catalytic disassembly. ACS Sustainable Chemistry &amp; Engineering. Jan. 17, 2024. DOI: <a href="https://pubs.acs.org/doi/10.1021/acssuschemeng.3c06368?ref=PDF" target="_blank">https://pubs.acs.org/doi/10.1021/acssuschemeng.3c06368?ref=PDF</a>&nbsp;</p>

Marcus Foston takes a detailed look at lignin disassembly on path to replace petroleum with renewables

Transforming wood waste for sustainable manufacturing

<p dir="ltr" id="isPasted">The electronics industry has some incredibly complex manufacturing practices and supply chains. Electronic technology evolves at a rapid pace, and products often contain dozens of components sourced from all over the world. Take the Apple iPhone 15, for example. The pocket-size device has a frame made by Chinese company Foxconn, a display made by Korean tech giant Samsung, and communications chips from U.S. companies Qualcomm and Broadcom. That’s a lot of technology and a lot of logistics.</p><p dir="ltr">But a complex supply chain is just the tip of the iceberg. Electronics manufacturers are faced with many diverse challenges such as expanding into new markets, ensuring quality products while dealing with increasing part complexity, reacting to supply chain volatility and resiliency, and dealing with rising concerns over the carbon footprint of electronics throughout their life cycle. Safety issues and smaller forms add further challenges.</p><p dir="ltr">Current trends in electronics address some of these issues but exacerbate others. Developments in material science are resulting in advanced electronics materials that are lighter and more energy-efficient, helping reduce the carbon footprint of electronic products while heightening their performance. 2024 may even see a rise in the use of biodegradable electronics. Elsewhere, <a href="https://xometry.eu/en/additive-manufacturing-in-electronics/" target="_blank">electronics 3D printing</a> continues to show promise in terms of agile manufacturing that eases pressure on global supply chains by localising production, as well as specific applications like 3D printed flexible PCBs. Yet these new developments bring added technological complexity and create new challenges.</p><p dir="ltr">So where does integration of artificial intelligence (AI) come into play? AI is expected to be a major electronics industry trend in 2024 — in terms of production, supply chains, and features of products themselves. As the technology continues to evolve at a rapid pace, engineers and product designers have the opportunity to harness AI for faster and more effective ideation, rapid prototyping, and shorter time-to-market, while suppliers and OEMs can deploy AI for tasks like predictive maintenance and defect detection. AI can also be deployed in procurement processes for smart supply chain management, using big data to make better forecasting and buying decisions. Finally, consumers are beginning to demand improved AI features in products. For example, the next iPhone is expected to provide a revamp of the AI capabilities of its “Siri” digital assistant.</p><p dir="ltr">This article discusses how AI is accelerating advancements in electronics manufacturing for vendors, suppliers, distributors, and beyond. It focuses on two key areas: expedited product development and smart procurement for improved part sourcing.</p><h2 dir="ltr">Accelerating Product Design and Development</h2><p dir="ltr" id="isPasted">One of the most exciting potential uses of artificial intelligence in the electronics industry is the acceleration of product design and development. Engineers and product designers can use AI tools to expedite idea generation and iteration, visualize and develop those ideas, automatically generate Design for Manufacturability (DfM) feedback, initiate and oversee rapid prototyping, and ultimately reduce the time-to-market for cutting-edge products.</p><p dir="ltr">AI can be implemented at the earliest stages of product development. For example, during market research, companies can use AI tools like Appen and Speak to turn data into consumer insights, helping them identify market opportunities. Some of the biggest limitations on this kind of AI use is limited or noisy data, but the electronics industry — particularly consumer electronics — can potentially provide vast datasets due to the large number of end-users.&nbsp;</p><p dir="ltr">Even greater opportunities arise during the ideation stage. Generative AI tools, including large language model (LLM) chatbots like ChatGPT and text-to-image systems like Midjourney, can assist product designers with concepts and early designs. For example, users could submit a prompt such as “five new plug-and-play USB devices targeted at senior citizens” to an LLM chatbot. Ideas can then be developed organically or with further dialogue with the chatbot.</p><p dir="ltr">Text-to-image generation tools provide opportunities for ideation, particularly in areas of electronics where innovative or unusual design can be a major selling point. While a tool like Midjourney may be unlikely to stumble upon an iconic new design like the Sony Walkman or iPod scroll wheel, it could be prompted to ideate new designs for a product such as a pair of headphones. Generative AI tools are helpful for product designers, as they encourage outside-the-box thinking and challenge preconceptions that humans may have trouble overcoming without assistance.</p><p dir="ltr">Generative design tools within established CAD applications like Solidworks Autodesk Fusion 360 and Siemens NX are another way to automate part design and allow engineers to define specific parameters and manufacturing requirements that would not be possible with simple text-to-image generation. This use of AI allows for the solving of specific engineering challenges — reducing the mass of a digital camera body by a set percentage, for example.</p><p dir="ltr">Further along the product development cycle, machine learning is steadily being incorporated into design for manufacturability (DfM) analysis. DfM allows engineers to validate the manufacturability of designs before prototyping, and is typically based on manually written rules (machine envelopes, material behavior, etc.). However, AI is opening up opportunities for more efficient and automated DfM analysis. For instance, researchers have successfully used supervised machine learning during semiconductor fabrication to more accurately identify errors.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 769px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwNzgzMDMwNjk1LXNodXR0ZXJzdG9ja18xMDU2ODAyNzYzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Generative design tools can enable the design the efficient design of complex systems.&nbsp;</span></span></span></p><h2 dir="ltr">Smart Procurement for Supply Chain Management</h2><p dir="ltr" id="isPasted">One of the most promising applications of artificial intelligence in the electronics industry is smart procurement: using AI to automate and streamline procurement processes and tackle supply chain challenges using big data. As discussed in the introduction to this article, electronics supply chains can be complex and volatile — a fact made evident by the industry-damaging global chip shortage of 2020–2023 — and buyers need all the tools at their disposal to deal with such challenges.</p><p dir="ltr">As discussed in the Xometry white paper <a href="https://www.xometry.com/resources/ebooks/ultimate-guide-use-of-ai-for-supply-chain-optimization/" target="_blank">The Ultimate Guide to the Use of Artificial Intelligence for Supply Chain Optimization</a>, smart procurement can be defined as the use of “advanced analytics, visualization, robotic process automation (RPA), big data, and artificial intelligence” within the procurement department in order to improve performance. The scope of AI usage can include machine learning, natural language processing, and other systems.</p><p dir="ltr">So what can AI achieve in electronics procurement? Ultimately, nobody is proposing that all part sourcing be left to computers. Rather, AI can be used to perform specific tasks, analyzing massive datasets to reduce risk, streamlining processes, and providing clearer information that leads to faster and more cost-efficient procurement. Would AI have been able to predict the pandemic-related chip shortage? Perhaps not, but datasets can include a very broad range of data points to help identify both risks and revenue opportunities such as new markets and suppliers.</p><p dir="ltr">Specific examples of AI usage in procurement include the use of machine learning algorithms for processes like vendor matching — connecting supplier data to a vendor hierarchy — and cloud-powered <a href="https://xometry.uk/" target="_blank" rel="noopener noreferrer">instant quotations</a> based on technical drawings that significantly shorten the pricing process. While speeding up such tasks may not seem like a radical application of AI, it is precisely the kind of area of supply chain management that can benefit from additional computing power, leaving humans to focus on high-level decision making. But AI algorithms deployed in such a way can have radical results — helping detect anomalies that could be missed using traditional methods, potentially helping to detect instances of fraud, for example.</p><p dir="ltr">While electronics procurement departments may be hesitant to overhaul their systems in favor of AI-driven smart procurement, change is certainly on the horizon. According to a <a href="https://www2.deloitte.com/us/en/insights/topics/operations/chief-procurement-officer-cpo-survey.html" target="_blank">Deloitte survey</a> of chief procurement officers, high-performing officers are “18x more likely to have fully deployed AI/cognitive capabilities” in their workflow.</p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Artificial intelligence is changing the electronics industry in many ways. As a consumer, expect to see greater advancements in AI-powered products like IoT devices, smart home components, and smartphone apps. However, some of the most impactful changes will be taking place behind the scenes in the form of AI-assisted product development and buying strategies, allowing for even faster emergence of new and exciting technologies.</p>

Artificial intelligence (AI) is providing an opportunity for the electronics industry to accelerate design and development and speed up part sourcing.

How AI is Accelerating Advancements in Electronics Manufacturing

<h2 id="isPasted">What Is a Smart Factory?</h2><p>A smart factory is a factory that achieves operational process improvements, higher quality, and lower costs based on digital data by connecting processes from design to development, manufacturing, and maintenance in a network. In the manufacturing industry, it refers to automating various processes in a factory to realize product quality and productivity improvements, a reduction in manufacturing costs, a shortening of the commercialization, mass production and delivery periods, and other areas of improvement. In other words, a smart factory is a factory working on digital transformation (DX) that aims to transform the entire business process from design to manufacturing, maintenance, and logistics in addition to improving productivity by automating factory equipment.</p><p>We introduce here the results of a questionnaire survey* we conducted with people involved in promoting the conversion of regular factories into smart factories in the manufacturing industry in Japan.</p><p>*About the Questionnaire Survey<br>Organization conducting the survey: Murata Manufacturing Co., Ltd.<br>Survey targets: 11,084 workers in the manufacturing industry in Japan (screening survey) and 500 people working in the manufacturing industry who are involved in converting regular factories into smart factories in their companies (main survey)<br>Survey method: Internet survey<br>Survey period: Three days from January 25 (Wed.) to 27 (Fri.), 2023<br>*Total figures may not match due to rounding.</p><h3>State of Progress in Converting Regular Factories into Smart Factories</h3><p>We learned that over 38% of factories are in the process of converting into smart factories or considering converting into a smart factory in the questionnaire we conducted this time (Fig. 1). We can see a trend for even more companies to convert their regular factories into smart factories in the future.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5NTg1NzUzLWltZzAwMDFfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 1: Situation concerning the conversion of regular factories into smart factories</span></span></span></p><p>Moreover, the most common reason for converting regular factories into smart factories is to improve productivity. The next most common reason is to reduce costs (Fig. 2).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5NjU1OTgxLWltZzAwMDJfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 2: Reasons for converting regular factories into smart factories</span></span></span></p><h3 id="isPasted">Main Factors Behind Inability to Promote the Conversion of Regular Factories into Smart Factories</h3><p>On the other hand, the following are given as the main factors behind the inability to promote conversion of regular factories into smart factories: following on from the understanding of top management, the establishment of specialist teams, the acquisition and training of specialist human resources, cooperation with external partners and other human resources and know-how shortage issues (Fig. 3).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5Njg1NDc4LWltZzAwMDNfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 3: Main factors behind inability to promote the conversion of regular factories into smart factories</span></span></span></p><p>In addition, we learned that even factories working to convert into smart factories are suffering setbacks in terms of data analysis and prediction and data collection and accumulation (Fig. 4).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5NzA2MzM1LWltZzAwMDRfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 4: Steps where setbacks are being suffered in the conversion of regular factories into smart factories</span></span></span></p><p id="isPasted">It is thought that how to overcome these steps will be the key to promoting the conversion of regular factories into smart factories. We will consider these issues using the example of short stoppages, which are one type of equipment loss that are a major factor adversely affecting the productivity of smart factories, from here onward.</p><h2>Short Stoppages: Blind Spot in the Conversion of Regular Factories into Smart Factories</h2><p>Equipment loss arising in each process is a major issue that must be resolved for the conversion of regular factories into smart factories that greatly contributes to improving productivity in factories.</p><p>The types of equipment loss include stoppage losses resulting from failures, setup changes, jig replacements and startup, defective product losses, speed reduction losses, and short stoppage losses. In particular, short stoppages are called idling losses and are losses included in the time when, in principle, the equipment could be demonstrating its performance (net operating time) (Fig. 5).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5NzI4Nzg2LWltZzAwMDVfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 5: Equipment loss times and types</span></span></span></p><h3 id="isPasted">Short Stoppages: Unseen Equipment Loss Lurking in Manufacturing Lines</h3><p>Setup change, jig replacement, and startup losses are planned. In addition, as it takes a long time to recover from failure losses, we keep a record showing the operational status. However, short stoppages occur unexpectedly on the line and workers at the worksite recover from it and resume work in a short time. The shortness of this time until recovery means that a record of these short stoppages is not kept in most cases. Furthermore, even if attempts are made to keep records of short stoppages, there is currently no time to do so because a speedy recovery is sought.</p><p>If we do not record the time of a short stoppage, the operating rate is calculated without including that time. Accordingly, a difference arises with the actual operating rate. Furthermore, the cause of long equipment stoppages such as failure losses may be lurking in short stoppages. It is possible to see cases in which problems in the operating rate due to such short stoppages are overlooked even in factories that have been converted into smart factories.</p><h3>Does Converting Regular Factories into Smart Factories Produce Short Stoppages?</h3><p>Many industrial robots and automatic machines are installed in the manufacturing lines of smart factories. These comprise precision components. It is not possible to avoid a decline in their precision due to the usage burden and degradation over time. If the precision of these components declines, malfunctions may occur. For example, an industrial robot may fail to grip work or a deviation may arise in the trajectory of a robot arm and it may not be possible to move the part equivalent to the fingers of the robot called the end effector to the correct position. Such malfunctions may cause short stoppages.</p><h2>Reasons Why Short Stoppages Are Not Eliminated and Countermeasures</h2><p>Why are short stoppages, which cause various problems in factories in addition to obstructing improvement in productivity, not eliminated? The reason is that in the midst of frequent short stoppages on a daily basis, there is an atmosphere in which manufacturing worksites do not take the situation seriously.</p><p>The most effective way to prevent such a situation is to calculate and visualize the losses from short stoppages. However, we would need to enter the process, cause, and equipment stoppage time on a worksheet each time such a short stoppage occurs and then aggregate that data to calculate it, which would interfere with production. Moreover, it is difficult to identify the cause of short stoppages by collecting data once a week or once a month.</p><p>We obtained results from the questionnaire showing that standardization and visualization using digital technologies and optimization of equipment maintenance with sensors and AI are effective ways of resolving such problems in factories which have been successful in promoting their conversion into smart factories (Fig. 6).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5NzUwNzg4LWltZzAwMDZfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 6: Initiatives in promoting the conversion of regular factories into smart factories</span></span></span></p><h2 id="isPasted">Clues to Reducing Short Stoppages</h2><p>We need data on the operating status of equipment to reduce short stoppages. For that, we must be able to accurately and quickly record the equipment stoppage times due to the frequent short stoppages and their causes. We introduce here the m-FLIP solution tool that helps to resolve such issues.</p><h3>What Is m-FLIP?</h3><p>m-FLIP is a solution that combines Murata Manufacturing’s worksite improvement know-how and IT technologies to maximize the operating rate of manufacturing devices. This solution makes it possible to quantify factors such as operating rate, actual working rate, and equipment stoppages to increase production and achieve optimal maintenance. This greatly contributes to the visualization of problems that are difficult to reveal such as short stoppages.</p><p>Furthermore, m-FLIP calculates and outputs the operating rate and actual working rate based on data obtained from PLCs made by multiple manufacturers. In addition, it collects workers’ work information through touch-panel PCs. As a result, we can clarify the duration and number of equipment stoppages, which was previously done by guesswork. We are also able to clearly see the main causes of equipment stoppages and the issues that must be resolved (Fig. 7).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5Nzc2NTU0LWltZzAwMDdfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 7: Services provided by m-FLIP</span></span></span></p><h3 id="isPasted">m-FLIP Utilization Examples</h3><p>m-FLIP can support the resolution of various issues at manufacturing worksites. We introduce here some typical utilization examples.</p><h4>Equipment maintenance:</h4><p>With checks by humans, it is only possible to monitor the operating status temporarily. However, m-FLIP can continuously monitor the operating status of equipment. It is possible to continuously collect data over several months or several years. This allows us to grasp the aging and changes over time of equipment. As a result, it enables maintenance at the optimal timing while minimizing the impact on the operating rate to the greatest possible extent.</p><h4>Quality control:</h4><p>For example, it is possible to monitor static electricity generation status based on data from temperature sensors and humidity sensors around the equipment and to output an alert when the set threshold is exceeded. We can utilize this in quality control such as to prevent the outflow of defective products. Moreover, we can also collect data including information on vibrations, current, and voltage. We can then integrate the data we have obtained from multiple sensors and output it as a single piece of information.</p><h4>Work procedure review, equipment improvement, and personnel allocation optimization:</h4><p>We can grasp the movements of workers and the operating status of equipment as quantified information. Therefore, we can also utilize it to consider work procedure reviews, equipment improvements, and personnel allocation optimization.</p><h4>Preparation of reports:</h4><p>m-FLIP comes with a function to prepare reports that can be used for reporting (Fig. 8). You can display information in charts and tables. It is also possible to input and save comments. You can share the reports you have prepared.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5ODAwNTEwLWltZzAwMDguanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 8: Monthly report screen</span></span></span></p><h4 id="isPasted">After-sales support by professionals:</h4><p>After introducing m-FLIP, we can identify issues from the data we have collected and receive suggestions for improvements and other advice from professionals familiar with production technologies, factory technologies, and other technologies.</p><h2>m-FLIP Introduction Case Study (Example of Ogaki Murata Manufacturing)</h2><p>We now introduce a case study from Ogaki Murata Manufacturing in which they resolved frequently occurring problems including short stoppages due to tray replacement in the product-washing process and short stoppages due to component adhesion errors with the m-FLIP operating rate improvement solution tool.</p><h3>Pursuit of the Causes</h3><p>We intuitively knew that short stoppages were occurring in the tray/rack refilling machine at the manufacturing worksite. However, we were not able to quantify the stoppage time or the number of stops. Accordingly, we collected data on the tray/rack refilling machine and the component adhesion device with m-FLIP. We uncovered the following problems as a result.<br>・Non-operation due to waiting for tray replacement: 12%<br>・Non-operation due to adhesion errors: 8%</p><h3>Improvement 1: Reduction in the Tray Replacement Time</h3><p>We now display on ANDON the number of trays remaining until the completion of the tray replacement (Fig. 9). We display in ANDON the timing of the tray replacement before the work of refilling the product into the tray is complete. This has meant we have been able to greatly reduce the time spent waiting for tray replacement.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5ODIxMDM5LWltZzAwMDkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 9: Countdown ANDON that predicts the equipment work completion</span></span></span></p><h3 id="isPasted">Improvement 2: Resolution of Short Stoppages</h3><p>We analyzed in detail the contents of the short stoppages. As a result, we ascertained that 80% or more of the short stoppages were component adhesion errors (Fig. 10 and Fig. 11).</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5ODQyMjMyLWltZzAwMTBfZW4ucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 10: Breakdown of the equipment operating rate and non-operating rate items</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwMTI5ODU2NjE4LWltZzAwMTBhLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Fig. 11: Operating status Gantt chart</span></span></span></p><p id="isPasted">We found that the cause of the component adhesion errors was changes in the clearance between the product adhesion nozzle and product due to changes over time in the washing rack jig. As a countermeasure, we shortened the gap between the adhesion nozzle and the product. This allowed us to significantly reduce short stoppages due to adhesion errors.</p><p>In this way, it is first necessary to digitize the operating status of equipment and the behavior of workers to improve short stoppages. We can pursue the causes of short stoppages by analyzing and parsing the data we collect.</p><h2>Summary</h2><p>This questionnaire revealed issues in the conversion of regular factories into smart factories and challenges in promoting that in numerical data. We can see that quantifying and visualizing the various losses lurking in production lines is essential for improving productivity from these results. We focused on the theme of short stoppages this time. However, quantified data is also indispensable to resolve other issues in the conversion of regular factories into smart factories. The questionnaire results show that this requires high density and quality of the data to be collected as well as analytical skills.</p><hr id="isPasted"><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711016095493-1711016095493.png" class="fr-fic fr-dii"></p><p>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.</p><p><a href="https://www.murata.com/en-eu/contactform?&Detail=Wevolver%20request" target="_blank" rel="nofollow" class="button-main-action">GET IN TOUCH</a></p>

A smart factory is a factory that achieves operational process improvements, higher quality, and lower costs based on digital data by connecting processes from design to development, manufacturing, and maintenance in a network.

Pitfalls in the Conversion of Regular Factories into Smart Factories Seen in Data

<h2 id="isPasted"><strong>Insights into the Inspection Challenges Arising during Sheet Metal Manufacturing.</strong></h2><p>Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry. No doubt, a combination of advanced technology and skilled labor must be involved to ensure that the sheet metal components are cut and shaped to precise dimensions. This includes checking for correct length, width, surface profile, and overall shape. Quality inspection is vital because automotive sheet metal must withstand stress and fatigue over the vehicle’s lifetime.</p><p>Apart from ensuring safety, quality inspection also ensures that the visual standards of consumers are met. This is achieved by guaranteeing that parts are assembled with the best possible flush (height on either side of a gap) and the smallest gap (width of a strip between two car components, e.g. door and chassis).</p><p>This blog post addresses the inspection challenges involved in sheet metal manufacturing. If you are looking to enhance the quality of your sheet metal parts, balance the thoroughness of inspections with cost and time efficiency, and gain some tips that could give you an edge over your competitors, this article might pique your interest.</p><h2><strong>The Most Popular Manufacturing Techniques for Sheet Metal</strong></h2><p>Stamping and laser cutting are among the most commonly used methods for manufacturing sheet metal components in the automotive industry. Both techniques require some level of dimensional inspection, ensuring that parts meet specified dimensions and tolerances. However, the extent and nature of the inspection vary depending on the process used.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817909876-Industrial-press-for-sheet-metal-stamping-and-CNC-laser-machine-cutting-sheet-metal-1536x507.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CNC laser machine cutting sheet metal with light spark. Technology plasma industrial, Blue steel color.</span></span></span></p><h3 id="isPasted"><strong>Stamping</strong></h3><p>Stamping involves using a stamping press to transform flat sheet metal (in either blank or coil form) into a net shape. This method is used to manufacture high-volume parts like frames, hoods, doors, and panels. Dimensional inspection is crucial in this process due to the high volume and precision required for these automotive parts. Inspections typically focus on checking the dimensions of features like holes, flanges, and bends, as well as overall part geometry.</p><h3><strong>Laser Cutting</strong></h3><p>Laser cutting, on the other hand, is used for cutting precise shapes in metal. It is typically used to produce intricate components or those that require a high degree of accuracy. Precision is key in laser cutting, so inspection typically focuses on the accuracy of cut dimensions, edge quality, and the position of features like holes or cutouts.</p><p>In each of these techniques, various tools and instruments can be used for dimensional inspection, such as traditional calipers and micrometers, coordinate measuring machines (CMMs), or laser scanning and 3D metrology tools. The choice of measuring equipment depends on the complexity of the parts, the precision required, and the production volume.</p><p>Laser 3D scanning is particularly advantageous for inspecting parts with complex shapes and detailed features or when high precision is required. Its ability to quickly capture a part’s entire geometry in high detail makes it a valuable tool, particularly for sheet metal manufacturing.</p><h2><strong>What to Inspect on a Sheet Metal Part</strong></h2><p>On sheet metal, certain features and dimensions are particularly critical to inspect due to their importance in the structural integrity and functionality of the part. Moreover, some bends or curved areas are often challenging to form and are prone to issues like spring back or deformation. Hence, manufacturers must control the quality of their parts, particularly the overall shape and edges.</p><h2><strong>Keys Points for Controlling the Overall Shape</strong></h2><p>Objective: Detecting any warping or distortion that might have occurred during manufacturing.</p><p>While common, regular shape control involves a flatness tolerance, the inspection of complex 3D geometries involves a profile of a surface (or surface profile) tolerance.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817936809-GDT-in-VXinspect_Sheet-Metal-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Mockup image of a businesswoman using laptop with blank white desktop screen with coffee cup on wooden table in cafe</span></span></span></p><h3 id="isPasted"><strong>Flatness</strong></h3><p>Symbolized by a parallelogram in GD&amp;T, a flatness tolerance specifies a tolerance zone defined by two parallel planes within which the surface or derived median plane must lie.</p><h3><strong>Profile of a surface</strong></h3><p>Represented by a half-circle in GD&amp;T, the tolerance zone established by the profile of a surface tolerance is 3D (a volume), extending along the length and width (or circumference) of the considered features.</p><p>The profile of a surface tolerance is similar to the flatness tolerance. However, it uses the geometry of the part to create a tolerance envelope that conforms to the shape of the part, rather than a flat plane. Tolerances for sheet metal parts can be applied to the entire part or specific areas. Local tolerances are indicated on the 2D drawing and are necessary for tighter assemblies in specific locations.</p><p>Moreover, tolerances (both flatness and profile of a surface) can be free in space, orientation, and position (no datum) or constrained to a specific alignment. This will affect the results, as a fully constrained profile of a surface tolerance will create an envelope that perfectly follows the geometry of the part, without any allowance for movement in space to fit all the points inside the envelope.</p><h2><strong>Key Points to Inspecting Edges and Corners</strong></h2><p>Objective: Detecting deformities and irregularities that might have appeared during the cutting and shaping processes.</p><p>On common sheet metal parts, two types of edges are mostly present: sharp edges and hemmed edges.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817960526-HandySCAN3D_Sheet-Metal-Car-Part-Inspection-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted"><strong>Sharp Edges</strong></h3><p>Sharp edges are mostly found on sheet metal parts that are laser-cut or stamped with a punch tool or die.</p><h3><strong>Hemmed Edges</strong></h3><p>Rather than sharp edges coming from stamping or laser cutting, hemmed edges present a rounded shape found in places prone to injuries, such as the contour of a car door.</p><p>In the process of stamping and laser cutting sheet metal, certain edges of circles, oblongs, or part sides can become very sharp, which can be dangerous and cause injury or damage if left untreated. Therefore, it is necessary to deburr these edges to break their sharpness and straightness.</p><p>To ensure that the edges, both hemmed and sharp, are safe and of high quality, manufacturers must accurately inspect their position, angle, and straightness. To achieve this, special algorithms have been developed and contribute to improving sheet metal manufacturing processes.</p><p>Learn more about VXinspect’s Edge method, designed specifically for sheet metal edges</p><h2><strong>More Areas to Control on Sheet Metal</strong></h2><p><strong>Holes, Oblongs, and Cut-Outs</strong>: Precision is key for holes, oblongs, and cut-outs in sheet metal parts, as they often need to align with other components. Inspecting these features ensures they are the correct size and properly positioned.</p><p><strong>Flanges and Tabs</strong>: Flanges and tabs are critical for the assembly process. Their dimensions and angles must be precise for proper fitment with other automotive parts.</p><p>In short, when inspecting these key areas, you can ensure that sheet metal parts are manufactured to the correct dimensions and tolerance. You also confirm that they are the closest to the nominal design, and interference risks are mitigated. With no physical or functional interference, all parts fit together seamlessly and function as intended in the final assembly. As a result, quality, safety, and comfort are optimized.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817982143-Sheet-metal_Quality-Control_MetraSCAN-3D_Geely-1536x1151.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>Which Sheet Metal Parts Are More Challenging to Inspect</strong></h2><p>Certain parts pose more inspection challenges than others. Here are a few examples.</p><h3><strong>Roof</strong></h3><p>The roof of a car plays a vital role in ensuring passenger safety, which is why inspecting it is of utmost importance. However, due to its large size, measuring specific points directly on the assembly line can pose accessibility problems, requiring adapted tools. Therefore, when choosing the right inspection method, it’s not only the part itself that must be considered, but also the condition in which the part is inspected. This is particularly important in an automated quality control (AQC) context or for troubleshooting purposes.</p><h3><strong>Doors and Fenders</strong></h3><p>Parts that have structural rigidity once assembled, such as doors, do not need to be physically conformed before inspection. However, other parts, like front and rear fenders, that do not have structural rigidity, must be conformed. Conforming a part can be easy if the appropriate checking fixture is available. (Checking fixtures are typically designed for a specific part.) However, in today’s manufacturing world, production is shifting from Low Mix-High Volume to High Mix-Low Volume. This shift demands more checking fixtures, which in turn adds extra costs to the manufacturing and inspection processes.</p><p>Holding fixtures are, however, more versatile than checking fixtures. They can be used on multiple parts, which reduces costs and saves storage space. Therefore, holding fixtures to which we add a fast measuring tool can significantly accelerate the conformation process.</p><h3><strong>Car Body</strong></h3><p>During the body in white (BIW) stage in which the car body’s frame is joined together, quality control is critical because it involves ensuring the quality of the vehicle’s metal framework before other components like the engine, chassis subassemblies, electronics, and interior trim are integrated into the structure. When inspecting large parts like the car body, pay close attention to the volumetric accuracy of the measuring tool used.</p><p>Since the measurement deviation increases by a few microns per meter, the cumulative error of scanning a larger part is higher. Such deviations cannot be ignored, and scanning methods have been developed to reduce errors, such as using markers like passive or active targets and photogrammetry.</p><h2><strong>Next Step: Understand the Technologies for Inspecting Sheet Metal</strong></h2><p>Sheet metal parts must meet the high standards of quality and safety required by the automotive industry. Inspection is crucial to ensure that the manufactured parts are accurately dimensioned, thereby minimizing waste and reducing the need for rework, ultimately reducing production costs. This efficiency level is critical for any part manufacturer operating in the highly competitive automotive market.</p><p>However, the manufacturing of sheet metal parts poses certain inspection challenges. To address these challenges, it is essential to select a suitable measuring technology among the different measurement solutions available by analyzing their respective advantages and disadvantages.</p>

Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry.

Unveiling the Hidden Hurdles of Automotive Part Manufacturers

<p id="isPasted"><a href="https://xometry.eu/en/injection-moulding/" target="_blank">Injection moulding</a> is a plastics manufacturing technology that is capable of very high production volumes. The process works by injecting liquid plastic into a mould at very high pressure. <a href="https://xometry.eu/en/compression-moulding/" target="_blank">Compression moulding</a>, on the other hand, is better suited to medium-volume production and is typically used with rubbers and silicones.</p><p>Injection moulding is better suited to creating complex parts, whereas compression moulding is better suited to simple geometries and large panels. Injection moulding is highly automated and does not need constant human supervision, while compression moulding often requires human intervention to load a charge and remove completed products. Tooling is also cheaper for compression moulding.&nbsp;</p><h2><strong>Injection moulding definition and comparison to compression moulding</strong></h2><p>Injection moulding works by injecting molten thermoplastic into a mould cavity. During the <a href="https://xometry.eu/en/injection-moulding-technology-overview/" target="_blank">plastic injection process</a>, the plastic resin pellets are melting inside a barrel. The barrel contains a screw with a shaft whose diameter increases along its length. As the screw rotates, plastic is forced into an incrementally smaller volume. This compression is the primary mechanism responsible for melting the plastic. The barrel is also heated to supply additional heat. Once enough plastic to fill the mould has melted, the screw retracts and then is pushed forward to force the plastic resins into the mould at very high pressures.&nbsp;</p><p>Moulds are made from at least two components and are held together with hydraulic rams so that the high-pressure plastic injected into the mould cannot escape from the parting line. The mould has cooling channels that cool the part enough so that it can be ejected from the mould without damaging it. Injection moulding can achieve high production volumes unmatched by any other plastic processing technique. Compression moulding, on the other hand, is better suited to medium-volume production.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637518953-ezgif-7-34a4753f4f.gif" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Injection moulding process animation</em></span></span></span></p><h3 id="isPasted"><strong>Advantages of injection moulding compared to compression moulding</strong></h3><p>Listed below are some advantages and disadvantages of injection moulding compared with compression moulding:</p><ul><li>Injection moulding is a method for large production runs that can produce millions of parts per machine annually.&nbsp;</li><li>Due to the high levels of automation and rapid manufacturing speed, injection moulded parts are cheaper than compression moulded parts.</li></ul><h3><strong>Disadvantages of injection moulding compared to compression moulding</strong></h3><p>Listed below are some disadvantages of injection moulding compared with compression moulding:</p><ul><li>Injection moulding requires very high plastic injection pressures. The mould must therefore be built to withstand these high pressures. This adds cost to the tooling.&nbsp;</li><li>Injection moulding is not well suited to manufacture large, thin parts like vehicle panels.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637547696-injection-moulding-setup-768x588.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Injection moulding setup</em></span></span></span></p><h2 id="isPasted"><strong>Compression moulding definition and comparison to injection moulding</strong></h2><p>Compression moulding is a process most often used to manufacture parts from pliable materials. <a href="https://xometry.eu/en/compression-moulding-technology-overview/" target="_blank">This moulding technique</a> typically employs a two-part mould, with one part fixed to the base of the compression moulding tool while the top half is free to move up and down. The moulds are usually heated to help cure the final product while also heating the charge before compression. A precisely weighed-out charge is heated until it is pliable. It is then placed into the bottom half of the mould.&nbsp;</p><p>The top half then moves down and forces the charge to conform to the desired shape of the mould. The heated mould stays closed while the material is allowed to cure. This typically takes a few minutes. Once cured, the part is removed from the mould. Post-processing is required to cut off any flash. Flash (or excess material at the parting line of the mould) is a common occurrence for compression-moulded parts.</p><p>Compression moulding is used for creating reinforced panels. The process involves laying out fibre-filled plastic sheets in the bottom half of the mould. Thereafter, the top half of the mould compresses and heats the material to force the plastic throughout the mould, creating a composite part. This is how large plastic car bumpers are made.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637616083-ezgif-7-1b2e488406.gif" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Compression moulding process animation</em></span></span></span></p><h3 id="isPasted"><strong>Advantages of compression moulding compared to injection moulding?</strong></h3><p>Listed below are some advantages of compression moulding compared to injection moulding:</p><ul><li>Compression moulding can make use of SMC (Sheet Moulding Compound) and BMC (Bulk Moulding Compound) to create composite panels. These panels do not have continuous fibre-impregnated sheets, but rather chopped fibre strands that are distributed throughout the bulk material. The injection moulding method cannot make composite material parts.&nbsp;</li><li>Compression moulds do not need to withstand high internal pressures as do injection moulds. Instead, the only load they experience is a compression force from above. This means that compression moulds tend to be less expensive.</li></ul><h3><strong>Disadvantages of compression moulding compared to injection moulding</strong></h3><p>Listed below are some disadvantages of compression moulding compared to injection moulding:</p><ul><li>Compression moulding is a very manual and slow process. Even if a robot arm is used to add the charge and remove the product, the cycle time between parts is still much slower than injection moulding due to the need for the parts to be set before being removed.</li><li>Compression moulding cannot create plastic parts with high levels of complexity. The materials used are typically very viscous and as a result, they don’t flow well into small, complicated features.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637640110-rubber-compression-machine-768x512.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">A rubber compression machine</em></span></span></span></p><h2 id="isPasted"><strong>Comparison table between injection moulding and compression moulding</strong></h2><p>Attributes of compression moulding and injection moulding are shown in the table below:</p><figure><table><tbody><tr><td><strong>Attribute</strong></td><td><strong>Injection Moulding</strong></td><td><strong>Compression Moulding</strong></td></tr><tr><td><strong>High-volume production process</strong></td><td>Yes</td><td>No</td></tr><tr><td><strong>Materials</strong></td><td>Thermosets, thermoplastics (including fibre and metal-filled), thermoplastic elastomers, metal-filled polymers, fibre-filled thermoplastics</td><td>Thermosets, thermoplastics, silicone, unvulcanized rubber, BMC, SMC</td></tr><tr><td><strong>High tooling cost</strong></td><td>Yes</td><td>No</td></tr><tr><td><strong>Can produce large, thin-walled panels</strong></td><td>No</td><td>Yes</td></tr><tr><td><strong>Post-processing required</strong></td><td>Yes</td><td>Yes</td></tr></tbody></table></figure><p><br></p><p>Injection moulding is better suited to high-volume production whereas compression moulding is better suited to pliable and flexible materials. Compression moulding also has cheaper tooling costs.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709637659491-capabilities-injectionmolding-xometry-768x511.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Blue injection moulded bottle nozzles in high-volume</em></span></span></span></p><h3 id="isPasted"><strong>Injection moulding vs. compression moulding: Lead cost comparison</strong></h3><p>When it comes to individual part cost, injection moulding can produce inexpensive, complex parts. However, this manufacturing process is only cost-competitive if production run volumes are large enough to spread the high cost of injection moulding tooling over a sufficient number of pieces. At lower volumes, compression moulding is cheaper than injection moulding due to the lower initial mould costs.</p><h3><strong>Injection moulding vs. compression moulding: Speed comparison</strong></h3><p>Injection moulding is significantly faster than compression moulding. The cycle time for injection moulded parts can be a few seconds, whereas compression moulding cycle times can easily reach a few minutes. This is because compression moulded components often need to cure thanks to the heating process before they are removed from the mould.</p><h3><strong>Injection moulding vs. compression moulding: Volume comparison</strong></h3><p>Injection moulding is a high-volume production method that is unmatched by any other manufacturing technology. Injection moulding processes can be fully automated, while compression moulding often requires a person to place the raw materials into the mould, remove it, and post-process it.</p><h3><strong>Injection moulding vs. compression moulding: Materials comparison</strong></h3><p>Injection moulding can make use of&nbsp;<a href="https://xometry.eu/en/injection-moulding-materials-selection-guide/" target="_blank">rigid thermoplastics as well as thermoplastic elastomers</a>. Compression moulding more often makes use of flexible elastomers like rubber and silicone, but can also produce rigid composite components by making use of SMC and BMC.</p><h2><strong>Summary</strong></h2><p>This article presented the comparison of injection moulding to compression moulding, explained what they are, and discussed the different attributes of each.</p><p>Xometry provides a&nbsp;<a href="https://xometry.eu/en/capabilities/" target="_blank">wide range of manufacturing capabilities</a>, including&nbsp;<a href="https://xometry.eu/en/injection-moulding/" target="_blank">plastic injection moulding</a>,&nbsp;<a href="https://xometry.eu/en/compression-moulding/" target="_blank">compression moulding</a> and other value-added services for all of your prototyping and production needs.</p>

This article will describe the similarities and differences between injection moulding and compression moulding to help you determine which process is best for your project in terms of the manufacturing process, materials used, and production rates.

Injection Moulding vs. Compression Moulding: Differences and Comparison

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manufacturing systems

manufacturing systems

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