Learn about the process of 3D printing with a new alloy, Aluminum F357.
This presentation addresses the successes and failures of 3D printing a topology optimized heat exchanger with a new alloy, Aluminum F357, that hadn’t been printed on a Xline 1000 printer before this project. Using X-ray computer tomography (CT), new print parameters were developed in one build and the redesigned heat exchangers printed in the next. Some background will be given on X-ray CT and the parameter selection method created and the positives/negatives of this method. Upon inspection of the printed parts, our workflow generated unexpected gaps in the parts. CT scanning the printed parts allowed us to determine the size of the internal gap and adjust the models accordingly. Updating a set of complicated heat exchanger models while changing the material and the 3D printer can be a daunting task. However, X-ray CT can give you confidence when selecting new print parameters and inspecting printed parts. X-ray CT allows rapid feedback when printing a design of experiments (DOE) of parameters and can inspect hard to reach regions such as internal channels. This presentation showcases the successes and setbacks we’re able to overcome while improving a set of heat exchangers.
Meet your presenter Curtis Frederick is an additive manufacturing (AM) application scientist with Carl Zeiss and is positioned at the manufacturing demonstration facility within Oak Ridge National Laboratory (ORNL) to support the CRADA between ZEISS and ORNL. Frederick researched parameter development for grain control using electron beam AM of Ni-based superalloys during his graduate studies. He also worked on alloy development of high temperature Al-based alloys for laser powder bed fusion at the production scale. He is currently developing workflows for linking defects in printed parts to properties of the powder feedstock for multiple powder bed AM processes. He received his Ph.D. in material science and engineering at the University of Tennessee, Knoxville in 2018.
About the company ZEISS develops, produces, and distributes innovative solutions for industrial metrology and quality assurance, microscopy solutions for the life sciences and materials research, and medical technology solutions for diagnostics and treatment in ophthalmology and microsurgery. The name ZEISS is also synonymous with lithography optics, used by the chip industry to manufacture semiconductor components. ZEISS consists of four segments: semiconductor manufacturing technology, industrial quality and research, medical technology, and consumer markets.
The facility in South Carolina expands biopharma processing tubing manufacturing capabilities marking a key milestone in DuPont’s healthcare growth strategy.
DuPont celebrated the opening of its new DuPont Liveo Healthcare Solutions manufacturing facility located at the Cooper River Site in South Carolina with a formal ribbon-cutting ceremony attended by state and local government officials and business leaders. The new facility will expand capacity for biopharmaceutical tubing extrusion to meet increased demand from Liveo customers.
The site, located near Moncks Corner, South Carolina operates using the same quality standards as the DuPont Healthcare Industries Materials Site (HIMS) in Hemlock, Michigan – DuPont’s long-standing healthcare manufacturing site. Operators at the new South Carolina facility were certified at HIMS.
“The Cooper River site will bring additional production capacity online over the next two years to serve strategic customers and expand our Liveo Healthcare Solutions customer base,” said DuPont Healthcare & Specialty Lubricants Global Business Director Eugenio Toccalino. “We’re committed to investing in our healthcare business, and this biopharma processing manufacturing investment at Cooper River is a key milestone in our growth strategy that will help us offer a highly reliable and sustainable product supply.”
DuPont worked with local companies, including more than 40 subcontractors on the project.
“Being selected as the second dedicated healthcare site is indeed an honor and a reflection of our team’s track record of dedication, ownership, and commitment to our core values and excellence in meeting customers’ needs. Thanks to collaboration between the DuPont team and our contractor partners, the Cooper River site was completed within 17 months – on time, on budget, and without a single recordable safety incident,” said Bill Alexander, DuPont Cooper River site leader. “The opening of the site already has enabled the creation of 25 jobs for startup, with another 25 expected by mid-2024 as we ramp up operations.”
The ribbon-cutting event included remarks from South Carolina Governor Henry McMaster, Berkeley County Supervisor Johnny Cribb, DuPont Electronics & Industrial Vice President and General Manager Sam Ponzo, Toccalino, and Alexander. Attendees also toured the site.
In the second half of 2022, the company expects to add biopharma silicone tubing capacity in China to serve the customers in that region.
Learn common fallacies and misconceptions in tooling.
About the presentation This presentation addresses common fallacies and misconceptions in tooling. We’ll discuss where they come from, what is wrong with them, and how to fix them. Additionally, this presentation covers innovations and how they impact profitability, how tool wear can drive productivity and savings, how cutting data impacts the process (wear, process stability, chip formation/control, etc.), and how to smart-index inserts.
Meet your presenterJan Anderson is a more than 20-year industry veteran. He has experience with global product management, global R&D in grades and geometrics, and tooling concepts.
About the company YG-1 always strives to develop unique products never seen in the market before. By seeking technical development from overturning common sense, YG-1 developed fascinating items for customers all around the world. From choosing the best raw material to proceeding with accurate heat treatment and passing YG-1’s tight quality inspections, new products with cutting and finished surfaces are developed.
The money is granted to four organizations for projects relating to additive manufacturing.
The U.S. Department of Commerce’s National Institute of Standards and Technology (NIST) has awarded $3.7 million in grants to help address current and future barriers to widespread adoption of metals-based additive manufacturing (AM) through measurement science research.
“The U.S. can take a leading role in developing the measurements and international standards that will help accelerate adoption of these important 3D-printing technologies,” said Under Secretary of Commerce for Standards and Technology and NIST Director Laurie E. Locascio. “To compete globally, we need to invest in programs such as this that bring together our best minds in industry, academia and government to solve important technical challenges.”
AM typically creates parts and components by building them layer by layer, based on a 3D computer model. Most metals-based additive processes form parts by melting or sintering material in powder form.
“Additive manufacturing offers advantages such as reduced material waste, lower energy intensity, reduced time-to-market, and just-in-time production that could bolster supply chains in the U.S.,” said Locascio. “Accelerating the adoption of new measurement methods and standards will help to advance U.S. competitiveness in this important industry.”
Through its own research and with these grants, NIST is addressing barriers to adoption of AM, including measurement science to support equivalence-based qualification and model-based qualification, the characterization of AM materials, and standards to support consistent data exchange/characterizing new advances in AM production systems.
The following organizations will receive NIST Metals-Based Additive Manufacturing Grants Program funding to be spent over two years:
The Research Foundation for the State University of New York (Albany, New York) – $957,706
The goal for this project is to demonstrate an enhanced nondestructive evaluation (NDE) technique that can determine key material properties such as oxide thicknesses, splatter particle percentage, grain size, and defect detection.
Colorado School of Mines (Golden, Colorado) – $956,888
This project will examine new optical metrologies to enable real-time process feedback and control to achieve process-based qualification and certification of metallic parts made by AM.
The goal of this project is to establish a data-driven framework with computer vision and machine learning for the nondestructive qualification of AM materials and parts for applications that can’t afford failures due to fatigue.
General Electric, GE Research (Niskayuna, New York) – $873,999
GE Research teamed up with GE Additive and the University of Texas at El Paso (UTEP) to establish the Intelligent Stitch Integration for Testing and Evaluation (I-SITE) program to extend existing standardized methods and build correlations between sensor response, material behavior, and mechanical properties.
Learn how to use a digital marketplace to improve your company.
About the presentation Manufacturing is foundational to the global economy because it brings innovation taking place across numerous industries to life. Its success going forward relies on digital marketplace platforms to efficiently connect buyers and suppliers to produce tomorrow's transformative technologies. Digital marketplaces are ushering in a new era where engineers and enterprise buyers can connect with manufacturers worldwide to make products that are the backbone of our economy. This paradigm shift impacts how future-oriented engineers are sourcing and pricing their prototype and production projects, from conceiving part designs to manufacturing them. Marketplace manufacturing acts as a supply chain consolidator without the downsides of single-sourcing or geographic vulnerabilities. It uses a distributed manufacturing strategy with a platform used by both customers and manufacturers.
Meet your presenter Greg Paulsen leads the applications engineering team at Xometry. He works with customers and suppliers on unique projects and shares the capabilities of Xometry's proprietary digital manufacturing marketplace. He sits at the intersection of technology and manufacturing, and under his direction his team plays a key role in Xometry’s mission of accelerating the digitization of the industry. He’s also a subject matter expert in 3D printing, CNC machining, injection molding, and beyond.
About the company For years, the on-demand manufacturing industry suffered from a lack of consistent pricing driven mainly by existing manufacturing sourcing and procurement processes that were complex, uncertain, costly, and time-consuming. Pricing was opaque. Xometry focused on developing a means to generate an instant and accurate price for our buyers and allow sellers to source curated manufacturing opportunities that match their specific processes and capacity. Artificial intelligence (AI) gives us the tools to create a machine learning approach that accurately and quickly prices part designs and lead times and matches them to the appropriate sellers. It allows us to combine part features with data gathered from financial transactions conducted on our marketplace to construct and continually improve prices that both buyers and sellers find acceptable across a wide range of designs, materials, and sizes.