Cloud-based computer applications are all around us and continue to expand and influence many aspects of our personal and professional lives. Digital, or computer-based machining (CAM) is no exception.
Although CAM and computer numerically controlled (CNC) technologies have been with us for several decades, cloud-based methods are relatively new, but evolving at a rapid pace.
The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with servomotors that moved tools or parts to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analog and digital computers, creating the modern CNC machine tools that revolutionized machining, and more recently, cloud-based processes.
MCADCafe recently interviewed Bre Pettis, CEO of Bantam Tools about several things regarding his past and current endeavors that interestingly involve additive and subtractive manufacturing.
Pettis has had many personal and professional iterations during his career, but has always stayed close to design and manufacturing. Pettis is probably still best known as the co-founder and former CEO of Makerbot Industries, a 3D printer/additive manufacturing (AM) company now owned by Stratasys. He left Makerbot in 2014. In June 2017, Pettis acquired start-up Other Machine Co. — now known as Bantam Tools — from its founder and CEO, Danielle Applestone.
Bantam Tools builds reliable and precise desktop CNC machines. Since 2013, the company has been manufacturing desktop CNC machines for engineers and product designers enabling them to bring machining in-house and accelerate their rapid prototyping processes. Its CNC machines are also widely used by educators in classrooms and makerspaces. The company is on an ambitious mission to build an ecosystem of hardware and software products that will empower its users to create sustainable energy sources, fight climate change, land on Mars, prevent the next pandemic, and close the growing skills gap in U.S. manufacturing.
Bantam Tools strives to keep as much of its manufacturing in-house as possible, and its machines are assembled and tested in-house in Peekskill, NY.
During the course of IMTS 2016 we visited and talked with several CAM vendors on what they specifically were showing at the event, as well as their take on the CAM industry in general.
In Part 2 of a series started last week, what follows are the results of some of the conversations we had while looking for the newest and most innovative in CAM software at IMTS 2016.
MachineWorks
MachineWorks functionality offers real-time simulation and verification for virtually any type of CNC machining, including kinematics, multi-axis, mill-turn, robotics, Swiss-type turning, Wire EDM, hybrid machining (subtractive + additive manufacturing) with features such as on-the-fly crash and gouge check, target part comparison, material removal and infinite zooming.
The forthcoming MachineWorks release contains many developments, one of the most significant being the support of cloud-based applications for CNC simulation and verification. This new feature allows networked devices such as mobile phones, tablets, laptops and desktops to visualize MachineWorks simulations running in the cloud.
IMTS is all about the many aspects of manufacturing from a technology standpoint, so it’s only natural that a lot of the major CAM vendors were represented on the exhibition floor.
During the course of IMTS 2016 we visited and talked with several CAM vendors on what they specifically were showing at the event, as well as their take on the CAM industry in general.
Almost without exception, every CAM vendor we spoke with talked of faster rates for increased efficiency/productivity, greater levels of automation with less operator intervention required, better integration with CAD, ability to handle a broader range of machines, tools, and materials, new roughing and finishing strategies, and so on. Some touted cloud-based capabilities and the ability to exploit the benefits of model-based design. Admittedly, though, with fancy new wrappers, some of the CAM tools were basically repackaged with aging technology more than a decade old underlying a new user interface. However, there were some notable exceptions, and these really stood out from the pack as CAM innovations.
What follows are the results of some of the conversations we had while looking for the latest and greatest in CAM software and what was truly new.
Autodesk
At IMTS 2016 Autodesk ushered in its new 2017 CAM products for many advanced manufacturing applications ranging from CNC mill- and lathe-programming to complex mold and die manufacturing that combine the legacy in CAM software from Delcam with Autodesk’s 3D design and manufacturing software.
When it comes to machining, Swiss-style is quite a different animal because of the degree of precision and pace the process it is expected to maintain. Swiss-style lathes and turning centers provide extreme accuracy, capable of holding tolerances as small as ten thousandths of an inch.
A Swiss-style lathe holds the workpiece with both a collet and a guide bushing and is almost always used under CNC control. The collet sits behind the guide bushing, and the cutting tools are located in front of the guide bushing, holding stationary on the Z axis. To cut lengthwise along a part, the tools move in and the material itself moves back and forth along the Z axis. This allows all the work to be done on the material near the guide bushing where it is more rigid with little chance of deflection or vibration.
Swiss-style lathes and turning center are very efficient, as these machines are capable of fast cycle times, producing simple parts in one cycle with no need for a second machine to finish the part with secondary operations. This makes the Swiss style ideal for large production runs of small-diameter parts.
Additionally, as many Swiss lathes incorporate a secondary spindle, or sub-spindle, they also incorporate “live” tooling. Live tools are rotary cutting tools that are powered by a small motor independent of the spindle motor(s). Live tools increase the intricacy of components that can be manufactured by a Swiss lathe.
Spatial Corp. recently joined CNC Software Inc. in announcing that the 3D ACIS Modeler and 3D InterOp power the latest release of Mastercam Swiss Expert 2012. Designed to control a variety of Swiss-style NC machines, Mastercam Swiss Expert is used in a range of applications such as watch-making, medical device, dental, automotive, and electronics companies — all known for requiring extremely small, but very precise parts.
Both my father and father-in-law (and his father) were master tool and die makers who made excellent tools and decent livings over the course of their careers. I chose not to follow in their footsteps, but rather, to go to engineering and design school instead. However, I consider tool making to be a noble profession and one that has contributed immensely to the quality of our lives for many years and will continue to do so for many years to come.
With all the news we continue to hear today about product design, engineering, and manufacturing increasingly being outsourced in every direction away from North America, surprisingly little coverage seems to be given to the heart of product manufacturing, namely, tooling and tool making.
Although most of our readers are obviously manufacturing-savvy, let’s first define what we mean by “tooling,” because it’s often a misunderstood term by those outside manufacturing. Simply put, tooling entails the tools, machines, or other devices required to manufacture products – everything from car fenders to detergent bottles. The two most prominent groups of toolmakers are die makers whose tools stamp out metal parts, and mold makers whose tools mold plastic parts.
Beginning a long time ago, the huge transportation market (primarily automotive) still dominates the tooling industry. Because the automotive sector is rapidly outsourcing as much of its manufacturing overseas, it becomes very clear why tool and die makers, especially the family-owned small ones with five to 100 employees have suffered the most. It’s estimated that approximately 60% of stamping dies and 40% of plastic molds are used directly or indirectly by automakers worldwide, so it’s no wonder the smaller tool shops are bearing the brunt of offshore outsourcing. This offshore outsourcing has cost a huge number of tooling jobs in North America, according to estimates from several sources.
Historically, toolmakers and machinists have been among the most highly skilled and highest paid trades in the manufacturing world, but also people who provided among the highest value-added services on or near the manufacturing floor. Although some would argue that technologically enhanced professions are just as valuable, a good toolmaker/machinist is still a true asset and value-added provider today. If nothing else, these toolmakers have been instrumental in the quality level and success of manufacturing in North America for 200+ years.
As if offshore outsourcing weren’t enough of a problem, there is also the problem of money. Let’s face it, tools are expensive to make and toolmakers generally don’t get paid until a job is complete. In fact, many toolmakers are forced to wait for months to be paid until the customer is satisfied with the quality of parts that a tool is producing. During this period, however, toolmakers’ bills must still be paid to keep their businesses running. This payment lag also can make it difficult for toolmakers to obtain bank loans to either allow toolmakers to grow their businesses, or merely keep them afloat until payment is finally received.
So what does this all mean and where is it all going? Is there a direction or solution for tool makers? That’s what we’ll discuss next time.
It’s no secret that many tool makers have experienced and are still experiencing difficult times.
By necessity, the tooling industry is transforming from its roots as a craft to a future as a complex business. For this transformation to be successful, the tooling industry as a whole must realize that it is not just undergoing a temporary downturn in business, but a radical restructuring. This restructuring is evident in not only mergers and acquisitions (consolidation), but also in cooperative and collaborative practices taking place between small- and medium-sized tool shops. Additionally, new business models are being developed by innovative toolmakers for supporting their ability to compete today and tomorrow with just about anyone, regardless of geographic location.
Restructuring an industry, however, is an extremely tall order because it involves cultural change as much as it does developing new business models. One of the toughest cultural aspects that must be recognized and addressed is the fact that although tool making historically has been regarded as a craft requiring high degrees of skill, unfortunately, it is increasingly becoming regarded as a commodity.
What, a commodity with no real distinguishing characteristics?
To a certain extent, yes, (although there are notable exceptions) because what was done by hand and eye by a select number of tool shops can now be performed by just about any shop anywhere, due to technologies (3D solid modeling, rapid tooling and manufacturing processes, high-speed machining (HSM), etc.) available to just about anybody who chooses to employ them. There is a remedy to this commodity perception; however, by seeking out niches and having outstanding product, material, process and customer knowledge, and many North American tool shops are embracing these practices.
Like virtually all other aspects of manufacturing, integrating technologies in tool making assist in becoming more competitive, but in the end, it is the creativity and adaptivity of people (both on the production floor and in the management office) to an ever changing business climate, in concert with appropriate technologies, that will ultimately win the battle and more business.
