MCADCafe Editorial 
Sanjay Gangal
Sanjay Gangal is the President of IBSystems, the parent company of AECCafe.com, MCADCafe, EDACafe.Com, GISCafe.Com, and ShareCG.Com. Hybrid Manufacturing Technologies: Bridging the Gap Between Additive and Subtractive ManufacturingOctober 14th, 2024 by Sanjay Gangal
At the bustling IMTS 2024 in Chicago, a city that has long symbolized American industrial prowess, Hybrid Manufacturing Technologies Global (HMT) is making waves. Led by co-founder and CEO Jason Jones, the company has pioneered a novel approach to manufacturing that seamlessly integrates additive and subtractive processes. The goal? To push the boundaries of efficiency and scalability in manufacturing while addressing critical gaps in both 3D printing and traditional methods. “We live at the interface between 3D printing and mainstream manufacturing,” Jones explained during our interview. The “hybrid” in their name is no mere buzzword—it reflects a revolutionary combination of technologies. Hybrid Manufacturing Technologies Global (HMT) focuses on blending additive manufacturing, particularly metal deposition and polymer extrusion, with conventional subtractive techniques like CNC machining. As Jones quipped, “We’re like an athlete that can do more than one sport.”
The company’s approach leverages existing machine platforms from your traditional CNC to gantries and robots, equipping them with deposition heads that allow for both 3D printing and traditional machining within the same system. This unique integration helps streamline production processes and opens up opportunities for industries ranging from power generation and oil and gas to the highly demanding mold manufacturing sector. “We can make things out of more than one material, giving customers the best of both worlds—like using bronze to wick away heat and adding a hard-facing material for durability,” Jones elaborated. Driving Innovation with PracticalityHMT’s cutting-edge innovations aren’t just theoretical. At IMTS 2024, the company introduced its new Flex 22 head, a tool designed to print inside hard-to-reach areas. According to Jones, this new head is poised to significantly improve manufacturing flexibility. “We’re excited to show the Flex 22 here at IMTS,” Jones noted, gesturing toward the equipment behind him. HMT also unveiled a high-speed laser deposition head that applies ultra-thin metal layers—a breakthrough that could compete with traditional chrome plating methods, which are becoming increasingly regulated due to environmental concerns. In fact, sustainability is at the core of many of HMT’s innovations. The company’s extra high-speed laser deposition technology (EHLA) offers a cleaner, more efficient alternative to hexavalent chrome, which has been flagged for its human and environmental risks. “We’re offering a way to apply coatings more sustainably, which could have a real financial and environmental impact,” Jones added. Materialise Expands Its Reach in Traditional Manufacturing Through Strategic Partnerships at IMTSSeptember 13th, 2024 by Sanjay Gangal
At this year’s International Manufacturing Technology Show (IMTS) in Chicago, Materialise, a global leader in 3D printing software and services, took the spotlight by announcing two major partnerships aimed at revolutionizing the investment casting process. These collaborations with Stratasys and Formlabs underscore Materialise’s commitment to integrating 3D printing with traditional manufacturing practices, offering innovative solutions that reduce cost and improve efficiency. I sat down with JP Velasco, OEM Partner Manager, and Don Licht, Director of OEM Partnerships and Channel Development, to discuss Materialise’s latest initiatives and their broader implications for the manufacturing industry.  Manufacturers Can Now Quickly Produce High-Quality Master Patterns for Investment Casting Production with New 3D Printing Build Processor from Stratasys and Materialise (Photo: Business Wire) Bridging the Gap Between Additive and Traditional ManufacturingMaterialise has been at the forefront of the 3D printing revolution since 1990, initially serving as a service bureau before evolving into a provider of advanced software solutions for additive manufacturing. According to Velasco, Materialise recognized early on that files for 3D printing often failed, prompting them to focus on developing software designed specifically for additive manufacturing. “Our software connects every industry with every technology, ensuring that users of 3D printers can create high-quality parts,” said Velasco. This commitment to quality is what has positioned Materialise as a crucial player in the additive manufacturing ecosystem, particularly in sectors like investment casting, where the stakes are high. General Lattice Unveils GL Frontier: Simplifying 3D Printing for the MassesAugust 8th, 2024 by Sanjay Gangal
In an industry where innovation often walks hand in hand with complexity, General Lattice is charting a different course. Founded six years ago, the company has steadily evolved from its beginnings as a service bureau into a leader in digital manufacturing services, focusing on computational design. Now, General Lattice is making headlines with its latest offering: GL Frontier, a web-based software that promises to make 3D printing accessible to a broader audience. “GL Frontier is really the culmination of everything we’ve learned over the past five years,” said Nick Florek, CEO of General Lattice, in a recent interview. “We’ve worked with a wide range of companies, from the Department of Defense to sporting goods manufacturers, and we’ve taken those experiences to create a tool that anyone can use.”
General Lattice’s journey began with a focus on LP technology, but the company soon pivoted away from printing parts for customers, instead turning its attention to designing them. This shift allowed the team to develop a deep understanding of various industries and their unique needs. It also provided the foundation for GL Frontier, which distills the complexities of 3D printing into three key components: materials intelligence, intuitive design tools, and connected manufacturing. The materials intelligence feature of GL Frontier is perhaps its most significant innovation. It provides users with a database of lattice materials, helping them choose the right material for their projects, whether they’re focusing on mass customization, part consolidation, or advanced geometry. “We’ve tried to break down the keys to success with 3D printing,” Florek explained. “And materials intelligence is a big part of that. Our database allows users to find the right hardware, the right material, and the best lattice structure to use.” Read the rest of General Lattice Unveils GL Frontier: Simplifying 3D Printing for the Masses Navigating the Evolution of Additive Manufacturing: Insights from the 2024 RAPID+TCT Executive PanelJune 27th, 2024 by Sanjay Gangal
As the 2024 RAPID+TCT event unfolded, industry leaders gathered to discuss the current landscape and future prospects of additive manufacturing (AM). The panel, comprising Avi Reichental (Nexa3D), Fried Vancraen (Materialise), Savi Baveja (HP), Nils Niemeyer (DMG MORI), and moderated by Laura Griffiths (The TCT Group), offered a candid look at the challenges and opportunities facing this dynamic sector.
The Promise and Reality of Additive ManufacturingThe session opened with a shared sense of optimism tempered by realism. The panelists agreed that while AM has made significant strides, it remains a technology marked by both remarkable achievements and ongoing hurdles. Avi Reichental highlighted the transformative potential of AM, especially in fields like healthcare and aerospace. He cited examples such as the deployment of additive manufacturing systems in conflict zones, showcasing the technology’s ability to provide on-demand solutions in critical situations. However, Reichental also emphasized the need for the industry to shift from selling capabilities to delivering scalable solutions. Fried Vancraen echoed these sentiments, pointing out that while AM has revolutionized certain sectors, it has not been an overnight success. Vancraen’s experience with Materialise, a company founded in 1990, underscores the slow and steady progress required to integrate AM into mainstream manufacturing. He noted that the industry must focus on creating real value and moving beyond the initial hype. Altair Enhances Aerodynamics Capabilities with Acquisition of Research in FlightMay 3rd, 2024 by Sanjay Gangal
In a move that significantly bolsters its aerodynamic analysis offerings, Altair has acquired Research in Flight, the developer of the groundbreaking FlightStream® software. This strategic acquisition integrates FlightStream®, known for its exceptional capabilities in the computational fluid dynamics (CFD) arena, into Altair’s extensive suite of simulation tools, marking a pivotal advancement in aerodynamic research and applications across multiple sectors.  Altair acquired Research in Flight, forging a new path for aerodynamic analysis and pushing the the boundaries of modern computational techniques “Our growth in the aerospace, defense, and surrounding industries has accelerated in recent years through our best-in-class computational intelligence solutions,” said James R. Scapa, founder and chief executive officer, Altair. “The integration of FlightStream® into our portfolio will enhance our offering with its specialized, modern, and efficient approach to meet the increasingly complex customer demands in these industries, including the urban air mobility and eVTOL sectors.” FlightStream® is recognized for its cutting-edge panel methods aerodynamic solver which allows for a comprehensive analysis of flow problems across a diverse range of applications. With a modernized graphical user interface, the software enables engineers to navigate complex aerodynamic challenges efficiently. It includes specialized toolboxes like Solver Sweeper, Stability & Control, and API scripting, enhancing its capability to rapidly estimate aircraft performance and conduct extensive aerodynamic studies. “We are proud to be a standard tool in the aircraft designer’s toolbox,” said Vivek Ahuja, co-founder, Research in Flight. “Joining Altair will allow us to scale and reach countless engineers seeking best-in-class, powerful, and specialized tools for faster design iterations.” Read the rest of Altair Enhances Aerodynamics Capabilities with Acquisition of Research in Flight Innovations and Partnerships Fuel Progress: Weekly Roundup in MCAD and 3D Printing IndustriesApril 5th, 2024 by Sanjay Gangal
This week in the MCAD and 3D printing industries, we’ve seen groundbreaking collaborations, strategic investments, and innovative advancements across various sectors, signaling a vibrant period of growth and technological evolution. From SIGGRAPH 2024’s return to Colorado, highlighting IT industry growth and advancements in computer graphics, to strategic partnerships like ESI Group and FAW-Volkswagen, and significant financial achievements reported by PyroGenesis, the landscape is rapidly evolving. Moreover, OpenBOM’s operational enhancements at TTM Technologies, RAPID + TCT 2024’s upcoming event in Los Angeles, and NUBURU’s secured investment for blue laser technology development exemplify the dynamic progress and potential within these fields. The Exploration Company is revolutionizing sustainable space exploration with Ansys simulation solutions to develop Nyx, a modular and reusable space vehicle. Focused on a methane-based propulsion system, Nyx aims for missions around Earth and to the Moon, showcasing a leap in eco-friendly space travel. Ansys tools like Fluent and Mechanical are pivotal in optimizing Nyx’s engine designs for performance and durability, highlighting Ansys’s role in bridging the gap between visionary concepts and real-world space applications. RAPID + TCT 2024, North America’s premier additive manufacturing event, is returning to the West Coast with a range of new features and experiences. Set in Los Angeles, the event will showcase the latest advancements from over 400 solution providers in the additive manufacturing industry. Attendees can expect a curated program of talks, presentations, and workshops, highlighting the event’s commitment to fostering innovation in 3D printing. SIGGRAPH 2024 is set to return to Denver, Colorado, marking a nod to the state’s burgeoning IT industry. The conference, known for pushing the boundaries of computer graphics and interactive techniques, will feature programs across arts, design, and technology. The choice of Colorado reflects its significant role in IT and the event’s origins, inviting professionals to explore the latest innovations in the field. ESI Group and FAW-Volkswagen have entered a strategic partnership aimed at advancing automotive simulation technology. This collaboration will focus on meeting China’s automotive safety regulations and fostering industry innovation. A new joint laboratory for material testing and intelligent simulation signifies a major step in automotive research and development, potentially leading to cleaner, safer, and more productive future automotive technologies. PyroGenesis Canada Inc. announces its financial results for 2023’s fourth quarter and the fiscal year, highlighting its role in reducing greenhouse gases through advanced plasma processes. Despite facing economic challenges, the company has positioned itself as a leader in decarbonization solutions for heavy industries, with a robust sales pipeline and a focus on technological commercialization. This strategy underpins its optimistic outlook for future growth. Altair’s Vision for Future Engineering: A Holistic Approach to InnovationMarch 8th, 2024 by Sanjay Gangal
In a virtual presentation at Altair’s Future.Industry 2024 event, Sam Mahalingam, the Chief Technology Officer, delved into the platform-centric approach that Altair offers to expedite customers’ digital engineering journey. Mahalingam emphasized the transformative potential of computational intelligence in fostering a connected, safer, and sustainable future.  Sam Mahalingam, CTO Empowering Digital TransformationAltair’s commitment to advancing digital transformation through computational intelligence is evident in its platform-centric approach. By harnessing the power of autonomous artificial intelligence and automation, Altair seeks to revolutionize various industries, including aerospace, automotive, pharmaceuticals, and manufacturing. Mahalingam highlighted the significance of autonomy, defining it as augmented intelligence, continuous learning, and self-optimization. This approach underscores Altair’s vision of democratizing powerful technologies, such as simulation, high-performance computing, and AI, to empower organizations with the tools needed to drive innovation and make data-driven decisions. HyperWorks: Redefining EngineeringHyperWorks stands out for its ability to address a wide array of engineering challenges within a single, unified platform. Mahalingam emphasized its versatility, enabling users to tackle complex problems spanning multiple disciplines such as structures, motions, fluids, electromagnetics, and electronics. With HyperWorks, engineers can seamlessly transition between different phases of the design and simulation process, streamlining workflows and enhancing productivity. Its intuitive interface and comprehensive suite of tools empower users to explore new ideas, iterate on designs, and optimize performance with unparalleled efficiency. What sets HyperWorks apart is its integration of AI solutions and advanced visualization techniques. Mahalingam highlighted how AI algorithms embedded within HyperWorks enable users to achieve unprecedented results, driving innovation and pushing the boundaries of what’s possible in engineering design. Moreover, HyperWorks’ true-to-life visualization capabilities provide users with valuable insights for informed decision-making. By leveraging AI-driven visualization, engineers can gain deeper understanding of their designs, identify potential issues, and explore alternative solutions with greater confidence. Mahalingam underscored HyperWorks’ commitment to interoperability and open architecture, allowing seamless integration with existing workflows and third-party applications. This flexibility enables users to leverage their preferred tools and methodologies while harnessing the power of HyperWorks for advanced simulation and design tasks. The platform’s open architecture also facilitates collaboration and knowledge sharing within and across organizations. Engineers can easily collaborate on projects, share simulation models, and leverage collective expertise to drive innovation and solve complex engineering challenges more effectively. Mahalingam emphasized that HyperWorks is not just a software platform—it’s a catalyst for innovation and success in engineering. With its unparalleled capabilities, intuitive interface, and commitment to interoperability, HyperWorks empowers engineers to push the boundaries of what’s possible, driving breakthroughs and shaping the future of engineering. Read the rest of Altair’s Vision for Future Engineering: A Holistic Approach to Innovation Revolutionizing Design and Innovation: Highlights from the 3DEXPERIENCE WorldFebruary 16th, 2024 by Sanjay Gangal
The 3DEXPERIENCE World, a gathering that annually brings together the brightest minds in design and engineering, once again showcased groundbreaking innovations and transformative stories from various industries. This year’s event was no exception, offering a treasure trove of insights into how SOLIDWORKS capabilities are being leveraged to push the boundaries of creativity, efficiency, and problem-solving. Here are some of the standout moments and key takeaways from the event. A New Horizon: The Narrative of Solidworks CEO, Manish Kumar’s Vision at the 3DEXPERIENCE WorldOn a stage illuminated by the eager anticipation of innovators, designers, and visionaries, Manish Kumar stood poised to address the gathering at 3DEXPERIENCE World. With a calm demeanor reflective of his profound insights into the future of technology, Kumar embarked on a journey to outline a new horizon for businesses and creators alike.  Manish Kumar, Solidworks, CEO The auditorium, buzzing with the collective curiosity of its attendees, fell into a hushed silence as Kumar began his narrative. He spoke of a future not far from reach, where businesses transcend the traditional confines of product delivery to offer rich, immersive experiences. This vision, he proposed, was not merely an aspiration but a necessity in the rapidly evolving digital landscape. The essence of adaptation, Kumar emphasized, lay in embracing change and leveraging technological advancements to redefine innovation. As the narrative unfolded, Kumar introduced the audience to the story of Proteus Motion, a beacon of innovation that embodied the transformative power of the 3DExperience platform. Proteus Motion, with its groundbreaking sports science equipment, had revolutionized athlete training and testing, condensing the capabilities of a full-scale lab into a singular, ingenious device. Kumar detailed how the seamless collaboration, design efficiency, and rapid iteration facilitated by the platform had propelled Proteus Motion to the forefront of its field. This tale of success served not only as a testament to the platform’s capabilities but as an inspiration for the potential within every innovator in the room. (More on the Proteus Motion Story is covered later in this article). The journey continued with Kumar exploring the uncharted territories of design and innovation shaped by Artificial Intelligence (AI). With vivid examples, he painted a future where AI-driven initiatives, from virtual twins of homes to AI-generated furnishing proposals, streamline the creative process, inspire new ideas, and expedite decision-making. Kumar’s discourse on AI as a catalyst for design excellence highlighted its critical role in navigating the complexities of modern-day innovation. Read the rest of Revolutionizing Design and Innovation: Highlights from the 3DEXPERIENCE World MCADCafe Industry Predictions for 2024 – MeltioJanuary 6th, 2024 by Sanjay Gangal
By Angel Llavero López de Villalta, CEO at Meltio
For Meltio, the year 2023 is being a year of consolidation at a technological level in terms of strengthening our commercial network and our distribution channel worldwide. We have expanded the facilities of our Meltio factory in Linares (Jaén) to develop new metal AM solutions and industrial applications, we have expanded our production capacity, we have acquired new land to further expand our factory in Linares, we have rented new spaces to expand our R&D capacity to launch in the market new wire-laser metal 3D printing products and we aim to expand our production capabilities and to certify our technological applications in all the industrial sectors in which we are involved. With this technological consolidation, we will be able to secure new contracts with our industrial customers. The year 2024 for us is going to be a very exciting year in which we are leaving behind our pre-adolescence. Read the rest of MCADCafe Industry Predictions for 2024 – Meltio MCADCafe Industry Predictions for 2024 – MaterialiseJanuary 4th, 2024 by Sanjay Gangal
By Bart Van der Schueren, Chief Strategy and Technology Officer (CSTO) at Materialise. Bart Van der Schueren, 3D Printing Trends For 2024: Shaping the Future of Manufacturing As we stand on the brink of 2024, Materialise reflects on the dynamic landscape of 3D printing, anticipating not just growth, but a fundamental shift in adoption patterns. In the coming year, we predict four key trends – or shifts – that will redefine the industry. Trend 1: 3D Printing – Fast Friend or Part of the Family? In the realm of 3D printing, we’re witnessing a dual evolution—two approaches coexisting harmoniously. The first approach, “3D Printing as a Service,” embraces external expertise, offering swift and cost-effective solutions for one-off parts and prototypes through service bureaus. Simultaneously, the second approach sees 3D printing seamlessly integrated into production processes, revolutionizing mass manufacturing. Companies now recognize its intrinsic value and leverage it to print specific components for larger series of end-use parts or engage in the mass production of customized goods. This dual approach marks a departure from the traditional role of 3D printing, transforming it from a peripheral player to an integral part of the production orchestra. At the same time, the demand for application-specific machines and workflows is driving innovation across the entire spectrum, from hardware to post-processing and software. Read the rest of MCADCafe Industry Predictions for 2024 – Materialise |
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