The Best Desktop CNC Milling Machines - top carbide end mills for aluminum

New U.S.-based event announced in 2021 finally debuts next year: focuses on complete additive manufacturing value chain. More at formnextchicago.com.

Through the adoption of AM, new design possibilities are available to mould manufacturers. Such design freedoms must be mastered, bearing in mind both the layer-by-layer manufacturing approach as well as the raw material involved in the process – the fine metal powder. These two elements result in a very limited set of constraints to the part design, mainly related to overhang regions, feature size and ease of powder removal. For additively manufactured parts with conformal cooling channels, such constraints may be easily overcome by adhering to a few design guidelines, which have become well-established over the years.

The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

In the late 1800s, a new technology — Swiss-type machines — emerged to serve Switzerland’s growing watchmaking industry. Today, Swiss-machined parts are ubiquitous, and there’s a good reason for that: No other machining technology can produce tiny, complex components more efficiently or at higher quality.

In addition, when using AM directly on a section of the final machined geometry, the costly cutting operation needed to remove the insert from the build platform is eliminated. This combination of subtractive and additive technologies – which is proving cost-effective – results in what is now commonly referred to as a hybrid part.

Mitsui Seiki USA Inc. appoints Joseph Farkas as its director of sales West and Terry Ritterbush as its director of sales East.

In Fig. 7, we can observe the temperature inside the ‘outer channels’, which transport the coolant in the insert. In this image, the latter is located in the middle in a grey colour. We can already see a colder temperature inside the channels, but also more homogeneity between the conventional approach and the conformal approach.

Once the part is built (Fig. 13), final machining operations are required to achieve the expected surface roughness on the final geometry. A first programming stage is performed to generate the tool path for the surface finishing of the required area. A real benefit here is 3D Systems’ Cimatron® software, which provides the technology user with a seamless transition between AM and post-machining.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Chiron Group combines the best of both worlds at IMTS 2024, featuring live demonstrations of their Micro5 and Mill 2000 machines, alongside a cutting-edge virtual showroom. This innovative approach allows visitors to explore Chiron’s full product lineup without the logistical challenges of transporting large equipment.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

McArthur’s “faster” motto mitigates the thermal issues that often plague plastic operations. This is because plastic — in this case, ultra high molecular weight (UHMW) polyethylene — often has significant problems during milling operations. The melting point is around 260°F, and thermal expansion happens rapidly. If the feed rate were too slow, the material could build up around the cutting edge and start to melt back together. These blobs and hanging bits of melted plastic interfere with the cut and lead to even greater heat buildup, compounding the problem. Running without coolant also promotes faster chip evacuation with the plastic material.

McArthur used a 0.25", 3-flute carbide end mill with a 0.030" corner radius for all operations on this part, from roughing to finishing. The rounded end of the bit enabled chamfering operations without changing the tool. A final cycle time of 37 minutes made this a profitable part for the shop.

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

Plastic machining requires thinking differently than machining other materials, but McArthur has a simple approach: “I treat it like aluminum, but faster.” Asked for more specifics, he cites the following principles as key to plastic milling success:

The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

When cutting any kind of plastic, a brand-new tool is best. This ensures that the material will not absorb any additional friction as result of a dull cutting edge.

Understanding all the things that contribute to a machine’s full potential accuracy will inform what to prioritize when fine-tuning the machine.

As a last step, the AM build was performed in 3D Systems’ LaserForm® Maraging Steel – a proven material for the mould and die sector thanks to its wear resistance – on a DMP Flex 350 machine.

By enabling the generation of conformal cooling paths within inserts, the adoption of AM in the mould and die sector has repeatedly been proven as an effective way to enhance the yield of moulding processes in terms of both productivity and part quality. This is confirmed by the application case study from TK Mold, and its now firmly established use of AM mould inserts in everyday production.

In this webinar, industry-leading experts will demonstrate how additive manufacturing can revolutionize your operations and answer the question: Can you afford not to? From rapid prototyping to robust fixturing and specialized custom tooling, it’ll showcase the diverse applications that can drive your business forward in a time where cost and time saving can be crucial. Discover how to reduce costs, accelerate production cycles and achieve unparalleled design freedom through the strategic integration of 3D printing technology. Phillip’s panel of seasoned professionals will share real-world examples and practical insights to help you understand the potential of additive manufacturing. Learn how to overcome production challenges, improve product quality and gain a competitive advantage. It will explore the cost-benefit analysis of 3D printing — including material and labor savings — as well as the potential for increased revenue. Join this webinar to discover why additive manufacturing is no longer a luxury, but a necessity for success. Agenda:  Prototyping example: quick-change prototype Custom tooling real-world example: press brake, tube bending die CMM fixturing and workholding example: CMM fixture and soft jaw

Considering that this case represents just one application, and that TK Mold can use this technology for many moulds and produce them at multiple locations at the same time, AM is very quickly paying for itself. As a result, TK Mold is now operating its AM machine at a very high capacity, in order to meet the demand for various optimised inserts.

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

3DXpert includes tools such as the ‘heat map’, which allows designers to quickly evaluate the homogeneity and efficiency of the cooling. This does not replace more complete rheology simulations, but allows the user to quickly assess the design quality early in the process.

Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

The plastic part was a good candidate for Optirough in part because it has features and faces at different heights, McArthur says. Such geometry facilitates aggressive roughing between the features using as much of the tool flute as possible. For this job, McArthur was able to maintain a 1.125" depth of cut with a 10% step over. Reducing passes is a common way that NTL Industries seeks to make their processes more efficient, “How can I create this part with the smallest number of passes to get the shape I need?” McArthur asks.

Join thousands of other AM professionals and get the latest industry news, deep dive articles and more, to your inbox.

Additional considerations are the cost savings that are available due to improved productivity by reducing the hourly cost of machine use and increased flexibility in terms of machine capacity. Due to the improvements in thermal homogeneity and the reduction or elimination of hot spots, TK Mold also improved repeatability and final part quality, thereby reducing these waste costs while better satisfying its end customer.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

In some cases, saying “yes” involves working with whatever material the customer specifies, even if it falls outside the norm. One recent example was a small plastic part for the automotive industry. The size and shape of the part didn’t immediately lend itself to a fast cycle time, but McArthur was confident that he could make it a profitable part.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

Reach a truly international audience that includes component manufacturers, end-users, industry suppliers, analysts, researchers and more.

In conclusion, for the mould and die as well as other sectors, a whole ecosystem has to be considered, encompassing software, AM and subtractive machines, materials, automation and tooling solutions. These must be efficiently combined and integrated to drive design and manufacturing costs down, thus allowing AM technology to express its full potential as an industrial process.

Join Mahr for an informative webinar to discover the latest advancements in precision measurement, designed to elevate your quality assurance processes and unlock peak productivity. It'll explore cutting-edge technologies — such as modern height gages and contour measuring systems — along with their applications, benefits and technical capabilities. Discover the power of height gages: Learn how intuitive and sophisticated height gages can revolutionize your measurement processes, enabling quick and accurate results in inspection and production areas. Explore the practical functions and ease of use that make height gages an ideal solution for manufacturers seeking high-performance and reliable measuring technology. Examine sample applications and industries where height gages excel, such as qualifying first parts, inspecting incoming parts and measuring series of parts in industries like aerospace, automotive and medical. Unlock efficient contour measurement: An introduction to the latest contour measuring technologies that enable fast, simple and comprehensive contour measurement in the production environment. Discover how these innovative solutions ensure reliable measurements, saving time and increasing efficiency while measuring a wide range of workpieces. Learn how to streamline your contour measuring process with speed and simplicity, achieving fast and precise measurements with incredible versatility. Register now and discover how to unlock peak productivity with new innovations in precision measurement. Agenda: Insights into the latest precision measurement technologies and their applications Understanding of how to improve quality assurance processes and increase productivity Knowledge of how to select the right measurement solutions for your specific needs Tips on how to optimize your measurement processes for maximum efficiency

The challenges of this type of packaging component are quite common, and the number of similar applications is infinite. Concerning this application, TK Mold faced three critical manufacturing challenges:

Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

The way a G-code program is formatted directly affects the productivity of the CNC people who use them. Design CNC programs that make CNC setup people and operators’ jobs easier.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.

Additive Manufacturing has proven to be a valuable solution for the optimisation of the cooling process, because it allows for the creation of cooling channels that closely follow the moulding surface – this is known as conformal cooling. These moulding surfaces can be highly complex and are therefore difficult to cool. AM enables the design and manufacture of parts that incorporate cooling channels that would be impossible to produce using conventional manufacturing technologies.

Although the benefits of AM for efficient cooling are well-documented and have often been presented, adoption has been slow due to initial concerns about material properties, costs, and a lack of knowledge on how to apply the technology in a market segment that is often regarded as quite traditional. In addition to the fact that mould makers are often risk-averse, they are generally under tremendous pressure to manufacture injection moulds at the lowest price possible. The use of additively manufactured inserts in moulds offers significant benefits, but also comes with additional costs. Mould manufacturers must, therefore, demonstrate the value of the additional investment to the final customer. This is clearly illustrated by the fact that adoption of conformal cooling has been higher in companies which manage both mould production and injection moulding. These companies fully understand the value, and actively incorporate AM into their manufacturing workflow, demonstrating return on investment (ROI) and increasing their use of the technology as they further master the process.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

When it comes to presenting a review of the world's largest international exhibition for AM, one can go about it in two ways: very broad generalisa...»

In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes.  All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

Standards for surface finishes and profiles are not static; they change as technology changes or new processes come along that need to be considered.

In this webinar, CloudNC Co-Founder Theo Saville reveals how U.S. machine shops are using cutting-edge AI today to accelerate their CNC machining, helping them become more efficient and save over 1,000 production hours per year. Theo will demonstrate CAM Assist, an AI solution that automates CAM programming within existing CAD/CAM platforms — and even provides working physics-based cutting parameters for your existing toolsets. Attendees will learn how the technology has developed, its current capabilities and applications, and how it is expected to progress in the near future. Agenda: How U.S. machine shops are using AI tools to automate their CAM programming and increase their productivity and efficiency How AI tools can help fill the CAM programming skills crisis What tasks AI can be successfully applied to today and what the future holds How AI can fit into machinists' workflows today without specialist training Advanced applications, such as setting cutting parameters and soft jaw fixtures with AI

FABTECH 2024 will be held October 15-17, 2024, in Orlando, Florida, at the Orange County Convention Center. FABTECH provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, discover innovative solutions, and find the tools to improve productivity and increase profits. There is no better opportunity to network, share knowledge and explore the latest technology, all here in one place. Future U.S. Show Dates and Locations 2025 – September 8-11 at McCormick Place in Chicago, IL 2026 – October 21-23 at Las Vegas Convention Center in Las Vegas, NV 2027 – September 13-16 at McCormick Place in Chicago, IL

The choice between buying a new machine or refurbishing the current one will become clear after a thorough assessment of the machine.

Refined machines at EROWA are handling heavier loads, while its precision workholding enhances stability and rigidity.

To overcome this issue, GF Machining Solutions and 3D Systems have developed a software solution that leverages the power of the meltpool monitoring hardware available on the partners’ DMP series of metal AM machines. In machines such as the DMP Flex 350, DMP Monitoring in-process monitoring software acquires meltpool data during the build process to detect potential defects such as lack-of-fusion pores.The DMP Calibration tool function exploits this light-sensing monitoring hardware for another purpose: scanning preforms to identify pre-machined locating holes in the part surface. The contrast in light reflection between the part surface and such holes allows for an extremely reliable method of establishing the precise location of the preform on the build platform (Fig. 9).

As the part is produced in large series, the packaging and the support must also be produced in large series. The challenges therefore relate to cost and productivity. As the final product is considered a high-value item, there are also requirements in terms of the support’s aesthetics.

TK Mold applies AM to produce mould inserts where conventional subtractive machining is unable to achieve the necessary quality and productivity at a reasonable cost. The example presented here is common in the packaging sector – particularly for products linked to the information and communications technology (ICT) industry. Used as an element of the packaging box of a smartwatch, the plastic part is the support for fixing the watch inside the box (Fig. 2).

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Additionally, some traditional design considerations for the mould-making sector are still valid in the case of additively manufactured moulds and dies. These mainly concern the minimum distance of channels from part walls for structural resistance, as well as the pressure drop throughout the whole channel path, and ease of cleaning (both mostly influenced by the channel section size, path and number of branches). Leakage is not an option. In these cases, the minimum distance should be large enough to safely process and post-process the mould. Thus, from the design phase, risks can be greatly reduced.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

Fryer Machine Systems Inc. presents its TC Series of CNC machining centers for high-performance cutting, accuracy, reliability and ease of use.

Nesting parts for fabrication, woodworking or soft goods production saves money by optimizing material usage and reducing waste. NestingWorks is a SolidWorks add-in that can be used independently for nesting or in combination with your integrated CAM software to create CNC programs for machining of the nested sheets of parts. It automatically flattens parts and includes several advanced options to save you time in CNC programming. Join this webinar to experience the benefits of integrated nesting software. Agenda: See how integrated nesting uses full associativity with SolidWorks and automatically nests parts, assemblies and folders of parts Learn how integrated nesting provides true shape nesting, part-in-part nesting, user-specified grain direction and layouts for parts with varied thickness Watch a demonstration to see how integrated nesting produces the maximum number of parts from a single piece of raw material in a matter of minutes

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

NTL Industries Inc. serves a wide range of industries but is pushing its product development into the motorsport industry. With each new job, the shop is quick to equip itself with machines and tooling that keep it ahead of the competition.Photo Credit: Jeannie Skirpan, NTL Industries Inc.

Chiron Group combines the best of both worlds at IMTS 2024, featuring live demonstrations of their Micro5 and Mill 2000 machines, alongside a cutting-edge virtual showroom. This innovative approach allows visitors to explore Chiron’s full product lineup without the logistical challenges of transporting large equipment.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

Modern Machine Shop is the leading publication and media brand in North America devoted to CNC machining. MMS combines unprecedented editorial access to manufacturing facilities with decades of experience to provide long-form content that is both insightful and impactful. About Us

From quadruped robot dogs, to an in-booth putting green where you can test out a new golf putter, to a 3D-printed car and more, attendees enjoyed cutting-edge technology and innovations all week long. Take a look to see what (or who!) you might have missed this week!

Did you know that the show was postponed for WWII? Or that McCormick Place was expanded in the ’70s just to accommodate IMTS? A fascinating look at the show’s history from 1927 to today.

While the Norwegian market for Additive Manufacturing has long revolved around prototyping and polymer materials, metal Additive Manufacturing has ...»

The injection data collected in Fig. 14 show that the total injection cycle time varies between 21.70 and 21.79 seconds with a traditional insert. With the optimised insert, the cooling time of the plastic is reduced and cycle times stabilise between 16.98 and 17.01 seconds. This represents a significant cycle time reduction of 22%.

Effective team collaboration is a critical component of success in today’s manufacturing world. With cloud-based technologies that make it easy for team members to brainstorm and problem solve remotely from various locations, design-to-manufacturing processes can become faster and more efficient. This webinar will demonstrate how fully integrated CAM software can be utilized with 3DExperience SolidWorks in a seamless work environment to accelerate product development. Agenda: See how HCL CAMWorks can be used as an add-in for all SolidWorks applications working with the cloud-based 3DExperience platform Learn how fully integrated CAD/CAM saves significant amounts of time during the design to manufacturing process Gain a new understanding of how software can connect users worldwide to accelerate product development Watch a demonstration of team collaboration using platform tools in the CAD/CAM software environment

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

McArthur also cites Mastercam’s Optirough tool paths as critical to making this plastic part a profitable part. This strategy improved cutting efficiency by engaging a larger portion of the end mill’s length, thereby avoiding concentrating wear at the tool tip.

Before starting to build a mould insert in an AM machine, performing rheology thermal assessments is often done to detect where potential issues may arise. This makes it possible to interpret whether the optimised channels will be effective, particularly whether there is a need to improve the temperature homogeneity to reduce hot spots (Fig. 6).

GF Machining Solutions and 3D Systems have partnered to develop an end-to-end solution that enables manufacturers to more efficiently produce complex metal parts. This is accomplished by seamlessly integrating metal AM into existing manufacturing processes through the development of an optimised workflow. Here, each step of the workflow is illustrated as it applies to the custom solution created for TK Mold.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

Injection moulding is, without a doubt, one of the most widely-used and successful manufacturing processes. It is most commonly applied to the production of thermoplastic and thermosetting polymer parts, using moulds manufactured from steel alloys, which allows for, in many cases, millions of injection cycles in serial production. The process entails injecting molten material into a cavity shaped like the final part, followed by rapid cooling to ensure hardening. The cooling time must, however, be sufficient for the part to properly solidify so it can be ejected with limited deformation. The cooling aspect of the injection cycle is, therefore, a key factor in achieving high-quality parts while keeping the cycle time efficient. Cooling of the mould insert is achieved by circulating a cold fluid (typically water or oil) through the mould to cool the mould surface.

Learn more about the variety of technology and machinery Hwacheon Machinery America, Inc. is featuring at its IMTS 2024 booth.

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

In Fig. 8, we can analyse and compare the potential hot spots during injection with or without conformal channels. Here again, we observe a decrease in the temperature of the hot spots, going for example from 96°C to 86°C. Most important is the much more even temperature gradient, which is the critical factor influencing the quality of the part in terms of warpage and distortion. In this specific case, a productivity increase is the main goal, but customers are always looking for quality improvements.Today, these simulations are more reliable as rheology models have improved, taking cooling geometries into consideration; this type of data was previously not easy to simulate.

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

Manufacturers continue to feel the pressure to reduce costs, increase efficiencies and meet their sustainability strategies. As the industry evolves to keep pace with these priorities, there are opportunities within metalworking processes to use less resources with advanced lubricants and technical expertise. Agenda:  An overview of metalworking lubrication Evolutions in metalworking lubrication Experience on the shop floor Key takeaways

Moreover, as this case study demonstrates, for companies to fully grasp the end-to-end value offered by this disruptive manufacturing technology, and thus quickly achieve ROI, AM should not be evaluated as a ‘stand-alone’ process. For the technology to shift to the full industrial scale, its integration with conventional, well-established manufacturing processes is crucial; a complete workflow approach, from design to final part, is required.

Sunnen Products Co. is celebrating its 100th anniversary, highlighting the history of its line of honing and precision solutions.

The simulation tools allow the designer to better predict the real-life efficiency, and thus more confidently design, the conformal channels placed inside the mould insert. It theoretically validates that the channels will have a positive impact on the injection process and, ultimately, on the plastic part. TK Mold uses these types of tools to demonstrate the added value of conformal cooling to its customers (internal or external) before the manufacturing of a mould.

The generation of conformal cooling paths in adherence to the above design guidelines may quickly become very time-consuming with traditional computer-aided design (CAD) software tools. For this reason, a dedicated software solution such as 3DXpert®– and particularly its Additive Moulding Add-on – is very helpful for mould designers and tooling manufacturers in optimising part quality and reducing design and manufacturing costs.This add-on makes it possible to create conformal cooling inserts and to combine traditional and conformal cooling where appropriate (Fig. 4). This is made possible by a unique set of functionalities that save the user hours of design work before moving to the simulation-based verification and validation stages of the mould design:

With thirty-seven years of mould design and fabrication experience, the company is dedicated to providing the best performance injection mould solutions and final plastic parts. As both a mould maker and a parts producer, the company quickly grasped the advantages of metal AM and invested in it to develop mould inserts with conformal cooling channels. TK Mold’s mould-making and injection capabilities uniquely position the company to benefit from using these inserts to produce final parts – the benefits include productivity and quality gains, as well as the ability to deliver more efficient solutions to its customers.

To demonstrate the benefits AM can bring to the injection moulding process, this article reports on how TK Mold, a customer of GF Machining Solutions’ subtractive and additive systems headquartered in Shenzhen, China (Fig. 1), is using Laser Beam Powder Bed Fusion (PBF-LB) technology and, specifically, how workflow optimisation was able to support the business case for AM mould inserts with conformal cooling.

Structured light scanning is used to create a digital twin of a manufactured part, but we must understand the measurement reproducibility to best use the data.

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

User-friendly inspection software for CNC machining centers is shown monitoring measurements between and after machining while performing SPC based on recorded measurement values.

Metal Additive Manufacturing is on a long journey, from the early technology concepts of several decades ago to its current usage in a relatively s...»

Automation is no longer a luxury in manufacturing today – it’s a necessity. The Automated Shop Conference (TASC) will connect job shops with experts who offer advice and considerations for this process.

Thanks to their expertise in multiple fields and processes, GF Machining Solutions and 3D Systems are able to offer industrial solutions that make this possible. Their joint offering is further enhanced by the availability of dedicated products and tools, such as the Additive Molding module of 3D Systems’ 3DXpert software for the design and analysis of conformal cooling channels, and the DMP Calibration tool offered with the DMP machine series for the manufacturing of hybrid parts through the automated, user-error-free alignment of preforms and substrates to the highest accuracy inside the AM machine.

Incremental mode can be more advantageous when programming sculptured surfaces or for certain hole-machining canned cycle applications.

Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.

With AM, cooling channels can be set at a constant distance from the surface of the part to achieve uniform cooling, and deliver two main advantages:

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

ANCA CNC Machines is celebrating its 50th anniversary as a global producer of CNC tool and cutter grinders.

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

First, the size and shape of the internal channels have design constraints. Large overhanging regions require support structures that are impossible to remove from the inside of the part after Additive Manufacturing. Channel diameters are thus constrained in size and self-supporting channel shapes (such as diamond, elliptical, or teardrop, among others) are preferable to the traditional round cross-sections typical when straight-drilled holes are used by traditional methods (Fig. 3).

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

With a business model sketched out on a napkin at the start of 2017, Greg and Shelly McArthur dedicated their home garage to a new business venture: a CNC machine shop. NTL Industries Inc. would be Greg’s opportunity to take everything he had learned in his 20 years of CNC machining experience and make a go at running his own business from the ground up.

To improve the process, TK Mold’s engineers focused only on the improvement of the most critical mould inserts: those with the most influence in terms of cycle time or part quality. This is where the ROI in metal AM is the highest.

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Sustainability has risen to the top of the global manufacturing agenda. Whilst metal AM has long been considered a green technology because of its ...»

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

At the seminar, representatives from multiple companies discussed strategies for making orthopedic devices accurately and efficiently.

Milling plastic can pose a variety of challenges, but keep a few principles in mind and quality parts will follow.

OptiRough is well suited for tall parts with significant horizontal steps. Deep, optimized cuts with a consistent chip load save machining time and reduce tool wear. Solid verification of the process not only lets the user check the results, but provides a solid model reference for the finish tool paths to work from.  Photo Credit: Mastercam

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

Lastly, the use of dedicated tooling and fixtures, such as those from GF Machining Solutions’ System 3R unit, allows the hybrid parts built in the DMP machine to undergo all the necessary post-processing operations with reduced setup and changeover times, thanks to the standardised part interfaces being compatible with multiple machines.

After a year in the garage shop, the shop had the opportunity to upgrade to a larger space in Sterling Heights, Michigan. The move to the new facility was built on a culture of saying “yes” to as many RFQs as possible.

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

Q-Mark has built its metrology business by providing what customers need, when they want it. This goes for its IMTS booth, too, with free drinks alongside custom technology.

Unlike many AM applications, here the manufacturing process begins with the machining of the preforms. In this case, the outer geometry of preform is typically produced by cutting a blank plate with wire electrical discharge machining (EDM). Ejection holes and cooling channels are, on the other hand, previously machined in the blank by deep-hole drilling. It is crucial that all preforms are identical in terms of height, since the Additive Manufacturing process must be conducted on a level plane.Beginning the process with subtractive machining, however, introduces new positioning and referencing challenges. This type of hybrid process must therefore start with the preform fixed on the build platform before the intended AM section is aligned by using a referencing system. The use of this type of referencing is especially challenging because, unlike in CNC machining, in an AM machine there is no physical link between the optics and the target substrate.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Established in 1983, TK Mold is a subsidiary of TK Group (Holdings) Limited, a well-regarded manufacturer of plastic moulds and parts for a variety of industries including healthcare and consumer goods. TK Mold manufactures plastic moulds and parts for mobile phones, healthcare applications, smart homes, packaging and precision electronics. In addition to its Shenzhen base, TK Mold has three other factories in Suzhou and Huizhou, China, and Braunschweig, Germany.

JD Machine, 2024’s Top Shops Honoree in Human Resources, embodies its “Education for Life” core value with a robust apprenticeship program and significant continuous improvement efforts.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Succeeding in aerospace manufacturing requires high-performing processes paired with high-performance machine tools. IMTS can help you find both.

Once the program is ready, the insert is clamped inside a Mikron MILL S 400 U Milling machine from GF Machining Solutions. This product is well-established in the mould-making industry and enables a perfectly homogeneous surface finish. The excellent mould surface quality is particularly valuable for plastic parts with a final transparent finish, where flaws can be easily visible. Mirror surface finishing also reduces the need for hand polishing of mould components, reducing lead time. The square sections of the ejector pins required a milling operation (3+2 pre-machining) and a final grinding operation.

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

SSP’s commitment to adopting the latest machining technology benefits not only the business, but its employees as well.

Instead, manufacturers generally have to rely on visual alignment or external coordinate measuring machines (CMMs) to confirm positioning accuracy. Both techniques are time-consuming and, in the case of simple visual alignment, prone to operator error. With variances in excess of 100 µm, these techniques are also unable to provide the accuracy required for most final applications.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

Zoller’s open house in Ann Arbor, Michigan, provided attendees with a glimpse of the connectivity and efficiency the company’s products offer to users.

If you want to streamline production and be competitive in the industry, you will need far more than a standard three-axis CNC mill or two-axis CNC lathe and a few measuring tools.

Horn USA’s new booth concept is designed to enable attendees to (literally) get a better feel for its various tooling offerings.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

The right tool path enabled milling the entire part with a single end mill in three setups and 37 minutes on a 3-axis mill.  Photo Credit: Jeannie Skirpan, NTL Industries Inc.

With user-defined threshold values, this referencing process offers exceptional repeatability and accuracy without any risk of human error. Furthermore, the use of the laser enables the referencing of multiple parts on the same build platform in a single operation, further accelerating high-volume production. Thanks to this optical system’s exceptional level of accuracy, the final quality of the referencing operation, and thus of the resulting hybrid parts, is higher as well.

Aerospace machining is a demanding and competitive sector of manufacturing, but this shop demonstrates five ways to find aerospace success.

TK Mold uses the above-described process and equipment to produce high-quality hybrid parts, and manufactures around 90% of the moulds requiring AM-enabled conformal cooling by this method. As an example, the hybrid mould insert object of the smartwatch packaging support was achieved from a preform obtained by wire EDM in two different positioning steps. Each preform was then clamped onto the System 3R interface plate ‘AM Carrier’, mated with the DMP machine (Fig. 10). Here the DMP Calibration tool was exploited to correctly reference each preform independently through its set of two locating holes, automatically calculating and applying both translation and rotation corrections to the job file (Fig. 11).

Wingman is powered by a secure AI model developed to extract critical information from quote packages so that estimators can work faster, automate administrative aspects of setting up quotes and minimize the risk of missing important details.

Surface and sub-surface porosities are particularly critical for mould and die applications, as they may emerge on the part cavity walls after their subsequent machining, leading to defects on the moulded product; moreover, they may be greatly detrimental for the lifetime of the mould/die, constantly undergoing thermal fatigue while being in operation. Thanks to a finely tuned laminar argon flow, the DMP Flex 350 ensures a high removal rate of fumes which are the main driver of inconsistent density (Fig. 12).

Misapplication of these important CNC features will result in wasted time, wasted or duplicated effort and/or wasted material.

While AM technology is helping many companies in the mould and die sector achieve new cost savings and efficiencies through conformal cooling, the economic viability of many applications requires other approaches. Indeed, for structural reasons, these applications typically include parts that require large amounts of mould material – in the case of AM, metal powder. This can make large parts costly to manufacture, as an AM insert’s price will be directly linked to the volume of material required for the AM process.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

While the adoption of AM is increasing, many manufacturers are still reluctant to take this step. One of the biggest challenges in using AM is the need to integrate the new process into manufacturing workflows built on well-established, mature manufacturing technologies. In particular, in the mould-making segment, additively manufactured components and inserts require – in nearly all cases – additional subtractive machining operations to achieve the very high surface quality required on the mould surface.

The consequences of this productivity gain are multiple. TK Mold was able to increase its production from 189,788 pieces to 242,250 pieces produced per month, equating to an increase in monthly revenue from this application of RMB 92,871, or approximately €12,000.

Such a solution can also help companies to meet demand without needing to invest in additional new moulds. According to TK Mold, the ROI on the production of this insert by AM is very attractive and, in this specific case, was achieved in fewer than twenty-six days of production.

Once the optimised insert is finished, it replaces the conventional insert inside the mould, and the injection process can begin. This article’s observations focus on two elements: cycle time and part quality. The first element influences productivity and the second element influences waste costs.

Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.

Ceratizit USA announces it has appointed Carlos Garza as its business development leader for the oil and gas industry sector.

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

Walter USA has acquired PDQ Workholding, intending to strengthen its offering of workholding products and develop future cutting tool sales.

As a result, manufacturers expect metal AM providers’ solutions to cover the complete workflow, from design to final part, to deliver moulds that meet precise specifications. Software, AM machines, materials, subtractive technologies, automation and clamping solutions must be combined to provide an efficient ecosystem to drive down costs and complexity.

To overcome these challenges and find ways to profitably integrate this new technology into their operations, manufacturers can pre-machine a so-called preform and then, using AM, produce a portion of the part with value-added features in the location where the technology can prove most beneficial.

So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?

When revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.