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Bağmancı, M. et al. Wideband metamaterial absorber based on CRRs with lumped elements for microwave energy harvesting. J. Microw. Power Electromagn. Energy. 52, 45–59 (2017).

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.

Hyun, W. J., Secor, E. B., Hersam, M. C., Frisbie, C. D. & Francis, L. F. High-resolution patterning of graphene by screen printing with a silicon stencil for highly flexible printed electronics. Adv. Mater. 27, 109–115 (2014).

where n is the refractive index, \({\eta }_{0}\) is the impedance of free space (air), d is the thickness of the non-magnetic dielectric, and \({k}_{0}\) is the wave number in free space. With the concept of equivalent circuit model, the total impedance value of the whole absorber structure can be calculated with the following equation:

Huang, Y. et al. Optimization of flexible multilayered metastructure fabricated by dielectric-magnetic nano lossy composites with broadband microwave absorption. Compos. Sci. Technol. 191, 108066 (2020).

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In particular, Dr. Schoop and I focus on the difference between physical vapor deposition (PVD) and chemical vapor deposition (CVD) coatings. PVD is a line-of-sight process allowing for a thinner coating and therefore a sharper edge. CVD produces a thicker coating more effective as a thermal barrier.

Confocal laser microscope measuring results of the resistive double square loops filled with the conductive ink machined by the planing process. (a) 3D image of ink surface after removing the overflowed conductive ink, (b) roughness profile of the ink surface after removing the overflowed conductive ink.

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.

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.

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

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Fan, M., He, Z. & Pang, H. Microwave absorption enhancement of CIP/PANI composites. Synth. Met. 166, 1–6 (2013).

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

Grbic, A. & Eleftheriades, G. V. Experimental verification of backward-wave radiation from a negative refractive index metamaterial. J. Appl. Phys. 92, 5930–5935 (2002).

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

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.

A typical metamaterial absorber is composed of a metal-backed dielectric layer and a top resistive layer. The impedance of the metal-backed substrate can be calculated with the following equation:

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!

Why are cutting tools coated? Most would say it is to protect the tool. That answer is true as far as it goes, but the function of the coating is more varied and more specific than that. In this video, I get to talk about coatings with Julius Schoop, Ph.D., machining expert with the Cincinnati-based manufacturing consulting firm TechSolve. (Actually, he is now formerly with TechSolve—he accepted a university professor position while this video was in production.)

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."

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.

As a second step, machined double square loop arrays on the surface of PMMA were filled with conductive carbon ink by the inking process. The most important factor in the inking process was the sheet resistance of conductive carbon ink. If the sheet resistance was different from the target value for generating electromagnetic field, the bandwidth of radar absorption could be changed or the performance of the RCS reduction could be degraded. The sheet resistance of the conductive carbon ink used in this experiment was controlled by mixing polymers of conventional carbon ink and silver paste with a solvent of thinner. Properties of the conductive carbon ink, the silver paste, and the developed conductive ink are presented in Table 2. The conductive carbon ink was GST 4500 manufactured by SunChemical Co. in the USA. It had a sheet resistance of 50 Ω/sq at 25 μm. The silver paste was p-100 manufactured by CANS Co. in JAPAN. It had a sheet resistance of 4 × 10–8 Ω/sq at 25 μm. In order to achieve designed sheet resistance, conductive ink, silver paste, and thinner were mixed as a ratio of 47.5:1:1. The mixed conductive carbon ink had sheet resistance of 15 Ω/sq at 25 μm.

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

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 planing process for removing the conductive carbon ink applied over the PMMA workpiece and the machined workpiece after removing the over filled ink.

Liu, T. & Kim, S.-S. Design of ultra wide-bandwidth double-layer electromagnetic wave absorbers with square-loop frequency selective surfaces. Microw. Opt. Technol. Lett. 60, 2013–2018 (2018).

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.

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).

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.

Conceptualization, T.J.Je., J.S.Han., E.c.Jeon., J.Y.Jeong.; Machining process, J.Y.Jeong., T.J.Je.; Inking process, J.S.Han., J.R.Lee.; Design of microwave absorber; H.J.Park., J.K.Jung., J.H.Shin.; Measuring machined pattern, J.Y.Jeong., J.R.Lee., D.S.Choi.; Measuring RCS reduction of microwave absorber, E.c.Jeon., H.J.Park., J.K.Jung., J.H.Shin.; Writing-original draft preparation, J.Y.Jeong., H.J.Park.; Writing-review and editing, J.Y.Jeong., J.S.Han., T.J.Je., J.H.Shin.; Supervision, J.S.Han., T.J.Je.; Project administration, D.S.Choi.; Funding acquisition, D.S.Choi. All authors have read and agreed to the published version of the manuscript.

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article's Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article's Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Li, W. et al. Broadband composite radar absorbing structures with resistive frequency selective surface: optimal design, manufacturing and characterization. Compos. Sci. Technol. 145, 10–14 (2017).

where \(\eta\) is the impedance of the whole absorber structure and \({\eta }_{r}\) is the impedance of the top resistive layer. The required impedance value of the top resistive layer can be calculated for the specific frequency range with the predetermined value of thickness and the dielectric index. The strategy to attain the required impedance value is very wide. Various designs including cross, ring, and patch for the resistive layer have been reported. We selected double square loop arrays and designed to have different sheet resistance for each square loop in order to confirm the performance of the developed manufacturing process due to high degrees of freedom in its shape, including length, width, and depth of each loop.

Advanced Cutting Tools Research Team, Daegu Mechatronics and Materials Institute (DMI), Daegu, 42714, Republic of Korea

Hao, S. et al. Broadband microwave absorber by direct drawing metamaterial on paper. In 2019 International Conference on Microwave and Millimeter Wave Technology (ICMMT) (IEEE, 2019). https://doi.org/10.1109/icmmt45702.2019.8992265.

The micro-end-milling system for engraving of double square loop arrays on the PMMA workpiece and the cutting tool of TiAlN coated solid carbide.

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.

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

Padilla, W. J., Basov, D. N. & Smith, D. R. Negative refractive index metamaterials. Mater. Today 9, 28–35 (2006).

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

Liu, T. et al. RCS Reduction of waveguide slot antenna with metamaterial absorber. IEEE Trans. Antennas Propag. 61, 1479–1484 (2013).

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

Ling, F., Zhong, Z., Huang, R. & Zhang, B. A broadband tunable terahertz negative refractive index metamaterial. Sci. Rep. 8, 1–9 (2018).

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.

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

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

Microscope images of cutting tools before and after machining: (a) before machining and (b) after machining of the 144th double square loop.

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

Structural design of the microwave absorber with resistive double square loop arrays. (a) Top view of unit-cell, (b) cross-section of the unit-cell, (c) full structure of the microwave absorber.

Singh, G. et al. Fabrication of a non-wettable wearable textile-based metamaterial microwave absorber. J. Phys. D Appl. Phys. 52, 385304 (2019).

This new quick-change tooling system enables shops to get more production from their Swiss turning centers through reduced tool setup time and matches the performance of a solid tool.

A schematic diagram showing the developed manufacturing processes for microwave absorber with resistive double square loop on a PMMA.

Rosenblatt, G. & Orenstein, M. Perfect lensing by a single interface: defying loss and bandwidth limitations of metamaterials. Phys. Rev. Lett. 115, 195504 (2015).

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

Landy, N. I., Sajuyigbe, S., Mock, J. J., Smith, D. R. & Padilla, W. J. Perfect metamaterial absorber. Phys. Rev. Lett. 100, 207402 (2008).

Colombi, A., Roux, P., Guenneau, S. & Rupin, M. Directional cloaking of flexural waves in a plate with a locally resonant metamaterial. J. Acoust. Soc. Am. 137, 1783–1789 (2015).

Momeni-Nasab, M., Bidoki, S. M., Hadizadeh, M. & Movahhedi, M. Ink-jet printed metamaterial microwave absorber using reactive inks. AEU Int. J. Electron. Commun. 123, 153259 (2020).

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

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.

where Ra,e is the average surface roughness machined by the micro-end-milling process, ft is the feed per revolution, nt is the number of teeth on the end-mill, and D is edge diameter of the tool. The plus sign means an up-milling process and the minus sign means a down-milling process. The up-milling process was applied to obtain excellent surface roughness as minimizing burr formation. The rotation speed of the cutting tool and feed per revolution were applied to 80,000 rpm and 9 μm/rev, respectively. The theoretical surface roughness under the above conditions was calculated to be about 12.3 nm.

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

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.

The machined surface by the planing process was measured using a confocal laser microscope (Keyence VK-X1000). Figure 11a shows a 3D image of the PMMA surface after removing overfilled ink. Linear lines were formed on the PMMA surface with an equal direction to the cutting direction. Figure 11b shows roughness profile of this surface. Ra,p is 38 nm which is close to the calculated value with Eq. (4). Figure 12a shows a 3D image of the carbon ink surface after removing the overfilled ink. Unlike the PMMA surface, the cured ink surface machined by the planing process was difficult to identify cutting lines. It was rougher than the PMMA surface. The Ra,p of this surface was 68 nm as shown in Fig. 12b, which was close to twice of the value shown in Fig. 11b. This result was caused by the fact that the perfectly cured ink was more fragile than the PMMA. It was also caused by the irregular surface structure because of mixing various materials. Although the machined surface of PMMA and the surface of the conductive ink were different, both surfaces showed excellent characteristics with an average roughness of less than 100 nm, which had less effect on the progress of microwaves. In addition, each array was completely filled and isolated without showing any residual ink on the surface. After the planing process as the final step, an absorption material for ultra-wide bandwidth microwave from C- to Ku-band (about 5–15 GHz) was fabricated by attaching a 160 μm of the adhesive-applied aluminum sheet as a reflection layer on the back surface of PMMA workpiece for oscillating of the microwave.

Jeong, JY., Lee, JR., Park, H. et al. Fabrication and characterization of resistive double square loop arrays for ultra-wide bandwidth microwave absorption. Sci Rep 11, 12767 (2021). https://doi.org/10.1038/s41598-021-91868-y

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

Tak, J. & Choi, J. A wearable metamaterial microwave absorber. IEEE Antennas Wirel. Propag. Lett. 16, 784–787 (2017).

Montgomery, D. & Altintas, Y. Mechanism of cutting force and surface generation in dynamic milling. J. Manuf. Sci. Eng. Trans. ASME 113, 160–168 (1991).

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

Wang, C. et al. Radar stealth and mechanical properties of a broadband radar absorbing structure. Compos. B Eng. 123, 19–27 (2017).

Department of Nano Mechatronics Engineering, University of Science and Technology (UST), Daejeon, 34113, Republic of Korea

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.

Figures 2 and 3 show the real part of the Ex field and Hz field distributions at the middle plane of the double square loop. In the simulation settings, a plane wave was normally incident on the absorber structure and the electric field was on the X direction. Figure 2 shows electric and magnetic field distributions for 5.7 GHz wave incidence. Figure 3 shows electric and magnetic field distributions for 12.7 GHz where the reflectance dips occur. As shown in each figure, two sides of the ring parallel to the external electric field showed inductive behaviors while others showed capacitive behaviors. Due to these resonant behaviors of conductive rings at different frequencies, high absorption can occur. Simulation results for reflectance of the absorber structure are shown in Fig. 4. The designed structure showed an absorption performance more than 80% at 4.7–14.3 GHz.

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda: Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

Jaiswar, R. et al. Inkjet-printed frequency-selective surfaces based on carbon nanotubes for ultra-wideband thin microwave absorbers. J. Mater. Sci. Mater. Electron. 31, 2190–2201 (2019).

Huang, X. et al. Calculations of a wideband metamaterial absorber using equivalent medium theory. J. Phys. D Appl. Phys. 49, 325101 (2016).

As the first step, a flat PMMA workpiece was mechanically machined using an ultra-precision micro-end-milling system. Figure 6 shows an ultra-precision machining system having a three-axis with 10 nm positioning resolution and air bearing spindle having a max rotation speed of 100,000 rpm. TiAlN (Titanium Aluminum Nitride) coated solid carbide with two flutes and a square end shape having a diameter of 400 μm was used as a cutting tool for strong wear resistance and lubrication ability. Cutting oil of ISOPAR-H was spread to the endmill using a mist nozzle to prevent built-up edge caused by the characteristic of PMMA that could easily stick to the cutting tool surface because of cutting heat.

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

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Fang, N. & Zhang, X. Imaging properties of a metamaterial superlens. In Proceedings of the 2nd IEEE Conference on Nanotechnology (IEEE, 0). https://doi.org/10.1109/nano.2002.1032233.

where Ra,p is the average surface roughness machined by the planing process, f is the cutting pitch, and R is the diameter of nose radius of the cutting tool. According to this equation, the roughness of the machined surface by the planing process was determined by the nose radius of the cutting tool and the cutting pitch. Since the nose radius of the cutting tool was a fixed variable, the cutting pitch was set to be 50 μm to have a theoretical surface roughness of 31.25 nm. Figure 10 shows the planing process to remove the overfilled ink on the PMMA workpiece. The overfilled ink was removed step by step as cutting depth was decreased from the highest position to the target thickness of 4 mm.

Figure 8a,b show cutting tools before and after machining of the 144th double square loop. Machinability of the cutting tool was remarkably decreased because the machined materials were adhered to the cutting edge. An ultrasonic cleaning method was additionally applied for removing the built-up edge on the cutting tool. The cleaning time was set to be 3 min after machining each of 24 patterns.

This presentation focuses on the vital role that linear and angular encoders play in ensuring precision in machine tools. Attendees will learn about the common challenges compromising accuracy, such as thermal expansion, mechanical misalignments and vibration. Whether you're an OEM, integrator, or machine operator, this webinar will offer valuable insights into optimizing CNC performance. Agenda: Challenges to CNC machine accuracy Understanding encoder technology How encoders address accuracy challenges

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.

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.

After experiencing process stalls in the finishing stage of production, Bryan Machine Service designed an air-powered twin spindle and indexable rotating base to effectively double its production of small parts.

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

Machining footage of different coatings in both roughing and finishing passes reveals how choosing the right coating can have a dramatic effect on the performance of the process.

Sarkhel, A. & Bhadra Chaudhuri, S. R. Compact quad-band polarization-insensitive ultrathin metamaterial absorber with wide angle stability. IEEE Antennas Wirel. Propag. Lett. 16, 3240–3244 (2017).

Liu, T. & Kim, S.-S. Design of wide-bandwidth electromagnetic wave absorbers using the inductance and capacitance of a square loop-frequency selective surface calculated from an equivalent circuit model. Opt. Commun. 359, 372–377 (2016).

Figure 9 shows machined PMMA workpiece with 144-member double square patterns (150 mm × 150 mm in width and 4.05 mm in thickness). Widths of the machined inner and outer patterns were about 772.18 μm and 1081.05 μm, respectively. Heights of the machined inner and outer patterns were about 22.05 μm and 30.35 μm, respectively. Their average surface roughness was about 55 nm. The surface roughness was larger than twice of theoretical value because factors such as vibration and machining environment were excluded from the theoretical formula. In consideration of these factors, we fabricated an excellent surface with an average roughness of less than 100 nm. Also, machined patterns were successfully fabricated within 1% of machining error compared to the target size through an optimized end-milling process.

Yoo, M., Kim, H. K., Kim, S., Tentzeris, M. & Lim, S. Silver nanoparticle-based inkjet-printed metamaterial absorber on flexible paper. IEEE Antennas Wirel. Propag. Lett. 14, 1718–1721 (2015).

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.

To characterize absorption properties, an RCS-measurement setup was constructed as shown in Fig. 14. A transmitting antenna with a focusing lens launched a Gaussian-like microwave beam to the target. A receiving antenna, also with a focusing lens, collected the reflected microwave from the target. These antennas were connected to a network analyzer. To evaluate the RCS reduction characteristics over a wide bandwidth, two sets of horn antennas, rated at 8.0–12.5 GHz and 12.7–18.0 GHz, respectively, were used.

Jaiswar, R. et al. A ultra-wideband thin microwave absorber using inkjet-printed frequency-selective surfaces combining carbon nanotubes and magnetic nanoparticles. Appl. Phys. A 125, 1–8 (2019).

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

Measuring results of engraved double square loop on the PMMA workpiece by the micro-end-milling. (a) A camera image of machined PMMA workpiece after the end-milling process, (b) top view of the outer pattern, (c) top view of the inner pattern, (d) depth profile of the outer pattern, and (e) depth profile of the inner pattern.

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.

Microscope images of the machined inner pattern: (a) the first inner pattern, (b) the 72nd inner pattern, and (c) the 144th inner pattern.

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.

Bhati, A., Hiremath, K. R. & Dixit, V. Bandwidth enhancement of Salisbury screen microwave absorber using wire metamaterial. Microw. Opt. Technol. Lett. 60, 891–897 (2018).

Department of Materials Science and Engineering, Korea Advanced Institute of Science and Technology (KAIST), Daejeon, 34141, Republic of Korea

Li, M., Muneer, B., Yi, Z. & Zhu, Q. A broadband compatible multispectral metamaterial absorber for visible, near-infrared, and microwave bands. Adv. Opt. Mater. 6, 1701238 (2018).

Optimized machining conditions are summarized in Table 1. Since the machining quality by the end-milling process can greatly affect the performance of microwave absorption, quality optimization of roughness, shape, and size accuracy is needed by optimizing machining conditions. Especially, burr has a significantly degrading quality of roughness and shape accuracy of the engraved pattern. Burr can be easily formed on the edge and machined surface in the first and finish cuts. Moreover, the volume of burr tends to increase as more materials are removed at one time37. For these reasons, in order to minimize burr formation, the depth of cut was set to be 5 μm for the first and finish cuts. The rough cut with a relatively low impact on the machining quality was applied to the remaining depth. Total cutting depths of each pattern were designed at 22 μm for the inner pattern and 30 μm for the outer pattern that included 5 μm of the planing margin. Theoretical surface roughness after the end-milling process can be calculated with Eq. (3)38.

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

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

Electromagnetic metamaterials can possess unique electromagnetic attributes that can be explained with unusual values of effective material parameters such as magnetic permeability and electric permittivity. Smith, Padilla, and others have proposed that a broad range of electromagnetic responses can be achieved by arranging conductive scatterers5,6. Based on their research, many studies have been actively conducted for unnatural properties such as negative refractive index7,8, super resolution9,10, and wave absorption11,12,13. Especially, when applied to absorbers, electromagnetic metamaterials can improve the device performance and impart desirable qualities such as polarization-insensitivity, wide incident angle characteristics, multi-resonances, and multi-band absorption14,15,16. Due to the vastly increased freedom of material choice, electromagnetic metamaterial-based absorbers can have additional advantages in strength, elasticity, heat conduction, and other mechanical or chemical properties. However, there are still hurdles remaining in implementing these ideas in real devices and finding fabrication-friendly designs as well as practical and cost-effective fabrication methods is among the missing pieces. For example, the lumped resistor inclusions in some of the proposed metamaterial absorber designs are not ideal in terms of fabrication cost and durability. To solve these problems, many studied metamaterials using a polymeric conductive material including carbon or graphite with periodic patterns as a circuit and specific sheet resistance instead of using materials having lumped resistances14,17,18,19,20.

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.

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.

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

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.

Zabri, S. N., Cahill, R., Conway, G. & Schuchinsky, A. Inkjet printing of resistively loaded FSS for microwave absorbers. Electron. Lett. 51, 999–1001 (2015).

Figure 13 shows fabricated microwave absorber with resistive double square loop arrays by the manufacturing process developed in this study. Figure 13a shows the fabricated microwave absorber with an area of 150 mm2 and an enlarged view of a double square pattern which has fully filled and cured conductive ink. Figure 13b shows the total thickness of 4.16 mm that comprises two polymer materials and a metal sheet. The PMMA material with a thickness of 4 mm conducts an isolation layer between the electromagnetic field and the ground. The resistive double square loops with array numbers of 12 × 12 generate an electromagnetic field with a distance of 4 mm from the ground surface. The size and the width of the inner pattern were about 2.46 mm and 0.77 mm, respectively. The outer pattern size and width were about 9.26 mm and about 1.08 mm, respectively. These patterns were machined within a size error of 1% compared to the target size and width. An aluminum sheet with a thickness of 0.16 mm reflected transmitted microwaves.

Luukkonen, O., Costa, F., Simovski, C. R., Monorchio, A. & Tretyakov, S. A. A thin electromagnetic absorber for wide Incidence angles and both polarizations. IEEE Trans. Antennas Propag. 57, 3119–3125 (2009).

Table 3 shows results of comparison in terms of layer number, pattern shape, thickness, bandwidth, and the maximum RCS reduction with other state-of-art broadband microwave absorbers. Previously reported microwave absorbers having multiple layers of resistive patterns have different sheet resistances or shapes on each layer to increase the absorbing performance and broaden the effective frequency range. On the other hand, the microwave absorbers by the proposed manufacturing process in this study can have patterns with different sheet resistances on a single layer. This advantage allows, thinner absorber designs with good absorption performance.

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

Figure 1a,b show a designed unit cell of microwave absorber. This absorber structure is optimized with a PSO (particle swarm optimization) algorithm applied to a Lumerical FDTD solver. The target performance of the absorber was set to be lower than 20% reflectance at 5–14 GHz, a sufficient performance to confirm the effectiveness of the manufacturing process developed in this study. Eight parameters were optimized during the process, including period, thickness of the structure, length, width, depth of each ring with a predetermined refractive index of substrate \(n=1.732+0.00866i\) and an ink conductivity \(\sigma =2352.9\,{\mathrm{S}}/{\mathrm{m}}\).

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

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

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

Wang, C. et al. Radar stealth and mechanical properties of a broadband radar absorbing structure. Compos. Part B Eng. 123, 19–27 (2017).

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.

A microwave absorber fabricated by the developed manufacturing process. (a) Top view of the fabricated microwave absorber and enlarged image of resistive double square loop pattern with measuring the size and width of the pattern, (b) side view and measuring thickness of the microwave absorber.

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.

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

Dewantari, A. & Munir, A. Bandwidth enhancement of artificial magnetic conductor-based microwave absorber using square patch corner cutting. In 2012 7th International Conference on Telecommunication Systems, Services, and Applications (TSSA) (IEEE, 2012). https://doi.org/10.1109/tssa.2012.6366053.

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

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

In the third step, the over filled ink was removed using the planing process to completely isolate each pattern. In the planing process, the theoretical surface roughness was calculated with Eq. (4)39.

Department of Nano Manufacturing Technology, Korea Institute of Machinery and Materials (KIMM), Daejeon, 34103, Republic of Korea

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.

In this study, a manufacturing process was developed for a wide-bandwidth microwave absorber. The fabricated microwave absorber has 144 resistive double square patterns without connection among them. These patterns were precisely fabricated within a size error of 1% and a flat surface with an average roughness under 100 nm. The developed microwave absorber showed a performance of RCS reduction with reflectance less than − 10 dB over 8 to 14.6 GHz frequency range. To extend the RCS reduction performance to the entire Ku-band or higher frequencies and to make the performance more uniform across the frequency band, shapes of resistive array patterns and properties of the conductive carbon ink need to be optimized with further study.

Li, Y., Li, W., Wang, Y., Cao, J. & Guan, J. Refractory metamaterial microwave absorber with strong absorption insensitive to temperature. Adv. Opt. Mater. 6, 1800691 (2018).

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

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.

For filling the ink, the machined PMMA workpiece was detached from the machining table of the micro-milling system. The machined PMMA surface was then completely covered by manually pouring and spreading the developed conductive ink onto its surface. To completely cure the ink without deforming the workpiece by heating, the conductive ink was cured at room temperature (23℃) for one day. The workpiece with the fully cured ink was remounted on the planing system that changed the cutting tool from micro-end-mill to single crystal diamond with a nose radius of 10 mm.

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

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

Fabrication of microwave metamaterials composed of conductive materials usually involve a screen-printing process or an inkjet printing process20,21,22,23,24,25. These processes can fabricate various shapes of circuit patterns (square loop26,27,28, cross dipole29,30,31, fivefold23,25,32, square patch33,34,35, and so on) on a dielectric substrate. Although printing processes are promising candidates for low-cost fabrication of microwave metamaterials, it is difficult to adjust the sheet resistance value for different parts of a pattern in a finely-controlled fashion. In addition, typical printing processes result in embossed (rather than engraved) patterns because they are additive process depositing new material on flat substrates. The embossed conductive materials are more prone to mechanical deformation or damage in the removing and curing process of the ink36. By contrast, engraved ink patterns on mechanical machined substrates allow a fine control of the thicknesses of different parts of the pattern on the same layer simply by controlling the machining depth. Moreover, rheology properties of inks have much less effects on final shapes of patterns because inks only fill engraved patterns.

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

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

Measured and simulated RCS reduction of the fabricated microwave absorber according to radar frequency.

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

Threading tools with the flexibility to thread a broad variety of holes provide the agility many shops need to stay competitive. They may be the only solution for many difficult materials.

The aim of this study was to develop and characterize the manufacturing process for a microwave absorber with resistive double square loop arrays. The developed process consisted of micro-end-milling, inking, and planing steps. End-milling means engraving double square loop arrays. Inking is filling conductive carbon ink to the engraved array structures. Planing is removing overfilled conductive ink and machining the planar surface. Under the established process, the fabricated microwave absorber having a thickness of 4.16 mm showed RCS reduction with reflectance less than − 10 dB in the range of 8.0–14.6 GHz.

Confocal laser microscope measuring results of the PMMA surface after removing the overflowed conductive ink with the planing process. (a) 3D image of the PMMA surface after removing the overfilled conductive ink, (b) roughness profile of the PMMA surface after removing the overflowed conductive ink.

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.

Figure 15 shows the measured reflectance as a function of the microwave frequency. The microwave absorbing performance of the fabricated microwave absorber was the highest near the center of the measured frequency range and gradually decreased towards the boundary. In the frequency band of 8.0–14.6 GHz, the measured reflectance was less than − 10 dB. The minimum reflectance of − 41 dB was measured at 12.4 GHz. From simulations, it is expected that the frequency range with more than 10 dB attenuation may extend down to ~ 5 GHz, but it requires further investigation. Although the measured RCS reduction performance showed a slight difference compared to simulated results, the tendency of absorption performance was similar. The cause of such difference between simulated and measured such as the maximum RCS reduction value and the resonance frequency was attributed to the non-uniformity of the applied conductive ink. This problem can be improved through a future study by optimizing the conductive ink application and curing process.

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

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

Liu, H.-T., Cheng, H.-F., Chu, Z.-Y. & Zhang, D.-Y. Absorbing properties of frequency selective surface absorbers with cross-shaped resistive patches. Mater. Des. 28, 2166–2171 (2007).

Meshram, M. R., Agrawal, N. K., Sinha, B. & Misra, P. S. Transmission line modeling (TLM) for evaluation of absorption in ferrite based multi layer microwave absorber. In TENCON 2003. Conference on Convergent Technologies for Asia-Pacific Region, 1273246. https://doi.org/10.1109/tencon.2003.1273246 (2003).

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.

Korkmaz, E., Onler, R. & Ozdoganlar, O. B. Micromilling of poly(methyl methacrylate, PMMA) using single-crystal diamond tools. Procedia Manuf. 10, 683–693 (2017).

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.

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

The MB45 series is designed to deliver the low cutting force benefits of positive inserts and the fracture resistance of negative inserts.

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.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

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

Figure 5 shows the developed manufacturing process for the designed microwave absorber with resistive double square loop arrays on an insulator material. The developed process had four steps. The first step was a micro-end-milling process for engraving array structure on the surface of the insulator layer. The second step was an inking process for fill up the engraved array structure with the conductive ink. The third step was a planing process to remove the conductive ink overfilled in excess of the array structure. The final step was attaching a metal sheet to the bottom of the insulator layer. In this study, the PMMA material was used as an insulator layer. This is because it has advantages such as good machinability, appropriate refractive index, and superior transparency. The refractive index of PMMA was confirmed by simulation of magnetic and electric filed distributions. Transparency of PMMA has advantages in confirming the residual conductive carbon ink on the microwave absorber after removing overfilled conductive ink by a planing process. For these reasons, the PMMA was chosen as the insulator material in this study. In the entire step, each processing condition was experimentally developed and optimized.

Smith, D. R. et al. Left-handed metamaterials. In Photonic Crystals and Light Localization in the 21st Century (ed. Soukoulis, C. M.) 351–371 (Springer, 2001). https://doi.org/10.1007/978-94-010-0738-2_25.

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

Zhao, J. & Cheng, Y. Ultrabroadband microwave metamaterial absorber based on electric SRR loaded with lumped resistors. J. Electron. Mater. 45, 5033–5039 (2016).

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?

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.

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.

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

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.

Yan, S. J., Zhen, L., Xu, C. Y., Jiang, J. T. & Shao, W. Z. Microwave absorption properties of FeNi3 submicrometre spheres and SiO2@FeNi3core–shell structures. J. Phys. D Appl. Phys. 43, 245003 (2010).

Microwave absorbers using conductive ink are generally fabricated by printing an array pattern on a substrate to generate electromagnetic fields. However, screen printing processes are difficult to vary the sheet resistance values for different regions of the pattern on the same layer, because the printing process deposits materials at the same height over the entire surface of substrate. In this study, a promising manufacturing process was suggested for engraved resistive double square loop arrays with ultra-wide bandwidth microwave. The developed manufacturing process consists of a micro-end-milling, inking, and planing processes. A 144-number of double square loop array was precisely machined on a polymethyl methacrylate workpiece with the micro-end-milling process. After engraving array structures, the machined surface was completely covered with the developed conductive carbon ink with a sheet resistance of 15 Ω/sq. It was cured at room temperature. Excluding the ink that filled the machined double square loop array, overflowed ink was removed with the planing process to achieve full filled and isolated resistive array patterns. The fabricated microwave absorber showed a small radar cross-section with reflectance less than − 10 dB in the frequency band range of 8.0–14.6 GHz.

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

Khalid, N. K. B. A. & Seman, F. B. C. Double square loop frequency selective surface (FSS) for GSM shielding. In Lecture Notes in Electrical Engineering 223–229 (Springer International Publishing, 2014). https://doi.org/10.1007/978-3-319-07674-4_23.

The machining footage in this video shows the difference as we experiment with different coatings in both roughing and finishing passes in 4140 steel. Choosing the right coating for the cut can have a dramatic effect on the performance of the process.

Recently, with increasing importance of electronic warfare in the military field, microwave absorbers with perfect absorption against incident electromagnetic waves are vigorously studied. The conventional method for absorbing a microwave is using a paint that contains tiny spheres made of carbonyl iron or ferrite. These particles convert microwave energy to heat through coupled electromagnetic oscillations1,2,3,4. However, the required minimum thickness of paint for a high absorptance and low reflectance is considerably high. Because ferrite materials have a high specific gravity, thick ferrite paints can increase the weight of the applied body significantly. For this reason, light and thin absorbers that can strongly absorb microwave without using heavy ferrite materials are in demand. Such needs have resulted in various research on ‘electromagnetic metamaterial absorbers’.

This work was supported by the Center for Advanced Meta-Materials(CAMM) funded by the Ministry of Science and ICT as Global Frontier Project(CAMM- No. 2019M3A6B3031046). The work was also funded by the Technology Innovation Program of Ministry of Trade, Industry & Energy(MOTIE, Korea) (20003945, Development of Core manufacturing technology of 4-axes ultra-precision machining system and lens module for next-generation mobile lens having about 100nm shape accuracy).

The microwave absorber was designed to have three layers with resistive patterns, insulator material, and a metal sheet: (i) conductive carbon ink based on frequency selective surface layer, (ii) PMMA based insulating layer for the spacer to adjust the resonance position between incident microwave from radar and reflected microwave from ground, and (iii) metal sheet layer for reflection of transmitted microwave. This absorber material had a 144-number of double square loops in 150 mm2 area of PMMA material with a thickness of 4.16 mm as shown in Fig. 1c.

Kundu, D., Mohan, A. & Chakrabarty, A. Single-layer wideband microwave absorber using array of crossed dipoles. IEEE Antennas Wirel. Propag. Lett. 15, 1589–1592 (2016).

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

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.

Park, K.-Y. et al. Fabrication and electromagnetic characteristics of microwave absorbers containing carbon nanofibers and NiFe particles. Compos. Sci. Technol. 69, 1271–1278 (2009).

Figure 7a,b,c show the first, 72nd, and 144th inner patterns of double square loops after the end-milling process, respectively. The first inner pattern showed clear edges with a smoothly machined surface. However, with increasing machining number of patterns, the size of the burr was also increased and the machined surface was roughened with a significant tool mark.

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

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