Professional design engineers to composite enthusiasts now have access to a web shop platform for creating and ordering standard or fully customized composite tubular products with ease.

Explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.

The new Agathon grinder has totally replaced the semiautomatic grinders. Improvement in the quality and precision of the insert’s IC grind means rejects are virtually eliminated, according to Mini. Should a problem occur, the machine will automatically cease grinding and go into a standby mode.

YG-1’s router designs are intended to resolve the challenges of machining composites and stacked materials, enabling shops and production facilities to help customers maximize the cost and weight reductions and other benefits of composites use. YG-1 says its routers are made with best-in-class solid carbide and feature special CVD coating for superior cost and time savings. The company’s engineering teams developed the routers’ double-angle point geometry specifically to counteract or eliminate the machining problems typically encountered with composites. The CVD coating is said to increase abrasion resistance from the fibrous materials and extends tool life by a factor of five to 10, at minimum.

CW explores key composite developments that have shaped how we see and think about the industry today.

American Bureau of Shipping (ABS) certifies use of jointly developed CFRP repair technique on FPSO and FSO industrial systems, addressing traditional steel restoration challenges.

The company cites up to 80% reduction in NC code generation time when using Jetcam Expert CAD/CAM software version 24.

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The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.

In these sessions, experts will discuss the emerging hydrogen economy and the opportunities for composites in this lucrative space.

Celebrating National Composites Week, CW shares ways in which composites continue to evolve mass transit.

CAMX 2024: James Cropper, formerly known as Technical Fibre Products, is bringing its new name to the U.S. composites industry, highlighting its specialization in carrier, surface and fire protection veils, among other products.

During this webinar, the audience will be introduced to a variety of fiber composite technologies — as well as the machines and equipment — from short fibers to continuous fibers, from thermoset to thermoplastic, as well as the according process technology, including a special focus on long-fiber injection (LFI) and structural composite spray (SCS). Focus markets include automotive, aviation and AAM, transportation, and construction. This webinar will provide a detailed overview of according application examples. Agenda: Long fiber injection (LFI) Structural composite spray (SCS) Resin transfer molding (RTM), wet compression molding, etc. Pultrusion FiberForm

Base Materials introduces a high-performance, toughened epoxy tooling board designed for thermoforming and vacuum forming processes, direct-to-part applications and more.

The new Agathon Leo Peri grinder has changed the entire production dynamic at Illinois Carbide Tool and its divisions, Mini said. “In addition to carbide indexable insert grinding, we are utilizing the new Agathon to grind our cast alloy woodworking inserts for our Crobalt customers. This is something we could not have done on the older-technology grinders.”

Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.

CAMX 2024: Nanopoxy and Nione are presenting a session describing tests and results of incorporating niobium nanoparticles into epoxy resins.

Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.

Herone, Spiral RTC, Teijin Carbon Europe and Collins Aerospace Almere recycle A350 thermoplastic composite clips/cleats waste into rods for the all-thermoplastic composite Multifunctional Fuselage Demonstrator’s crown.

Program will focus on sustainable, next-gen wing solutions, including in wing design and manufacturing and advancements in carbon fiber-reinforced composite materials.

As a CAMX media partner, CW develops three show dailies throughout the week that report on interesting exhibitors and their technologies, events not to miss and more. Whether you’re attending the show, or watching from afar, make sure to tune in to these digital editions!

“It was a major initial step in enabling us to get our production up to where it needed to be at a critical time,” Mini said.

In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.

New aircraft is expected to deliver wind turbine blades from 105 meters up to expand the reach of wind energy and achieve global climate goals.

Combined with guidance margins and open flutes, these specialized routers are also said to drill holes with no dust jams or pressure overload. Suited to manual hole-making, countersinks and counterbores, hand drilling reduces delamination and fiber pullout, and increases opportunities for dust-free drilling, improving operator comfort, health and safety.

Together with Plastivaloire and Stellantis, the new Peugeot 3008’s center console structure is being produced with Borealis’ Borcycle M GD3600SY material grade.

Novel, modular design minimizes weight for high-precision cutting tools with faster production speeds.

CW Tech Days are virtual events dedicated to the topics impacting the composites industry today. Access past event recordings and register for upcoming Tech Days.

To wrap up another successful CAMX trade show, we give a second look at the ACE Award technologies, provide highlights of show floor activity, celebrate legacy CAMX exhibitors and more.

The Italy-based companies merge technological know-how to develop novel systems for the processing and assembly of light alloys and carbon fiber components.

One of Crobalt’s long-term cutting tool customers primarily runs grinding machines from Agathon Machine Tools Inc., Bethel, Conn. When this customer offered Illinois Carbide Tool a used Agathon Model 250 PA-CNC Ultra grinder in 2014, the company purchased it.

Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.

The company says the new routers are optimized in composition, cutting angles, flute strength and stability for longer life and lower cost per part. Four distinctive cutting ends make these fiberglass/composites routers ideal for roughing, finishing, edge trimming, slotting, grooving, drilling or interpolation, achieving the same quality results on a CNC machining center or hand routing, YG-1 says.

Aerospace manufacturer joins forces with composite materials company to achieve sustainable manufacturing practices that overcome traditional composite layup tooling.

Addition of machining services for the Evonik structural foam brand expands Mel’s range of foam core delivery.

An on-demand mapping tool for anisotropic materials and polymer material fracture prediction model, i-Lupe, aims to help predict impact, crash behaviors.

Under the TACFI contract, Orbital is implementing the AMCM process to build 3D printed composite multi-mission UAS aircraft, surpassing $10 million in government awards.

Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.

Powers a grinding wheel or other abrasive tool for the purpose of removing metal and finishing workpieces to close tolerances. Provides smooth, square, parallel and accurate workpiece surfaces. When ultrasmooth surfaces and finishes on the order of microns are required, lapping and honing machines (precision grinders that run abrasives with extremely fine, uniform grits) are used. In its “finishing” role, the grinder is perhaps the most widely used machine tool. Various styles are available: bench and pedestal grinders for sharpening lathe bits and drills; surface grinders for producing square, parallel, smooth and accurate parts; cylindrical and centerless grinders; center-hole grinders; form grinders; facemill and endmill grinders; gear-cutting grinders; jig grinders; abrasive belt (backstand, swing-frame, belt-roll) grinders; tool and cutter grinders for sharpening and resharpening cutting tools; carbide grinders; hand-held die grinders; and abrasive cutoff saws.

FAUSST technology enables fast, reliably welded connection of metal components in composite structures.

A combination of Airtech’s 3D printing materials and Ascent’s production capabilities aim to support increased use of composite additive tooling in spaces like defense and aerospace.

Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes. The engine lathe consists of a headstock and spindle, tailstock, bed, carriage (complete with apron) and cross slides. Features include gear- (speed) and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines. Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces (instruments, watches), normally without a power feed. Models are typically designated according to their “swing,” or the largest-diameter workpiece that can be rotated; bed length, or the distance between centers; and horsepower generated. See turning machine.

Eco-friendly natural fiber range of decking, cladding, fencing, railing options ensure durable and long-lasting structures.

CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

Stephen Heinz, vice president of R&I for Syensqo delivered an inspirational keynote at SAMPE 2024, highlighting the significant role of composite materials in emerging technologies and encouraging broader collaboration within the manufacturing community.

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Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.

The JEC Forum DACH is a business meetings event organised by JEC The JEC Forum DACH is organised on October 22 and 23, 2024 by JEC, in partnership with the AVK, gathering the composite materials community from the DACH Region (Germany, Austria and Switzerland).

Closed mold processes have many advantages over open molding. In this knowledge center, learn the basics and vital tools needed to produce parts accurately.

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In addition to its proven fire resistance as a pure foam and within a sandwich composite system, the new material offers efficient manufacturing of 3-dimensional geometries and opens new possibilities for direct function integration. Agenda:  Manufacturing process of thermoplastic particle foams Sandwich composite component requirements of commercial aircraft interior structures (e.g. FST, Heat Release) Function integration into net shape molded foam parts (e.g. inserts) Potential use-cases in fire critical applications

Kennametal will cover the influence of different composite materials characteristics on drilling performance and how to optimize the process. Agenda:  Who is Kennametal? Hole making challenges in composite materials Innovations for hole making applications Upcoming events and academic partnerships

This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.

Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.

The ITHEC 2024 will take place from the 9 to 10 October 2024 in Bremen, Germany. At the 7th International Conference, more than 300 participants from around the world will be presenting and discussing newest scientific results, meet leading international specialists, share their expertise and start business co-operations in the field of thermoplastic composite technologies. The international exhibition will feature 40+ exhibitors showcasing all steps of the supply-chain. Be it materials, machines, testing, processes, or solutions. By combining the exhibition and the conference ITHEC is further fostering the inter-connectivity between science and industry.

The first project is underway to recover carbon fiber used in an A330-200 aircraft, which will then be regenerated for other end uses by HRC.

Launch of the “Propellers and Rotors” Joint Partner Project looks to the potential of composite materials and technologies for future product concepts.

Replaceable tool that clamps into a tool body, drill, mill or other cutter body designed to accommodate inserts. Most inserts are made of cemented carbide. Often they are coated with a hard material. Other insert materials are ceramic, cermet, polycrystalline cubic boron nitride and polycrystalline diamond. The insert is used until dull, then indexed, or turned, to expose a fresh cutting edge. When the entire insert is dull, it is usually discarded. Some inserts can be resharpened.

The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.

The grinder interfaces with up to six standard pallets and these pallets can be purchased for specific sizes of inserts. Complete automation of the periphery grinding process by the new grinder achieves insert quality that was previously unobtainable by the older technology, according to Mini. “We currently are not producing on Sundays, but we certainly could if the need would arise.”

More production sometimes requires fewer machines. As orders for its carbide brake lathe inserts increased at least 20 percent during the last 18 months, Illinois Carbide Tool Co. Inc. transitioned from six grinding machines with obsolete technology to a newer CNC grinder and a brand-new CNC grinder, said Mike Mini, company owner and manager.

Over the last 8 months, Archer Aviation has completed a total of 402 test flights with its composites-intensive aircraft, adding to key milestones.

During this CW Tech Days event, sponsored by Composites One, experts will offer presentations to review and evaluate the composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

More applications include machining in carbon fiber, Kevlar and other aramid blends, natural fiber-based composites and thermoset resin/thermoplastic blends.

This collection features recent CW stories that detail a range of tooling technologies, processes and materials.

Workholding device that affixes to a mill, lathe or drill-press spindle. It holds a tool or workpiece by one end, allowing it to be rotated. May also be fitted to the machine table to hold a workpiece. Two or more adjustable jaws actually hold the tool or part. May be actuated manually, pneumatically, hydraulically or electrically. See collet.

Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.

Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.

Chuck Best, CNC operator and technician at Illinois Carbide Tool, sets parameters for the Leo Peri grinder’s pick-and-place robot. Image courtesy Presage Professional Inc.

Mini explained that automotive repair shops apply the brake lathe inserts to resurface brake drums and rotors. However, the six semiautomatic grinders the company was using to make these inserts were built in the 1980s and were unable to keep up with increasing production demands because they were slow and would consistently break down. Once out of service, the troubleshooting and the search for repair parts would commence. Because of their older technology, it could take up to 3 or 4 weeks to get a grinder back up and running. “There were usually only about four out of the six running at a time,” he said.

As insert demand continued to increase, the company purchased a new Leo Peri 4-axis grinding center from Agathon earlier this year. According to Mini, the new machine is ideal for producing the company’s carbide inserts, which do not require K-lands or special features, eliminating the need for a 5-axis grinder. “A gantry loads and unloads inserts, enabling the one-shift facility to run lights-out production,” Mini said.

An overview of ASTM Standard Guide D8509, and its coupon-level mechanical testing of design properties for analyzing composite bolted joints.

Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.

Any machining process used to part metal or other material or give a workpiece a new configuration. Conventionally applies to machining operations in which a cutting tool mechanically removes material in the form of chips; applies to any process in which metal or material is removed to create new shapes. See metalforming.

This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.

CompositesWorld is the source for reliable news and information on what’s happening in fiber-reinforced composites manufacturing. About Us

Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.

To wrap up another successful CAMX trade show, we give a second look at the ACE Award technologies, provide highlights of show floor activity, celebrate legacy CAMX exhibitors and more.

The Marservis PROeco is a mass transportation marine vessel using Bcomp natural fiber for interior parts in place of standard materials.

The second day of CAMX 2024 has all sorts of things in store for attendees, from Tuesday’s keynote centered around the world of AI, to award and poster session winners and what to look forward to at Good Day, CAMX on Thursday.

As a CAMX media partner, CW develops three show dailies throughout the week that report on interesting exhibitors and their technologies, events not to miss and more. Whether you’re attending the show, or watching from afar, make sure to tune in to these digital editions!

Alan holds a bachelor’s degree in journalism from Southern Illinois University Carbondale. Including his 20 years at CTE, Alan has more than 30 years of trade journalism experience.

Simple robot or piece of hard automation that is capable of the simple actions of picking an object from a fixed point and placing the object at another fixed point.

Imaginary circle that touches all sides of an insert. Used to establish size. Measurements are in fractions of an inch and describe the diameter of the circle.

Celebrating National Composites Week 2024, CW looks at how composites are being used to provide the next generation of energy.

The second day of CAMX 2024 has all sorts of things in store for attendees, from Tuesday’s keynote centered around the world of AI, to award and poster session winners and what to look forward to at Good Day, CAMX on Thursday.

CompositesWorld's Carbon Fiber conference offers you cutting-edge information and access to industry experts in streamlining manufacturing costs, market outlooks and forecasting, and more. You will make invaluable contacts as you meet and network with the industry's most innovative and influential leaders at Carbon Fiber. __PRESENT

Additionally, stitch-bonded non-crimp fabrics (NCFs) provide manufacturers and asset owners even more ways to gain a competitive advantage with products built specifically for the environments and loading conditions in which they will be utilized. Join Vectorply Corporation and Creative Composites Group (CCG) for this in-depth webinar detailing the process of engineering NCFs to build composite parts that will stand the test of time. Unlike steel, concrete and wood, composite NCFs can be optimized utilizing various fiber types, architectures and substrates to achieve the specific goals of their application efficiently. High corrosion resistance, strength and stiffness, and longevity can all be accomplished with custom-designed laminates for these heavily abused applications. Vectorply Vice President of Engineering Trevor Gundberg and Creative Composites Group Chief Sales Officer Dustin Troutman will share their industry-leading expertise on the process of laminate design and part production. Attendees can expect to learn when to use composite NCFs in their production process and the wide range of fiber-reinforced plastic (FRP) composites that Creative Composites Group produces for the industrial and infrastructure markets. Whether you want to learn more about utilizing NCFs in your production process or why CCG’s extensive product line may be the choice for your project, this webinar is the place learn the process and how to take the next steps. Agenda:  Distinct advantages of non-crimp fabrics versus alternative materials How to design laminates for specific processes such as pultrusion and infusion Real-world success spotlights of NCFs in industrial applications

EU project will develop bio-based, repairable and recyclable vitrimer composites and advanced sensors for highly reliable, sustainable wind blades.

Composites using graphene is not a new concept — but what is new is that the industry now recognizes "graphene" as an actual family of materials with different properties and promise. A new and exciting form of graphene is made from reclaimed methane, which uses new technologies to create green carbon materials. While showing great sustainability promise, functionalization is needed to unlock graphene's full range of properties for the next generation of composites to make these carbon materials useful. In this webinar, graphene manufacturer Mito Material Solutions will discuss how to bring functionalization and multifunctionality to these new "green" graphenes to enable a stronger, more robust and sustainable world.

IBEX 365 is the event’s year-round hub for buyers and professionals looking to source the most innovative technology and newest products available.

General Motors and partners Premix-Hadlock and Albar cite creative engineering and a move toward pigmented sheet molding compound (SMC) to produce cosmetic components that met strict thermal requirements.

Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.

This sidebar to CW’s August 2024 feature article reviews this technology for more efficient composites manufacturing and why it aligns with Koridion active core molding.

FAUSST technology enables fast, reliably welded connection of metal components in composite structures.

Four new solid-carbide fiberglass routers have been launched for CNC or hand routers to handle everyday composite machining.

CompositesWorld’s Tech Days: Design, Simulation and Testing Technologies for Next-Gen Composite Structures is designed to provide a multi-perspective view of the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.

“When you have older technology and you’re having problems with a grinder,” he said, “you hate to spend the money for these repairs because you’re throwing good money after bad. You start looking for solutions in the latest grinding technology.”

CAMX 2024 is right around the corner. Make sure to check out Part 2 of this two-part series highlighting some of the exhibitors you can expect to see in San Diego.

“After only a few weeks of initial orientation on the new grinder, our experienced CNC operator, Chuck Best, was able to have the grinder running at maximum efficiency, and lights-out operation is now standard operating procedure for four or five nights out of the workweek,” Mini said.

The Waukegan, Ill., manufacturer has two operating divisions: Brake Drum Tool Co., which produces inserts, tool bodies and cutting tools for the automotive industry, such as cylinder boring tools; and Crobalt, which manufactures a high-cobalt cast alloy used in metalcutting and woodworking tools and wear parts.

Tafnex carbon fiber-reinforced PP and 3D printed components find application in Toyota Fortuner-based car designed by TCD Asia.

“We did retain two of the older-technology grinders as emergency backup [machines], and the others are in storage for possible sale, or we may find someone who wants to purchase one for parts,” Mini said.

The Marservis PROeco is a mass transportation marine vessel using Bcomp natural fiber for interior parts in place of standard materials.

Explore the technologies, materials and strategies used by composites manufacturers working in the evolving space market.

Minimum and maximum amount a workpiece dimension is allowed to vary from a set standard and still be acceptable.

END USER: lllinois Carbide Tool Co. Inc., (800) 323-2414, www.crobaltusa.com, www.brakedrumtool.com. SOLUTION PROVIDER: Agathon Machine Tools Inc., (203) 730-8741, www.agathon.com. CHALLENGE: Keep up with increasing production demands for carbide brake lathe inserts. SOLUTION: A 4-axis grinding machine that enables lights-out production.

Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.

Advanced Engineering is the UK’s largest annual gathering of engineering and manufacturing professionals. The event will help you to source new suppliers, network, build connections and learn about the latest industry developments all in one place. Get involved and exhibit alongside 400+ exhibitors offering solutions and products across all industries and sectors to help improve your productivity and inspire creativity. With over 9,000+ of your peers due to attend and ready to network with and inspire you, this is the event you can’t afford to miss!

Low-melt polyaryletherketone (LMPAEK) unidirectional tapes provide outstanding thermal and fire protection, demonstrating their effectiveness through rigorous testing. These tapes are fire, smoke and toxicity compliant with FAR25.853 and meet OSU Heat Release Rate standards. The tapes were tested under ISO 2685/AC 20-135 Change 1, meeting the fireproof criteria. Additionally, they met UL 2596 requirements for battery thermal runaway tests. These tapes are crucial for high-temperature applications showcasing their resilience and safety in both aerospace and automotive applications. Part of a broader range that includes films and compounds, Victrex LMPAEK materials are valued for their excellent processability and weldability. They offer versatile solutions for complex needs beyond traditional structural parts, such as: thermal runaway and lightning strike protection, heat sinking, and intricate bracketry. Victrex LMPAEK materials facilitate automation and high-rate production while addressing performance and sustainability challenges. With reduced environmental impact, lower weight and cost-efficiency, they meet the evolving demands of the transportation industry and support innovative design solutions. Agenda:  Introduction to LMPAEK ecosystem, highlighting unidirectional tapes Thermal and fire protection performance: applications and benefits Material forms and processability Sustainability and efficiency Conclusion and future innovations

Steptics industrializes production of CFRP prostheses, enabling hundreds of parts/day and 50% lower cost.

YG-1 (Incheon, South Korea) has launched four new solid-carbide fiberglass routers for CNC or hand routers to handle every machining for fiberglass and other high-performance fibers.

The composites-intensive VTOL platform is next expected to undergo a series of test flights in various conditions to validate its performance, safety and reliability, leading up to eventual certification.

Left to right: Mark Wawiorka, operator and technician; Chuck Best, CNC operator and technician; and Dan Quinn, operations manager; discuss setup and operation of Illinois Carbide Tool’s two Agathon grinding machines: a 250 PA-CNC Ultra (foreground) and a Leo Peri. Image courtesy Presage Professional Inc.

The company’s fiberglass/composite routers are available in a range of sizes, including market standards and specials designed for unique applications.

A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.

Keynotes for the International Conference and Exhibition on Thermoplastic Composites on Oct. 9-10, 2024 include Randall Wilkerson’s update on the Hi-Rate Composite Aircraft Manufacturing project as well as Toray’s progress toward large-scale adoption.

Reliable news and information on where and how fiber-reinforced composites are being applied — that’s just the start of what you get from our team here at CompositesWorld.

Analyzing structural resonance of the aircraft under various loads becomes a critical step in obtaining flight certification.

Mini added that the person with the most experience operating these grinders could repair about 85 percent of the problems, but obtaining parts was a challenge and not an effective use of company resources. The inserts in these grinders had to be manually loaded and unloaded by the operator into the machine’s single magazine. The operator had to manually dress the grinding wheels, check that a machine was operating properly so an insert’s IC tolerance of ±0.001" (0.0254mm) was being held while ensuring that the center screw hole was concentric to the insert’s triangular shape.

Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.