How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

Decker Machine Works recently adopted Rego-Fix’s reCool through-coolant system for ER collets, reducing the cycle times on a nickel alloy job by 70%.

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.

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.

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

Although this simplified description of microwave block machining seems straightforward, Mr. Janzen cautions against that assumption. There aren’t any handbooks or tables to consult when unfamiliar cutting conditions are encountered or when familiar conditions yield unexpected results. Trial-and-error experimentation is sometimes the only option, he says.

After deburring, the blocks are cleaned ultrasonically and inspected on the Nikon measuring microscope. “This is when we discover where the cutting tool may have overshot an inside corner or violated and edge in the test cut,” Mr. Janzen explains. Programmed feed rates can be adjusted to correct for errors. Even when the team is confident about the process, several sets of blocks may have to be machined to yield one that is acceptable for delivery to final assembly.

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

Verisurf’s Machine Tool Probing (MTP) suite is an in-process automated inspection solution for CNC machine tools, offering inspection and reporting capabilities.

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.

What is markedly noticeable is the pace of the work conducted in this shop. It’s intense but not rushed. “You have to take your time with everything you do,” Mr. Janzen says. He and his team must go about their procedures methodically, consistently and very attentively. Successful results are never guaranteed, and predicting how cutting tools will perform is often impossible. “This is not a place for the easily frustrated,” Mr. Janzen says.

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

Two microscopes are some of the most important features of each milling machine. One microscope is integrated into the column of the machine so that its focal point is at a fixed, known distance from the spindle centerline. This single-eyepiece microscope is used to align the block halves and find their position relative to the tip of the cutting tool. In the machine jog mode, the operator touches the tip of the tool to the workpiece surface to create a witness mark. After jogging the workpiece over to the viewing area under the microscope, the operator can place the crosshairs on this witness mark and offset the point coordinates to check the relationship of the cutter tip centerline and microscope centerline. A similar procedure is used to find the edges of the blocks and align them so that the blocks are symmetrical to the home position of the program. This step ensures that any variations in the workpieces will create mirrored effects in the machined features and still achieve perfect alignment of these features when the blocks are assembled.

The shop produces its own end mills with diameters less than 0.002 inch (larger sizes are acquired from vendors.) Starting with commercially available blanks of super-fine-grain carbide, these end mills are ground on an Ewag WS11 tool grinder (United Grinding, Miamisburg, Ohio). All are two-flute, spade-type end mills with relief angles on the side cutting edges and at the center of the bottom edge to avoid a dead spot. The photograph (below, right) shows a profile of this end mill design. After grinding, the tools are inspected on a Nikon measuring microscope to check for excessive runout (any total above 0.0001 inch is unacceptable).

The MFG Meeting brings together manufacturing technology industry leaders to address key business challenges and provide actionable solutions. Sessions cover a wide range of topics, including workforce, economics, supply chain, leadership, politics, and more. This unique meeting experience provides unparalleled opportunities to network with executives from companies that make, sell, service, and support MT. These peers and competitors will learn from each other, build long-lasting connections, and share insights that will benefit their business.

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

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."

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.

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.

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?

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

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

(top)Pete Bruneau uses the microscope integrated to the column of the DAC milling machine for setup. (bottom) A second microscope mounted to the table allows him to observe the machining operation in progress.

How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?

Moving from an aging set of five-axis mills to more advanced machines enabled Hendrick Motorsports to dramatically improve its engine production.

The tool crib is the backbone of any machine shop — without the right tools, nothing moves forward. While most ERP systems overlook the tool crib, ProShop integrates it seamlessly with CNC programming, job planning, scheduling and more. Join this webinar for an exclusive look at how Roush Yates Manufacturing Solutions leverages ProShop to document tool requirements, sync tool demand from CAM software and efficiently manage the tool crib and work instructions. Discover how ProShop transforms the tooling workflow to maximize efficiency and precision.

One of the first things a visitor notices about each of the Space Instrument Shop’s two Bostomatic VMCs is the absence of the usual sheet metal enclosure. These machines were acquired without the enclosures so that operators would have unencumbered access to the machining zone. Having “bare” machines allows the operator to use the microscope mounted on an arm that is attached to the column of the machine. Cutting tools used on these machines may be as large as a 3/4-inch diameter end mill (a shop-imposed limit) or as small as a 0.0013 inch end mill (barely visible without magnification). The microscope is needed to align workpieces, set tool lengths and monitor cutting with extremely small tools. Because the microscope is attached to the column, it travels in the X and Y axes with the cutting tool so that the operator can follow the action during machining. Using mist coolant makes splash guarding unnecessary.

The blocks are produced in two major steps. First, matched sets of half-blocks are machined on one of the shop’s two Bostomatic VMCs and precision-ground on an older but well-maintained Thompson surface grinder. The material is usually a high grade of naval brass alloy. Each side of a block must be parallel and perpendicular to within 0.00005 inch and each block must be square to within 0.0001 inch or better. As the box at right shows, preparation of the blocks is extremely important. Mr. Janzen emphasizes that it sets the foundation for successful machining in the next step.

The shop is set apart because the machining techniques and equipment are unique among those utilized at JPL’s other machine shops. Its location is also more accessible to the engineers and scientists whose projects involve the Space Instrument Shop. Interestingly, none of the specialized equipment is so unusual that other shops would be mystified by the appearance or configuration of the shop’s vertical machining centers, milling machines and grinders. In many ways, the Space Instrument Shop looks a lot like an everyday job shop.

As parts get smaller and smaller, using EDM wire as small as 0.001 inch in diameter to cut these workpieces becomes an attractive option—actually, the only option.

The blocks are machined from bars long enough to accommodate two or three pairs of half-blocks to assure positional accuracy. The pairs are not separated from the bar until all other machining operations on the blank blocks are completed. Wave-guide blocks feature a number of threaded holes for assembly screws and precision-bored holes for press-fit dowel pins that maintain the alignment of the blocks when put together. These features are typically machined to a true position of 0.0004 inch.

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

Not only can Gelsight’s tactile sensor detect and evaluate defects, but it can also measure part features, surface roughness and even contamination.

The Space Instrument Shop has its own self-contained area in Building 168 at JPL’s extensive campus, where more than 5,000 are employed. The shop’s work team consists of two others besides Mr. Janzen, who has 42 years of experience in machining. Pete Bruneau is a senior machinist with more than 25 years of machining experience, and David Evans is the “new kid,” having worked in the shop for only two years following 15 years as a machinist.

1. Check, check, check. Mr. Janzen and his team purposefully review every step of each procedure to be sure it has been conducted properly. Following mental checklists becomes second nature. Members of the team review activities together to get a fresh perspective. “Everything is important; no detail can be neglected,” Mr. Janzen says.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

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

6. Keep the lights on. The Space Instrument Shop never goes dark because heat from ceiling lights affects ambient shop temperature. High-intensity task lighting is turned off quickly when not needed because small tools and workpieces can absorb heat rapidly. Holding a constant temperature is the main thing.

There are usually better solutions to chatter than just reducing the feed rate. Through vibration analysis, the chatter problem can be solved, enabling much higher metal removal rates, better quality and longer tool life.

OnLogic is partnering with AI development and implementation specialists to help companies use AI-powered solutions, aiming to drive real business value.

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

For this kind of work, the shop often uses spade-type end mills as small as 0.001 inch wide, although even smaller tools have been used occasionally. Cutting with end mills of this size is representative of this shop’s capability, and it gives a glimpse into the world of machining on a microscopic scale. As parts for medical applications, handheld computer devices and consumer products become smaller and smaller, other job shops and machining labs will have to learn many of the lessons that the Space Instrument Shop has already mastered.

Yet working here is very rewarding, he contends. One of the roles that this shop fulfills is to advise some of JPL’s top scientists, researchers and engineers. They are constantly working to develop systems that are more powerful, more sensitive or more capable. They come to the Space Instrument Shop to consult on the manufacturability of new designs. This means that the space instrument team gets involved in projects in the earliest stages and often sees them ultimately put into production in their own shop. “We take some of these innovations from the cradle to the grave,” Mr. Janzen says, but it would be more accurate if he had said from “sketch pad” to “launch pad.”

PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.

The Detroit Auto Show, formerly known as the North American International Auto Show (NAIAS), is located squarely at the intersection of technology and mobility. It’s a global event filled with tangible advances ready to hit the pavement today. Here, the software is as revolutionary as anything out there, and the hardware always looks better with a good polish. You won’t find any devices that will fit in your pocket, but you will discover machines that will move you in the most literal sense. You’ll also connect with thought leaders from around the world, both in and outside the automotive industry, whose collective visions for the future of mobility will shape the way we move for years to come.

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.

When machining is completed, the blocks are deburred by hand at a bench under a microscope. Burrs are gently removed with the ground tip of a bamboo chopstick or other type of wood. All edges must be dead sharp. No nicks or edge rollover is allowed. The edges can’t be touched by human hands at this point, Mr. Janzen says, because particles of skin left behind by contact can damage mating surfaces when the blocks are assembled.

3. Keep machines calibrated. Every machine tool in the shop is laser-calibrated at least once every six months. Even the two Bridgeport knee and column mills used for simple jobs and utility work are “lasered” on a regular basis. The aim of adjustments and realignments is to maintain a like-new or better performance. “You have to have a service provider that understands this goal,” Mr. Janzen says. The shop has been working with Lasers Inc. of nearby Glendora, California, for this service.

4. Spread the work around. To avoid concentrating wear in one part of a machine’s work zone, jobs are set up at different spots on the table. Don’t leave heavy vises or clamping fixtures where the machine has an overhang.

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

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.

At Carnegie Mellon University’s Manufacturing Futures Institute, researchers use a robotic test bed where AMRs deliver Lego bricks to robot arms for assembly to study AI, multirobot collaboration, assembly, safety and more.

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

The shop’s mission is to produce components for scientific instruments that allow space vehicles to gather, analyze and transmit information about the earth and other parts of our solar system—or beyond. Typically, these are components that other shops outside of JPL are unable or unwilling to produce. That’s because machined features on these parts may have dimensions that are fractions of the width of a human hair and have tolerances as low as ten millionths of an inch (less than a micron in metric terms).

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

Although the DAC has an electric air-bearing spindle capable of 120,000 rpm, the shop finds that 90,000 rpm is a practical upper limit. For a 0.001-inch end mill, feed rates are as low as 0.1 ipm. An atomized mist of vegetable oil-based coolant provides lubrication, cooling and chip removal. Proper application of the mist is no trivial matter, Mr. Janzen says.

Prime examples are sub-millimeter microwave blocks that are used to mix or boost the frequency of microwave signals ranging from 600 gigahertz to 2.5 terahertz. They are critical components in instruments and for applications such as detecting and measuring the presence of CO2 and other gases in the upper atmosphere. This information helps monitor climate change or predict weather patterns.

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.

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.

5. Test, inspect, analyze and adjust. That’s how the shop learns from every critical machining operation, and the shop never misses a learning opportunity. Projects are planned and reviewed collaboratively so that the whole team benefits. Logbooks and documentation can capture important information, but experience is the best teacher, Mr. Janzen notes.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

7. There is a lot to be humble about. “We are always looking for new tools, new techniques and new thinking,” Mr. Janzen says. He and his team are aware that they are only a small step ahead of what the researchers and scientists will want them to produce. Being constantly on the edge, however, is never boring.

The new space includes a showroom, office spaces and an auditorium that will enhance its work with its technical partners.

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.

Adding pallet systems brought Mach Machine success and additional productivity. The shop has since furthered its automation goals while adding new capabilities.

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.

Machining the wave-guide channels and pockets in the blocks is a bit paradoxical. As Mr. Janzen points out, all of the elements found in an ordinary machining operation are here. You need the right cutting tool, the right machine tool, the right setup, the right CNC program, and the right way to apply coolant. Yet each of these elements is adapted specifically to machining on a microscopic scale.

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."

Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.

Tool paths to machine the wave-guide channels are generated with Esprit CAM software from DP Technology (Camarillo, California). The shop uses this software because cutter paths must be postprocessed to six decimal places. Otherwise, inherent programming error would exceed the resolution of the machine’s positioning system. According to Mr. Janzen, cutter path geometry of the channels is usually programmed 0.00015 inch undersized to allow for runout in the end mill.

This is how details of the wave-guide channel appear through a high-powered microscope. The smallest channel is 0.0013 inch wide. The smallest end mill used was 0.001 inch wide. The heavy black bar across the top of the image is the profile of a human hair. Photo courtesy of JPL.

As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda:  Introduction The power of high-speed printing Know the process The practical side

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.

Work at the Space Instrument Shop is highly collaborative. The team consists of Pete Bruneau (left), Hal Janzen (right) and David Evans (seated).

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

JPL’s Space Instrument Shop does this routinely, but it takes some special equipment and some unusual procedures. Above all, it takes patience.

According to Hal Janzen, shop lead, producing parts with features visible only with magnification is vastly unlike the world of ordinary machine shop operations. Procedures for setup, tool-length setting, deburring and other production steps are rather different. The habits, outlook and discipline of the shop team are also distinctly characteristic. Formulas for machining parameters, rules of thumb and expectations that apply in the average shop often do not apply here. Skill, experience and insight are necessary to work in this shop, but perhaps more important are a willingness to experiment, the ability to think creatively and a generous capacity to be patient. “Patience, patience, patience” is Mr. Janzen’s mantra.

The new space includes a showroom, office spaces and an auditorium that will enhance its work with its technical partners.

Flex Machine Tools’ Open House event will take place Thursday, December 5 at the company’s headquarters in Wapakoneta, Ohio. It will feature a facility tour and live machining demonstrations.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

In this episode of the AM Radio podcast, Robots & Autonomy Editor Julia Hider joins Additive Manufacturing’s Executive Editor Stephanie Hendrixson and Editor-in-Chief Peter Zelinski to discuss how robots and 3D printing enable each other.

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.

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.

Even before inspection, Datanomix and Caron Engineering’s TMAC AI can extrapolate part quality from cut information. This information also helps shops push their tool life to its limits.

These machines are the shop’s high speed workhorses. They are 40-taper models with a 60,000-rpm auxiliary spindle mounted on the side of the column. Preliminary prepping of the guide blocks is one of the tasks performed on these machines.

No matter what your workholding application, automation always makes sense. Kurt Workholding helps you pick the right tool for the automation job — whether it be a single-vise setup or multiple vises holding large work pieces. This webinar will cover automation solutions using pneumatic, hydraulic and electronic actuation. Agenda:  Most common types of vise automation solutions How to pick the right type of automation for an application Key differences between custom workholding and off-the-shelf automation solutions

AI technology isn’t just a concept for the future—it’s here now, ready to transform your estimating process with the new AI BOM builder in JobBOSS². In this first-launch webinar, discover how AI can revolutionize bill of materials (BOM) entry in your shop, saving time, reducing errors and boosting efficiency. In this session, ECI will review how to use AI to build BOMs through a powerful feature that automates the extraction and input of BOM data from PDFs, Excel spreadsheets and images, all within JobBOSS². You'll have the opportunity to watch a live demonstration of the AI BOM builder in action — showcasing its ability to reduce BOM entry time from hours to mere minutes — thereby allowing you to focus on more strategic tasks. Additionally, you will learn about the real-world benefits of AI-driven BOM entry, including the minimization of manual errors, enhanced accuracy, and streamlined estimating processes — all of which can provide your shop with an immediate competitive edge. Finally, there will be a Q&A session with experts, giving you the chance to ask questions and find out how to integrate AI effectively. Agenda:  Experience AI in action in a real-world manufacturing setting Discover how the AI BOM builder can immediately impact your shop’s efficiency and productivity Get hands-on insights on implementing AI to streamline your operations

Finished blocks are roughly the size of a rectangular sugar cube or a pair of dice. These blocks are produced as a set of perfectly matched halves. When assembled, the internal features of the mating surfaces include microscopically small channels and pockets that must line up within 100 millionths of an inch. The most important features are the wave-guide channels. These are square-bottomed channels that form contoured paths through which the signals pass. The walls of the channel must reflect the signals precisely in order to modify the frequency as intended. The average width of such a channel is 0.002 inch.

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

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

2. Cleanliness counts. For example, every time a tool assembly or setup is taken apart, each component gets an alcohol wipe before being put back together.

Soraluce’s wide range of machine heads and the ability to have multiple heads on a single machine (with automatic changing stations) provides flexibility and reduced setups for large-format machining.

CCAI is offering a comprehensive Industrial Finishing Safety Seminar developed by industry experts well-versed in safety for finishing operations.  This day-and-a-half seminar focuses on NFPA 33, the Standard for Spray Application Using Flammable or Combustible Materials and will deliver important and critical information on how to safely operate an industrial finishing line. Topics Covered: An introduction to safety Overview and definitions General requirements and electrostatic spray equipment Ventilation Storage handling and distribution Fire protection Operations, maintenance and training Drying and curing Liquid and powder coatings Authority Having Jurisdiction panel discussion Who Should Attend? Manufacturing, staff and environmental engineers (industrial health & safety) Lead painters Maintenance leads and personnel Finishing equipment designers System controls and project engineers Facility managers Finishing industry distributors Date: Tuesday, March 11 and Wednesday, March 12 Time:  Tuesday - 9:00 AM - 4:00 PM and Wednesday 8:00 AM - Noon Location: Sames 45001 5 Mile Road Plymouth, MI 48170 Registration Fee: CCAI Members: $599  /  Non-Members: $750 Registration Fee Includes: Classroom instruction; lunch on day one; a certificate of completion; and a printed copy of the NFPA 33 Standard for Spray Application Using Flammable or Combustible Materials. Registration: CLICK HERE to register. Space is limited.

Because JPL scientists are interested in higher and higher frequencies for microwave devices, the designs of the microwave blocks are becoming more intricate and the necessary internal wave-guide channels must be smaller and smaller. The Space Instrument Shop is currently getting ready for the next generation of microwave blocks. As it is, production techniques are already extreme. Here are some of the key steps in machining these workpieces.

In this webinar, director of manufacturing Phil Linscheid will discuss how Hamilton Company has transformed its manufacturing operations with real-time production data. Learn how Phil and his team have increased throughput five times since 2017, while simultaneously improving production efficiency. Phil will share his journey over the past few years making strategic decisions to grow the machine shop’s impact as well as how his team uses MachineMetrics to improve production visibility, automate cycle time tracking, increase machine uptime and enable accurate quoting and planning. Agenda: Enabling production visibility in Nevada’s largest machine shop Improving quoting, planning and scheduling with accurate cycle times The importance of integrating shop floor data with operational systems

The inner face of this sample sub-millimeter microwave block is about 0.75-inch square. A penny placed next to the wave-guide channel port indicates the scale of the features machined by JPL’s Space Instrument Shop. Photos courtesy of JPL.

Hal Janzen uses the Ewag cutter grinder to produce the smallest end mills used in the shop. This work is done with the aid of a microscope. Everyone in the shop has “trained their eyes” to recognize and identify objects under magnification.

The other microscope is mounted on an adjustable swing-away arm that rides on a column mounted vertically to the table of the machine. This binocular-style microscope swings into position to magnify a view of the cutting zone. It is used to set the length of the cutting tool in the spindle, a process similar to workpiece alignment. Each click of the jog button advances the Z axis ten millionths of an inch at a time on the DAC (20 millionths of an inch on the Bostomatics). Each advance can be observed through the microscope. When the rotating tool tip makes contact with the workpiece surface, it leaves a circular mark that is barely visible at 50x magnification. The height in Z at that point is set as zero tool length and the appropriate offsets can be applied to the programmed tool path. This microscope is also used to observe the machining process in action and monitor it for tool breakage or negative cutting conditions such as raising a heavy burr.

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.

Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.

Spanning 113,500 square feet, the facility will centralize the company’s storage and distribution, as well as enhance operational efficiency.

Adding pallet systems brought Mach Machine success and additional productivity. The shop has since furthered its automation goals while adding new capabilities.

In this second step, the wave-guide channels and pockets are machined on either one of the Bostomatics or a modified three-axis milling machine from DAC International (Carpinteria, California). The smallest channels are machined on the DAC. This machine was originally designed to mill lenses that are surgically implanted in the eye for vision correction (intraocular lens haptics). The machine is based on a granite surface plate that is mounted on vibration isolators on a welded steel frame. The Space Instrument Shop replaced the X, Y and Z slides with high-precision Schneeberger slides and installed larger servomotors to run at slower feed rates without overheating. Heidenhain glass scales provide position feedback in 10-nanometer increments. Mr. Bruneau is the chief operator of this machine and he is responsible for most of the retrofits and enhancements.

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.

How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM 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.

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

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.

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.

Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.

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

Nevertheless, Mr. Janzen emphasizes that good habits need to be cultivated to maximize the shop’s overall success rate. The shop has its own tips for achieving good results and follows them rigorously. Some of the most important items are:

Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.

Each year Products Finishing partners with thousands of finishing operations in the U.S. to celebrate National Surface Finishing Day (NSFD) on the first Wednesday in March. NSFD is designed to celebrate and showcase the industry to trade schools, businesses, officials and media, as well as to celebrate employees and staff. The overarching goal of NSFD is to bring further awareness to the important roles plating and coating facilities play in their communities. Facilities are encouraged to host events and work with local media to build awareness about the contributions made by the surface finishing industry. For a helpful guide to reaching out to media outlets, download the NSFD toolkit here. How can you celebrate? Share your company’s story Hold an open house where the public can check out your facility –— either in person or virtual Offer student shop tours to local trade schools Invite local elected officials to visit and get to know your staff Celebrate your employees Share news about what you’re doing on social media and use the hashtag #NationalSurfaceFinishingDay or #NSFD

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

Founded in 2001, PMTS reconvenes in April 2025 to celebrate its 13th biennial event for precision machining pros. Mark your calendar now and plan to join the precision machined parts community when we once again gather in person to share challenges and insights, see new technology solutions and learn about process innovations you can take back and immediately put into use in your own shop. The Precision Machining Technology Show is centered at the intersection of the industry's newest and most advanced product technologies, process innovations, business development prospects and personal career growth opportunities.

By equipping MassRobotics with its advanced cobots, ABB aims to facilitate the creation of new and impactful solutions that address real-world challenges across various industries.

The Jet Propulsion Laboratory (JPL) in Pasadena, California, is NASA’s premier research and development facility. It is staffed and managed by the California Institute of Technology (Caltech), a leading private university. Satellites, space telescopes and planetary explorers are designed and built here. JPL is home to some of the most advanced and capable machine shops in the country. One of these, the Space Instrument Shop, is very small. It employs three machinists, houses about a dozen machine tools and is equipped with various pieces of inspection and measurement technology.

Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.

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.

The tip of this end mill is 0.001 inch wide. The inset shows the tip head on, revealing the relief angles on the sides and at the center. Photo courtesy of JPL.

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.