The underlying drivers of additive manufacturing’s advance are increasingly easy to spot on automated CNC machine shop floors.

The digitalization of manufacturing is set to transform production and global supply chains as we know them, and additive manufacturing has been leading the way in many industries.

Manufacturing has had a bad rap for a long time. The 3-Ds — Dark, Dirty, Dangerous — are almost a universal cultural belief wherever you go and no matter with whom you speak.

The DG modular interchangeable head milling system optimizes the interface between the cutting head and shank for greater versatility, stability and higher changeover precision.

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.

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

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.

The microstructure of bainite was unique in that it formed under continuous cooling or under isothermal conditions, with a structure that was like both martensite and pearlite. Pearlite contains a mixture of ferrite and iron carbide, and is diffusion controlled. Martensite is non-lamellar and not diffusion controlled. Bainite showed both the characteristics of pearlite and martensite, depending on the temperature of formation. Two different morphologies of bainite were observed: upper bainite that formed just below pearlite, and lower bainite which forms at just above the Ms temperature. It has a similar appearance to tempered martensite, with a feathery appearance. It is very similar to tempered martensite in terms of hardness and toughness. Because of the difficulty in controlling the formation of bainite, it generally has limited applicability, except for austempering. This is a process using molten salts where bainite is formed on isothermal holding at approximately 325°C (620°F). This process is used when a hard and tough structure is needed, in thin sections, such as lawn mower blades. Figure 2 shows the different etching behavior of bainite and martensite.

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.

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

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

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

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.

At Mill 19, the site of the Advanced Robotics for Manufacturing Institute and Carnegie Mellon University’s Manufacturing Futures Institute, robotics data provides the foundation for AI and digital twins.

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

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

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.

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.

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.

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.

Yes, according to 6K Additive. The materials company can use unconventional metal feedstock, including chips, in its unusual powder production process.

With the increased weight and speed of trains, there has been extensive interest in the use of bainitic steels for rails. Rail steels must be designed to resist plastic deformation and rolling contact fatigue. The use of bainitic steels for rails increases fatigue resistance and improves strength over traditional pearlitic steels [6].

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.

During the late 1920s, during studies of isothermal transformation of austenite, at temperatures above martensite formation but below martensite transformation, Davenport and Bain [1] discovered a microstructure that etched differently than martensite or pearlite. This microstructure was later named “bainite” in honor of E.C. Bain [2].

Bainite is becoming increasingly important in many industries because of its unique set of properties of good strength and toughness. It is being used in many areas, including automotive, agricultural, and rail transport. One major benefit is the elimination of tempering, and the ability to direct quench by controlled cooling.

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.

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?

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 goal of National Composites Week is to celebrate and bring attention to the myriad ways that composite materials and composites manufacturing contributes to the products and structures that shape the American manufacturing landscape today. Learn how you can participate in this year's National Composites Week on NationalCompositesWeek.com.

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

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.

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

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

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.

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.

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

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.

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.

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

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.

The Starrett AVR400 offers full CNC capabilities including XYZ positioning as well as zoom and telecentric lens options.

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

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.

But the potential of this technique extends beyond 6K Additive and even beyond additive manufacturing all together. A process that can make use of existing material rather than requiring virgin feedstock not only provides a home for scrap like machining chips, it also keeps valuable material local.

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

Ceratizit USA has promoted Troy Wilt from national sales manager to managing director of Ceratizit USA, cutting tools division.

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.

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

Grant funding for workforce training or the purchase of new equipment is an undervalued but complex resource for machine shops. We enlisted an expert to help navigate the process.

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

Implementing additive manufacturing means starting somewhere. Seeking out the right pathfinder part can illustrate valuable lessons about the advantages of this technology.

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.

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

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

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

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%.

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.

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.

In general, the formation of bainite is suppressed by many alloying elements. However, carbon has the strongest effect. An empirical equation for the start temperature for the formation of bainite (Bs) is [5]:

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.

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

Should you have any questions or comments on this article, or suggestions for further articles, please contact the editor or the author.

The digital landscape is evolving fast — are you ready for what’s ahead? Join SYSPRO Americas and Sam Gupta of ElevatIQ for exclusive insights into the key trends driving digital transformation in 2025. This webinar is perfect for business leaders, IT professionals and decision-makers across industries looking to prepare for the future. Whether you’re modernizing operations or staying ahead of industry disruptions, these trends will help shape your strategy for 2025 and beyond. Agenda:  AI and automation Geopolitical shifts and cybersecurity risks Collaboration and data integration Sustainability and energy efficiency

By separating the sizing of powder from its densification and shaping 6K Additive has been able to overcome some of the challenges of gas atomization, a common means of producing metal additive manufacturing feedstock. In gas atomization, large amounts of metal are melted and dropped through a stream of gas to produce spherical particles; once cooled and solidified, the entire lot of material is then sieved and sorted into various grades, which can result in waste when powder that is too large or too small results.

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

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.

Upper and lower bainite are plates of ferrite, separated by untransformed austenite, martensite, or cementite [4]. The shape of the groups of bainite is a wedge-shaped plate. The nucleation of bainitic ferrite is typically associated with the formation of small, needle-like precipitates of carbon-rich iron carbides, known as “sheaves.” The individual plates within a sheave are called sub-units and have a lens-shaped or lath morphology. The thickest part of the plate usually forms at an austenite grain boundary.

European manufacturers may have a different balance of markets than their U.S. counterparts, but the practical challenges they must overcome are often similar — as are the solutions.

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.

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.

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.

The VT Series of large-swing vertical turret lathes can be configured for turning, milling, boring and grinding in a single machine.

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.

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.

Bainite is becoming increasingly important in many industries because of its unique set of properties of good strength and toughness.

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.

This is part of the vision of 6K Additive, a materials processor based in Pennsylvania that has developed a way to turn various types of metal into high-value, infinitely flexible powders that can be applied in 3D printing. The technique can be used to refurbish leftover powder from the laser powder bed fusion (LPBF) process; refine oversized powder produced through gas atomization; or transform metal chips, grindings and even full parts into usable powder.

Consider that the United States has no domestic source for mining of titanium; like many other alloys, most of the stock comes from China so virgin titanium must be imported. Yet with an efficient recycling strategy, the U.S. could mine its own chip bins and aircraft boneyards and more for titanium feedstock. (6K Additive even envisions a future where large OEMs might have their own UniMelt reactors to convert scrap right on site.) And once converted into feedstock for additive manufacturing, the potential applications might be limitless.

Thanks to mechanical milling and an efficient microwave plasma process, 6K Additive does not need to produce large batches of powder which can make new alloys and unusual materials more accessible.

The application of bainitic microstructures is growing. The advantages of the elimination of tempering after quenching are of economic benefit in reduction of cost and cycle time. Advances in controlled cooling during rolling have shown benefits in creating bainitic structures in plate and rail. This plate is used in the creation of pipe for natural gas transportation, enabling easier welding and improved strength and toughness over traditional pipe. Austempered ductile iron, to create a structure of bainite, is used to manufacture automotive brake components. Automotive structures use bainitic steels for crash reinforcement to allow energy to be expended during a crash to protect the occupants. Additional applications are the use of bainitic steels in engine components such as cam shafts. This is accomplished by using controlled cooling from the die forging temperatures.

In contrast, because the UniMelt reactors use material that is already pre-milled down to size, it is nearly a 1-to-1 process. Without the need to melt large amounts of material, it does not need to produce a large batch in order to be economical (and may be more energy efficient). The mechanical step can also support the production of alloys that would not be possible otherwise.

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

One of the UniMelt reactors at 6K Additive’s Pittsburgh-area plant. Read more about the company’s material processing technique.

The 12,000-square-foot Center for Machining Excellence houses a wide range of technology and serves as a hub for industry innovation that is accessible to manufacturers and industry thought leaders worldwide.

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.

6K Additive uses a two-step process to do this. First, the feedstock material is cleaned and mechanically milled down to the desired size. Then, the particles are passed through a column of microwave plasma using one of the company’s UniMelt reactors. The plasma melts each particle just enough to densify and spheroidize the material into powder suitable for additive manufacturing (AM). Each pre-milled particle remains distinct during this step and cools quickly, so that the final powder can be collected soon after.

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.

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."

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.

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

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.

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

The decomposition of austenite, when occurring at a fast enough rate to exceed the critical cooling rate (based on the Time-Temperature-Transformation diagram), creates martensite. The critical rate depends on the chemistry and hardenability of the steel. At slow cooling rates, pearlite and ferrite are formed. At intermediate cooling rates, bainite is formed. This is shown in Figure 1.

6K Additive has developed a process that cleans and mills metal chips like these turnings (left) into a mechanically sized powder (center), which is then passed through microwave plasma to be densified and spheriodized into metal powder suitable for additive manufacturing (right).

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.

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.

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.

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

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

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

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.

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.

Vericut Intelligence and Vericut Assistant aim to simplify the way users can interact with and gain knowledge from Vericut’s software products.

Bainitic microstructures will both be harder and tougher than pearlite, but lower than martensite. Generally, the properties improve with lower transformation temperatures. “Lower” bainite will have properties approaching that of tempered martensite at the same hardness. It is this property of bainite that is the basis of the process of austempering.

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.

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.

Recycling of chips and scrap metal is a matter of course for most machine shops; sending this material off to a processor is a way to reclaim some of the capital invested in stock that cannot be used otherwise. But what happens to that metal once it is out of sight? Is there a way to not just recycle, but upcycle, that material into something even more valuable?