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LASERS EDGELASERS EDGELASERS EDGELASERS EDGELASERS EDGELASERS EDGEConquering hard materials with laser-assisted machining
Diving into deep-draw forming
Cleaning options for microparts
Growth of Swiss-style machining
PLUS: About Tooling Tech News Down Sizing Product Showcase
May/June 2015 Volume 8 Issue 3
MADE IN THE U.S.A.A Minnesota Company
Standard tools, superior performance.
Phone: (320) 455-0535Web: www.mitgi.us
Over the past two decades, MITGI has built a solid reputation for manufacturing precision cutting tools. Whether manufacturing industry standards or hard to find specials, we welcome the opportunity to stack our tools against the best that the industry has to offer.
Were pleased to announce that the MITGI standard catalog product line is expanding by more than 500% and now includes over 4,200 tools. All catalog tools are available coated and uncoated, and available to ship in three days or less.
MITGI Standard Catalog Tools:
Everything you guys send us works very well and the delivery is always when we need them. I appreciate the work you do for us and the quick turnaround. -Rich
QUALITY. PRECISION. MITGI.
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Contact us to receive a catalog or to place an order.
Smartphone Benefi tsYou can use your smartphone to scan the quick-response (QR) matrix code images below and instantly access the respective reports on our website, or enter the URLs into your Web browser.
UL backs AM training centerIn May, the University of Louisville and UL (Underwriters Laboratories) announced plans for a 3D printing training facility to open this fall adjacent to the university campus.micro.delivr.com/2vae3
Laser Video Series: How lasers workMICROmanufacturing columnist Ronald D. Schaeffer, CEO of PhotoMachining Inc., provides the history and future of laser technology and its importance to micromanufacturing.micro.delivr.com/234ht
Slim and accurate mechanical chuckShowa Tools Micron Chuck, a mechanical milling chuck featuring a slim design and inherent rigidity, is said to offer a higher level of accuracy than hydraulically operated chucks.micro.delivr.com/2cwg9
s & D
micromanufacturing.com | 1
COLUMNS4 Front Page
Heather Thompson, EditorMicromanufacturing and Big Manufacturing
13 About ToolingKip Hanson, Contributing EditorTurning microparts on a macro lathe
16 Fab UpdateDavid Sherrer, Nuvotronics LLCImproving the functional density of electronics
19 Swiss MachiningJohn ConroyRising use of Swiss-style machines
22 Down SizingDennis Spaeth, Electronic Media EditorWatches old and new
52 Last WordLouise Dickmeyer, PDP SolutionsCommunication and the manufacturing oor
DEPARTMENTS6 Tech News
10 MICRO Marketplace
47 Product Showcase
51 Advertisers Index
One Northfield Plaza, Ste. 240Northfield, IL 60093
StaffPublisherDon Nelson(847) 714-0173 firstname.lastname@example.org
Editorial DirectorAlan Rooks(847) 714-0174 email@example.com
EditorHeather Thompson(714) 915-9565 firstname.lastname@example.org
Senior EditorAlan Richter(847) 714-0175 email@example.com
Assistant EditorEvan Jones Thorne (847) 714-0177 firstname.lastname@example.org
Electronic Media EditorDennis Spaeth(847) 714-0176 email@example.com
Contributing EditorsKip Hanson (520) firstname.lastname@example.org
William Leventon(609) 926-6447 email@example.com
Art DirectorGina Moore(847) 714-0178 firstname.lastname@example.org
Ad Production ManagerJulie Distenfield(847) 714-0179 email@example.com
CirculationSynergy Direct Inc. (866) firstname.lastname@example.org
Advertising SalesScott Beller (North/Southeast)(847) email@example.com
Bill Klingler (E. Central/Far West)(847) firstname.lastname@example.org
Marc Condon (W. Central)(847) email@example.com
Jody Nelson (International)+1 (847) firstname.lastname@example.org
Cover Story24 Booster Beam
Kip Hanson, Contributing Editor Laser-assisted machining tackles hard materials
Features30 Life Enhancers
Kip Hanson, Contributing Editor Microscale sensors improve life, work and play
36 Drawing Attention William Leventon, Contributing Editor Growing interest in deep-draw forming
42 Clean Sweep John Conroy Cleaning options for small, complex parts
ON THE COVER:
May/June 2015 Volum
e 8 Issue 3
2 | MAY/JUNE 2015 | MICROmanufacturing
Laser-assisted machining photo courtesy of Purdue University. Cover design by Gina Moore.
I M P E R F E C T I O N I S NOT AN O P T I O N
O V E R
3000N E W I T E M S !
View online: kyoceraprecisiontools.com/micro
All new corner radius and extended reach end mills available with a wide range of radius sizes have been added to Kyoceras ever expanding solid round tooling lineup.
Kyocera also offers customized tooling options for medical manufacturing to optimize your production efficiencies.
K Y O C E R A P r e c i s i o n To o l s , I n c . / 8 8 8 . 8 4 8 . 8 4 4 9 / c u t t i n g t o o l s @ k y o c e r a . c o m
INTRODUCING THE NEW
2015 SOLID ROUND TOOLS CATALOG
As a relative newcomer to micromanufacturing, Im still amazed by the incredibly small scale of parts and devices. I still see things that make me want to say, Wow, did you see that? Its so incredibly small! I like to call out things like that because they seem so revolutionary. Ill bet thats not how you feel, because if it is a part of your everyday, you may even think its a bit boring.
Stay with me. Boring does not mean simple or easymicro is still enormously complex. But it does mean that we can stop looking at the technology as if it were magical. It also means that its time to improve micromanufacturing processes and make them more efficient.
One area ripe for improvement is software.Many micromanufacturers use jury-
rigged CAD/CAM systems on a daily basis, Lauralyn McDaniel told me during SMEs RAPID event for 3D printing in May. McDaniel is industry manager for medical device manufacturing for SME, a trade association for manufacturing professionals. She said she has yet to see proof that CAD/CAM software providers really understand the micro perspective enough to create an off-the-shelf solution. CAD/CAM developers just dont have the right technology, at least none that any manufacturers have told me about.
The way McDaniel sees it, in micromachining, for example, the part exerts more force on the tool than the tool exerts on the part. Macroscale machining is the oppositethe tool exerts more force on the part. Its a great way to illustrate the thinking required to produce microparts. Many people think its just smaller, but its more than that, said McDaniels.
The lack of specific software is just one issue. There are a host of digital technologies that could help micromanufacturers become big manufacturers. Big manufacturing (Big M) involves more than the shop floor, explained Ed Morris of America Makes, a network of companies, non-profits, academic institutions and government agencies based
in Youngstown, Ohio. He explained to RAPID attendees that Big
M refers to every aspect of manufacturing, from conception and design to production and disposal. According to Morris, the entire process must be supported and improved in order to increase efficiency, reduce lead times and improve margins. America Makes aims to help provide that support through membership-sponsored projects.
Another recent development that should improve support for micromanufacturing is the launch of the Digital Manufacturing and Design Innovation Institute (DMDII) in May. Managed by UI LABS, the 94,000-sq.-ft., Chicago-based consortium of academic, industry and civic partners is dedicated to finding new manufacturing technologies and solutions to industrial challenges.
The point of DMDII is to identify gaps where digital manufacturing needs work, distribute intellectual property developed from the research, engage small and medium-sized business, and contribute to workforce development, explained George Barnych, DMDIIs director of R&D programs, during a presentation at the Siemens Automotive Manufacturing Summit 2015. The idea is to get teams to work together that dont normally work together. DMDII wants to solve large-scale industrial challengesincluding those in micromanufacturingand develop and demonstrate the digital thread of technology across the manufacturing process.
The ability to share ideas across disciplines should improve all aspects of advanced technology. But even those of you who might be a bit bored with your daily grind, remember: You can always make it better.
Does micro have room for Big M?
4 | MAY/JUNE 2015 | MICROmanufacturing
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