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hyperMILL 2024 CAD/CAM software suite

OPEN MIND Technologies has introduced its latest hyperMILL 2024 CAD/CAM software suite, which includes a range of powerful enhancements to its core toolpath capabilities, as well as new functionality for increased NC programming efficiency in applications ranging from 2.5D machining to 5-axis milling. New and enhanced capabilities include: Optimized Deep Hole Drilling, a new algorithm for 3- and 5-axis Rest Machining, an enhanced path layout for the 3D Plane Machining cycle, better error detection, and much more.
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Find test data issues faster: AI Anomaly Detector

It can take months of manual engineering time to detect test data abnormalities. Now the task can be performed in a flash. Artificial intelligence software provider Monolith has developed the industry's first AI-powered Anomaly Detector software that can discover a broad range of issues in test data fast -- measurement or sensor errors, user errors, system malfunctions, or incorrect usage of the system during testing. It does this by automating the process of raw test data inspection to look for potential errors or abnormalities across hundreds of test channels.
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Loss-free conversion of 3D/CAD data

CT CoreTech-nologie has further developed its state-of-the-art CAD converter 3D_Evolution and is now introducing native interfaces for reading Solidedge and writing Nx and Solidworks files. It supports a wide range of formats such as Catia, Nx, Creo, Solidworks, Solidedge, Inventor, Step, and Jt, facilitating smooth interoperability between different systems and collaboration for engineers and designers in development environments with different CAD systems.
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Top 5 reasons for solder joint failure

Solder joint reliability is often a pain point in the design of an electronic system. According to Tyler Ferris at ANSYS, a wide variety of factors affect joint reliability, and any one of them can drastically reduce joint lifetime. Properly identifying and mitigating potential causes during the design and manufacturing process can prevent costly and difficult-to-solve problems later in a product lifecycle.
Read this informative ANSYS blog.

How a BattleBot was built using Onshape

Learn how RoboGym Robotics, a veteran BattleBots team, said goodbye to Solidworks and took their design game to the next level using Onshape, the cloud-native, all-in-one CAD and PDM solution. RoboGym was able to analyze key components of their Roundhouse BattleBot like its armor and weapon bar, run simulations, collaborate, iterate, and optimize their design to its fullest.
Read this informative Onshape blog.

Trick to measuring angles in SOLIDWORKS

Learn from the pros at TriMech how to take angle measurements easily in SOLID-WORKS. TriMech has an entire YouTube channel dedicated to SOLIDWORKS tips, and the company is excellent at training too.
View the video.

COMSOL Multiphysics Version 6.2 is here

COMSOL Multiphysics Version 6.2 introduces faster solvers for turbulent fluid flow, electric motors, and room acoustics. It also brings data-driven surrogate model functionality for creating multiphysics-based digital twins and building fast and accurate standalone simulation apps. Get the full details of what's new in the latest version.
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17 ways SOLIDWORKS 2024 helps you work faster

SOLIDWORKS 2024 helps designers and engineers work faster than ever. Learn all about improvements to core 3D CAD modeling features, new 3D modeling techniques, and graphical and software performance boosts that will help you get your parts made and your products developed in record time.
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6 tips to streamline workflow in Mastercam 2024

Mastercam 2024 CAD/CAM software has been intentionally upgraded to make programming fast and easy. It prioritizes streamlining workflow so that the entire machining process -- from design to QC -- is as efficient as possible. Learn how to maximize the benefits of Mastercam 2024, including special toolpaths, easier hole-making operations, wireframe shortcuts, and more.
Read this informative Mastercam blog.

How CT data analysis is helping TE Connectivity reach their goal of end-to-end quality inspection

In a bid to cut their mold and part development process to 25% of the time it took in the past, TE Connectivity has taken ambitious steps to interconnect design and simulation with quality measurement. Learn how the company, in collaboration with PTC (Creo) and Volume Graphics, has worked to ensure as-designed parts match as-manufactured parts as early in the process as possible. An in-depth and illuminating read.
Read the full article.

State-of-the-art mesh morphing technology for super optimization: Ansys and RBF Morph join forces

After a long and successful OEM partnership with Ansys, mesh morphing pioneer RBF Morph has two proprietary products featured among the world simulation leader's offerings: Ansys RBF Morph Fluids and Ansys RBF Morph Structures. Thanks to mesh morphing, companies can substantially reduce computational time while performing highly automated design optimization analysis, increasing products' reliability and performance while cutting costs, delivery time, and environmental impact.
Read the full article.

Top Tech Tip: Creating drafts with the rib feature in Onshape

Ribs are used to add stiffness and strength to parts without adding excessive weight or increasing wall thickness -- most commonly in molded parts that require a draft angle so the part can release from the mold. See the basics of how this is done in Onshape, which features the power of cloud computing, real-time collaboration tools, and a built-in PDM system -- all for the same price as CAD.
Learn more.

How to design a spoon with subdivision modeling: SOLIDWORKS xShape

Learn how to design a spoon with SOLIDWORKS xShape, which is found in 3D Sculptor on the 3DEXPERI-ENCE platform. xShape is a next-gen subdivision modeling tool that runs entirely in your browser and takes a freeform approach to creating complex shapes and surfaces. You can design 100% in the cloud or seamlessly integrate your xShape models with your SOLIDWORKS designs. Follow along with this 7-minute tutorial to see what it's all about.
View the video.

What's new in Onshape?

Check out the latest updates to Onshape, the cloud-native product development platform that delivers professional-grade CAD capabilities with next-gen product data management. New features include customizable keyboard shortcuts, better BOM navigation, improved drawing tools, and new Learning Center content. With Onshape, users can innovate quickly while simultaneously or asynchronously collaborating with other stakeholders on any web-connected device.
View the video.

Open-access learning center for multiphysics modeling

COMSOL, the developer of the COMSOL Multiphysics simulation software, has introduced a new online resource that provides no-cost, open access to modeling and simulation learning material across all areas of physics. Designed with the user in mind, the Learning Center offers a single entry point for users of all skill levels, where courses, articles, and videos present a clear path for learning how to use COMSOL Multiphysics for modeling and simulation.
Check out the COMSOL Learning Center.

Cincinnati Inc., ORNL working on machine that 3D prints HUGE parts; Local Motors plans to use the tech to 3D print electric car

By Mike Foley, Designfax

Cincinnati Inc., a metal fabrication juggernaut for more than 100 years, has teamed up with the Department of Energy's Oak Ridge National Laboratory (ORNL) to develop and commercialize a new large-scale additive manufacturing system capable of printing huge polymer components -- much, much faster than many current systems can build small parts.

Hmmm ... how can that be?

Well, according to Lonnie Love, Ph.D., group leader of ORNL's Manufacturing Systems Research Group, the secret is in the materials and the delivery.

Love says that the new machine has an 8 ft x 8 ft x 8 ft build envelope and is scalable, with the biggest near-term future platform envisioned to be 20 ft x 10 ft x 8 ft. That is huge, when you consider that a 3 ft³ build envelope is considered large these days.

The proposed large-part additive manufacturing machine from Cincinnati Inc.

 

 

But how can the material print and cure faster? Now that is interesting. Love says that the answer is two-fold.

First, the machine prints with a big nozzle, so more material is heated and extruded (but not anywhere near as precisely). Love says that a typical fused-deposition modeling (FDM) machine has a 0.020-in. nozzle. The ORNL machine uses a 0.3-inch one. The material comes out looking like, and this is a really accurate description, something you'd see when looking at your piped-icing-decorated birthday cake (see Local Motors video below). No one said this machine is fast and accurate, at least when it comes to the printing part.

The other difference is the material. Instead of using a line of (plastic or ABS) filament like most 3D printers use, the ORNL machine uses a mixed plastic-and-carbon-fiber material that comes in pellets. The carbon fiber greatly reinforces the material, so it can be formed lighter and stronger. But unlike traditional FDM, Love says that this material enables part stability at room temperature. "There is no oven," he says, so parts cure extremely fast, even if they are large.

A prototype of the large-scale additive machine is in development using the chassis and drives of Cincinnati's gantry-style laser cutting system as the base, with plans to incorporate a high-speed cutting tool, pellet feed mechanism, and control software for additional capability.

Cincinnati's experience in designing, making, and controlling large-scale manufacturing systems, as well as its long working relationship with ORNL, led to the partnership.

"As one of the oldest U.S. machine tool makers, with continuous operation since 1898, we view this as an opportunity to start a new chapter in our history," says Andrew Jamison, CEO of Cincinnati Inc. "Over the years, we've supplied more than 40 metal working machine tools to Oak Ridge and its subcontractors. Now, working together, we intend to lead the world in big-area additive manufacturing for prototyping and production."

According to Love, the capability of this machine to produce tooling -- and not particularly standardized "parts" -- is its big breakthrough. "We have already made and tested large metal forming tools for the aerospace industry," says Love. "It will revolutionize U.S. tooling. We've made custom furniture and are working with Local Motors on customized printed electric vehicles." Love says the project was initially an internal Lockheed Martin program. They partnered with ORNL last year, and ORNL has funded it internally for a year. This year the goal is transitioning to a commercial product with Cincinnati Inc.

So rather than printing "parts" (be they big or small) like most of us think of when we think of 3D printing, this printer can also print the base materials to create things like big molds or dies.

"But I thought you said this process isn't particularly accurate," you are probably thinking, "so how can you use it for tooling?" Well, that is where another process comes in: subtractive manufacturing (or milling). Remember that Cincinnati said that the machine can incorporate a high-speed cutting tool?

A look into the Local Motors project can shed a little more light on this. Alex Fiechter, head of R&D and community management at Local Motors, explains (in the video below) that the large ORNL 3D-printing machine also contains a machining head for material removal, so that once the 3D part is printed in the rough it can be machined to needed tolerance/specifications.

Local Motors, a pioneer in the online design and hardware co-creation market and known for creating a really cool customizable car called the Rally Fighter, has agreed to build a 3D-printed electric car for the Association For Manufacturing Technology to be featured at the upcoming International Manufacturing Technology Show (IMTS) 2014 in Chicago, IL, September 8-13, 2014.

Local Motors Direct Digital Manufacturing (DDM) electric car concept to be demonstrated at IMTS 2014.

 

 

"We're printing the body and frame of the vehicle, along with seats and anything else that we can," says James Earle, advanced manufacturing engineer at Local Motors. ... The printed parts will all be one piece."

"We won't be printing the drive train components or any other electrical systems," says Earle.

A look at a video update that Local Motors posted recently gives some insight into what is going on with their IMTS car and the ORNL printer. In it, Fiechter explains how the printer first lays down the basic form of the polymer/carbon fiber part quickly and then the part is machined out (that's the subtractive part) to produce a finished result. Local Motors also says that it is investigating using ULTEM with carbon as one possible material and ABS with carbon as another.

Using this method, both standard "parts" and tooling can be created.

"We're using chopped fiber that is integrated into the plastic pellets we buy (we don't add it ourselves)," says Earle. "For FDM parts (fused deposition modeling, how we're printing the car), it's relatively new. We're one of only a few using carbon fiber to reinforce printed plastic at this scale, but there are a lot of people interested in the idea and studying it."

Earle says that they probably won't be 3D printing metal parts for the IMTS car, but the project engineers "have looked into printing custom fasteners that we could incorporate into the car as we print."

"For our purposes, we want to print a functional car," says Earle. "That means printing 'usable' parts. There is a lot of interest in the machine from other companies for use in creating dies for tooling purposes, e.g. to form sheet metal, but Local Motors wants the car to be printed in one piece. It's possible we may, in the future, use the printer to create molds for door panels or something, but initially no."

Published March 2014

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