BUFFALO MANUFACTURING WORKS. Gardner Carrick Vice President The Manufacturing Institute

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1 BUFFALO MANUFACTURING WORKS Gardner Carrick Vice President The Manufacturing Institute

2 2 The Manufacturing Institute is the authority on the attraction, qualification, and development of worldclass manufacturing talent.

3 A resurgence in U.S. manufacturing?

4 4 Factors Driving Resurgence Cost of Business Overseas Transportation Costs Risk U.S. Energy Prices U.S. Innovations

5 5

6 Disruptive Innovations 6

7 ADDITIVE MANUFACTURING

8 The Good News 3DP Adoption 8

9 Large vs. Small 9

10 Impacts of 3D Printing 10

11 Barriers to 3DP 11

12 12 When to Use 3DP? Business Performance Specific parts are built in low volumes or have high fixed costs associated with them; Special parts have long lead times, or manufacturers want to get new products into the marketplace more quickly; Reduce part count or boost performance beyond what is now possible.

13 13 When to Use 3DP? Supply Chain & Logistics High inventory storage costs suggest making smaller batches on demand; Time-sensitive parts are needed in remote locations with expensive shipping costs; High import and export costs eat into profits for simple parts; Reduce the leverage that suppliers hold over manufacturers by creating an alternative or replacement source for critical parts.

14 FLEXIBLE MANUFACTURING

15 North American Robot Orders

16 Innovations in Robotics

17 Expected Uses of Robots

18 Robots Stealing Jobs?

19 INTERNET OF THINGS

20 The Internet of Things

21 The Internet of Things

22 The Internet of Things

23 Contact Information Gardner Carrick Vice President The Manufacturing Institute

24 Meeting the Challenge 6/19/2015 Ron Brown Technology leader

25 Buffalo Manufacturing Works Buffalo Manufacturing Works, operated by EWI, is a oneof-a-kind center for advanced manufacturing technologies Part of the Buffalo Billion Investment Development Plan designed to spur economic growth in Western New York A groundbreaking collaboration between leading industry, research and academic partners Industry Founders Council University of Buffalo Insyte Consulting World Trade Center Buffalo Niagara Workforce Development Resources Applied R&D Technical Inquires, Design Reviews and Library Retrieval Academic Research Process Excellence & Growth Consulting Market Expansion and Support Training and Education

26 EWI? Applied research and development services company that innovates, matures, and commercializes advanced manufacturing technologies Not-for-profit organization founded in 1984 in Columbus, Ohio Global thought-leader on manufacturing technologies Innovative solutions provider

27 Providing manufacturers access to leading-edge capabilities Talent driven innovators Highly educated staff of 160 engineers, technicians, industry experts, and member advocates Buffalo = 12 Columbus = 150 Partnerships with leading universities and institutes

28 Providing manufacturers access to leading-edge capabilities State of the art facilities and equipment EWI Columbus,135,000sqft Over $30 million in capital equipment Buffalo Manufacturing Works, 20,000sqft $6m in capital equipment currently committed $24m currently uncommitted

29 Providing manufacturers access to leading-edge capabilities Bridging the gap between research and manufacturing implementation EWI Focus: Manufacturing Technology Innovation, Maturation, Commercialization, Insertion

30 High-Impact Applied R&D Manufacturing Technologies Arc Welding Resistance & SS Welding Laser Processing Ultrasonic Processing Micro-Joining Soldering & Brazing Forming NDE Flexible Manufacturing Materials & Testing Additive Manufacturing Machining & Finishing

31 Flexible Manufacturing Focus Developing, simulating, prototyping, validating, agile automation and controls solutions. Toolbox Simulation: robotic cell and discreet event Robotics: various sizes, styles and function including vision, force control Controls: PLC, PAC, various protocols and sensors Inspection & NDE: optical, laser, ultrasonic and eddy current

32 Flexible Manufacturing Automation feasibility pilot laboratory The unique capability to assemble materials and equipment in the lab to pilot and validate flexible automation processes

33 Automated Inspection Surface Characterization System Alicona IF-Robot Technology: Focus-Variation based Robot Mounted Capable of measuring Ra > 6 μinch Differentiating Capability: Fast and modular inspection and in-situ monitoring

34 Flexible Manufacturing Collaborative Human-Robot Cobots

35 Flexible Manufacturing Single arm cobots Kuka Fanuc Universal Force torque sensors Soft synthetic rubber arms with force sensors Adjustable Reduced Mode And force sensing

36 Flexible Manufacturing Dual arm cobots YuMi Nachi Baxter ABB Stereo vision and force sensing Compliant arms with elastic joint actuators, force detection & vision Soft padded arms combined with built-in force sensing

37 Flexible Manufacturing The evolution of robot safety and decreasing costs Interlock Fixed Barrier Interlock Fixed Barrier Presence Sensing Path Barrier Software Force sensing Vision detection No Safety Barrier Cobot >$300k $200k <$100k

38 Flexible Manufacturing Cobots: A new paradigm Some companies are considering cobots as expensed workers not capital equipment, shifting robots from machines to labor

39 Flexible Manufacturing Making it easy

40 Flexible Manufacturing Making it easy A team at the University of Maryland recently developed a system that enabled robots to process visual data from series of how to videos on YouTube. Based on what was shown on a video, robots were able to recognize, grab and manipulate the correct object and perform the demonstrated task with high accuracy without additional human input or programming.

41 Additive Manufacturing Focus Development, proof-testing, and application of next-generation additive, digital and rapid manufacturing processes Toolbox Additive processes for 3-D and functional printing Design, modeling & simulation Operational expertise Prototyping and testing capability Application examples Application expertise across many platforms, development of next-generation AM technologies for metal, ceramic, and composite materials, validation and characterization of AM processes

42 Additive Manufacturing AM Process Technologies Material Extrusion, extrude hot material Stratasys uprint Vat Photopolymerization, UV light cure B9 Creator Material Jetting, lay material, UV cure Stratasys Objet30 Binder Jetting, lay material and binder Inovent

43 Additive Manufacturing AM Process Technologies Powder Bed Fusion, laser or EB fusion Arcam A2X Direct E Deposition, powder direct into beam RPM Sheet Lamination, ultrasonic welding Fabrasonic

44 Additive Manufacturing Columbus EOS M280 Heat Exchanger Enables complex 3D shapes Internal passages for cooling, light-weighting Properties comparable to conventional (depending on alloy and heat treatment, and surface condition) Titanium Spinal Implant

45 Questions

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