BUFFALO MANUFACTURING WORKS Gardner Carrick Vice President The Manufacturing Institute
2 The Manufacturing Institute is the authority on the attraction, qualification, and development of worldclass manufacturing talent.
A resurgence in U.S. manufacturing?
4 Factors Driving Resurgence Cost of Business Overseas Transportation Costs Risk U.S. Energy Prices U.S. Innovations
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Disruptive Innovations 6
ADDITIVE MANUFACTURING
The Good News 3DP Adoption 8
Large vs. Small 9
Impacts of 3D Printing 10
Barriers to 3DP 11
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 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.
FLEXIBLE MANUFACTURING
North American Robot Orders
Innovations in Robotics
Expected Uses of Robots
Robots Stealing Jobs?
INTERNET OF THINGS
The Internet of Things
The Internet of Things
The Internet of Things
Contact Information Gardner Carrick Vice President The Manufacturing Institute E-mail: gcarrick@nam.org www.themanufacturinginstitute.org @TheMfgInstitute
Meeting the Challenge 6/19/2015 Ron Brown Technology leader
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
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
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
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
Providing manufacturers access to leading-edge capabilities Bridging the gap between research and manufacturing implementation EWI Focus: Manufacturing Technology Innovation, Maturation, Commercialization, Insertion
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
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
Flexible Manufacturing Automation feasibility pilot laboratory The unique capability to assemble materials and equipment in the lab to pilot and validate flexible automation processes
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
Flexible Manufacturing Collaborative Human-Robot Cobots
Flexible Manufacturing Single arm cobots Kuka Fanuc Universal Force torque sensors Soft synthetic rubber arms with force sensors Adjustable Reduced Mode And force sensing
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
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
Flexible Manufacturing Cobots: A new paradigm Some companies are considering cobots as expensed workers not capital equipment, shifting robots from machines to labor
Flexible Manufacturing Making it easy
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.
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
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
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
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
Questions