Innovation in the metalworking industry is key — not only for improving product quality and controlling costs, but for remaining competitive. Currently, manufacturers face an unprecedented number of challenges, among them:
- Rising material costs and the need to reduce waste and increase production efficiency
- Increasing demand for more environmentally friendly manufacturing practices
- Supply chain instability and labor shortages that are forcing manufacturers to reduce costs wherever possible to remain in operation
It’s difficult to keep up with these changes without implementing innovative metalworking solutions. But what are the major innovations that can help? Read on for an overview of some of the biggest metalworking solutions available as well as tips to keep in mind for optimizing their benefit.
Innovative Metalworking Solutions for a New Era of Manufacturing
Manufacturing is always improving, but the most recent advancements impacting the industry have been in the realms of technology and engineering. Here are the three biggest breakthroughs in metalworking innovation for the 2020s so far:
1. 3D Printing
3D printing, also known as additive manufacturing (AM), has advanced far beyond prototyping capabilities and is increasingly used for production of parts. AM technology is rapidly advancing, and it has become a popular metalworking solution for prototyping and even producing parts with complex geometries — especially in the aerospace and medical sectors.
By reducing the need for connection points, AM can produce parts with high integrity and quality. When combined with subtractive manufacturing operations to finish and perfect parts, hybrid AM operations can achieve unique and complex parts previously not possible
Master Tip: Machining matrix composite metals used in additive manufacturing requires the use of a compatible next-generation cutting fluid to prevent damage to the workpieces and cutting tools. New metalworking solutions like TRIM® C390 and MicroSol® 692XT feature the latest coolant technology and can ensure flawless finish quality.
2. New Material Advancements
In addition to improving the strength of composites used for additive manufacturing, researchers have made significant strides in formulating new metal alloys that exhibit ultra high strength, corrosion resistance, and stability in extreme temperatures. Recently, scientists even developed a new category of metal called advanced high-strength steel (AHSS).
These new metals provide better strength-to-weight ratios critical for increasing fuel efficiency in aerospace, automotive, and other transportation products. In fact, lightweight but ultra strong metals are as important for vehicle electrification as batteries themselves. Reducing overall vehicle weight minimizes fuel and energy consumption during operation while maintaining proper protection for passengers.
Master Tip: Leading-edge cutting fluids such as eco-friendly HyperSol™ 888NXT are compatible with a wide array of materials, including the advanced alloys becoming increasingly important in the market. Upgrading to the latest generation of cutting fluids will ensure your operation can quickly incorporate new materials into its processes.
3. Lights-Out Manufacturing
Lights-out manufacturing is a style of production where operations can run largely unmanned, especially after normal work hours, enabling massive productivity gains for busy machine shops. A mixture of advanced robotics, artificial intelligence, and machine learning carry out many aspects of production on their own, ranging from setup and the operation itself to performance monitoring and maintenance.
Currently, many machine shops only use these capabilities for overnight production after employee shifts end to minimize machine downtime, but this is paving the way for more continuous operation in the future. In addition to lowering costs, lights-out manufacturing can improve part consistency and precision by reducing the chance for human error or operator variation. This technology can also improve safety by minimizing employee exposure to dangerous situations.
Master Tip: When machines run unattended for long periods of time, issues like carryoff and foam can create significant problems for a shop. That’s why it’s important to choose high-quality cutting fluids designed for challenging operations. Before trying to implement lights-out practices, upgrade to trusted fluids like TRIM MicroSol 692XT, TRIM C390, or bio-based HyperSol 888NXT to avoid unnecessary downtime, frequent tool changes, and rework.
Metalworking Solutions From the Masters
This is an unusually challenging time for manufacturing, but the industry is always producing new innovative metalworking solutions. Finding what’s right and worthwhile for your operation can be difficult, especially when the industry’s fast pace leaves little room for errors or poor investment.
Want support implementing a new metalworking solution? Contact our team today to schedule a site visit.
