Like so many other markets and industries, the COVID pandemic has affected the supply of components used to make semiconductor processing equipment. Semiconductor capital equipment manufacturers are turning to additive manufacturing to help repair the supply chain and enable designers to design for function first. I spoke with Scott Green, Principal Solutions Leader for semiconductors at 3D Systems on this subject. Here are some of the highlights of the interview.

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How additive manufacturing helps the semiconductor industry

3D printing/additive manufacturing and injection molding do not have to be competitors. In fact, 3D printing can aid injection molding. Formlabs recently commented that 3D printing is more of an accelerator for injection molding. 3D printers can introduce a hybrid approach where molds can be created fast and at low cost. Here are key points from an interview with Kathy Bui, engineering vertical lead at Formlabs

How 3D printing aids injection molding

Lattice structures have not been used as often as they could be because manufacturing methods that could produce them easily did not exist until the development of 3D printing / Additive Manufacturing. Today, though, 3D printing easily creates lattice structures in helmets, saddles, shoes, nasal swabs, and in other designs.

Taking advantage of lattice designs in 3D printing

As additive manufacturing gains acceptance as a production tool, the size of a typical 3D print slice data file is predicted to grow cubically. Handling all of these data could become an issue for the additive industry. Harshil Goel, CEO and Founder of Dyndrite discusses potential solutions to this problem.

The data challenge in additive manufacturing

The aerospace industry was an early adopter of additive technology, followed by the automotive industry.  Where do these industries stand in relation to additive technology today? In a recent interview, David Giebenhain, global product director at Protolabs, shares his thoughts.

Trends in aerospace and automotive additive manufacturing

3D printings effects on sustainability

The scale of sizes that 3D printing machines can handle is impressive, from huge wind turbine blades to parts that are small, such as two microns. John Kawola, CEO of Boston Micro Fabrication discusses the microscale side of 3D printing.

Going small with 3D printing

The supply chain continues to be a story for additive manufacturing, especially with the recent news from President Biden on the new AM Forward initiative. I recently interviewed Dave Evans, CEO of Fictiv, to discuss AM and the supply chain, among other subjects.

Going digital with additive manufacturing

3D printing/additive manufacturing can help designers simplify a part, reducing assembly steps in many cases, and creating a better end product. Is it possible, though, to over engineer a part? Here are some tips to help reduce excessive engineering and get parts out to market faster.

How to avoid over engineering a part

Some of the materials used in 3D printing are generally either not very, or even not degradable in the environment. Some developers and manufacturers though, are working to develop materials that are more eco-friendly, as well as delivering the mechanical properties designers look for. Here is an interview with Dr. Raymond Weitekamp, founder of the Berkeley-based 3D printing startup, polySpectra.

A look at eco-friendly materials

In our latest Technology Tuesday’s podcast, Design World’s Michelle Froese speaks with David Church, president of Sorbothane, about innovative shock and vibration solutions. Sorbothane has been developing materials and components that isolate vibration, attenuate shock, and damp unwanted noise for 40 years. In fact, the company is celebrating four decades in business this year!

In honor of Sorbothane’s anniversary, we discuss the unique history of the company, including how the material was developed for insoles to support runners and then became essential for industrial industries to protect vital cargo and equipment. We also cover Sorbothane material’s properties, the company’s new standard products (launching this fall), and how its online Design Guide Calculators can support your application.

Sorbothane marks 40 years of shock and vibration innovation

In our latest Technology Tuesday’s podcast, Design World’s Michelle Froese speaks with David Church, president of Sorbothane, about innovative shock and vibration solutions. Sorbothane has been developing materials and components that isolate vibration, attenuate shock, and damp unwanted noise for 40 years. In fact, the company is celebrating four decades in business this year!

Tech Tuesdays: Sorbothane marks 40 years of shock and vibration innovation

Several engineering companies say we have the technology to reverse climate change, one of which is using direct air capture. Interestingly, additive manufacturing has the potential to play a major role here.

Make Parts Fast

How Additive can help reduce CO2 emissions from industry

Copper is viewed as a material that will accelerate future aerospace production. For example, the privately funded company Ursa Major delivered a copper-based 3D-printed rocket engine combustion chamber from its additive manufacturing lab in Youngstown, Ohio. A challenge, however, is that the existing supply chain for high temperature metal alloy components is limited. However, development continues.

Tips on working with copper in additive manufacturing

In our latest Technology Tuesdays podcast, Design World’s Michelle Froese speaks with Mitsubishi Electric Automation’s product marketing manager for mechatronics and robotics, Patrick Varley. 
In this discussion, we delve into the topic of robotic automation and software provider solutions — and, specifically, how this combination can help ease labor shortages. Patrick explains the significance of consumer personalization and how advanced technology from leading innovators can address the contemporary issues facing today’s manufacturers.

Mitsubishi's Patrick Varley on how robots can ease labor shortages

In our latest Technology Tuesdays podcast, Design World’s Michelle Froese speaks with David Church, president of Sorbothane, about innovative shock and vibration solutions. Sorbothane has been developing materials and components that isolate vibration, attenuate shock, and damp unwanted noise for more than 40 years.

How Sorbothane is protecting lightweight devices from shock and vibration

In this episode of Design World’s Technology Tuesdays Podcast, VP, Editorial Director Paul J. Heney chats about vision systems with Philip Freidin, an Applications Engineer with IDS Imaging Development Systems Inc. They discuss new and interesting applications, how to select the best industrial camera system, and what the future holds for this important technology area.

IDS Imaging Development Systems Inc.’s Philip Freidin on vision systems

Micro tools play a critical role in the manufacturing of medical devices, microelectronics, semiconductors, and any miniature component where precision is essential. Darren Fox, a product manager at ANCA with over 33 years of experience in the cutting tool industry, discusses ultra-precision grinding and ANCA's FX7 Ultra.

A look at ultra-precision grinding for micro tool manufacturing

Electrostatic discharge (ESD) within precision additive manufacturing

The Engineering Research Visioning Alliance (ERVA) published a report on Engineering the Future of Distributed Manufacturing and identifies priorities that can revitalize U.S. manufacturing with sustainability and resilience in mind. In this podcast, Tali Rosman, startup advisor and Entrepreneur-at-Residence at Toronto Metropolitan University, shares how 3D printing plays a role in ERVA’s vision. Tali has worked at Stratasys, led Xerox’s former 3D printing subsidiary, Elem Additive, and now serves as a business advisor with expertise in advanced manufacturing.

How 3D printing optimizes distributed manufacturing

The BattleBots competition has become a popular entertainment. But it is also an opportunity for engineers to hone their fast design practices and study failure analysis. One of the more recent winners of the BattleBots is Hal Rucker, an engineer designer, builder, and co-driver, most notably of DUCK. DUCK won in Season 3 of the show.

2013 Ideas

Creating a winning BattleBot fast

A Minneapolis-based startup, Sprowt Labs, has developed a “personal malt-house” for those who enjoy home brewing beer. Part of the build involved using injection molding to create a humidifier box for the Acro. Sprowt Labs worked with Protolabs on the development of the humidifier box.

Injection molding helps inventors meet accelerated timeline

Recently a couple of stories have surfaced about using 3D printing/additive manufacturing for parts that are microns in size. One of these companies is based in Israel.  Now, a company out of Boston, Boston Micro Fabrication (BMF) has introduced a microscale 3D printer. I interviewed John Kawola, CEO of BMF,  to discuss this trend.

3D printing at the micro level 

Listen as Greg Thompson of Protolabs discusses how service bureaus are helping in the battle against the Coronavirus with their ability to offer a range of prototyping and manufacturing capabilities.

What service providers are doing to help battle the pandemic

The use of 3D printing technology to build devices with embedded electronics has evolved. In the early days, special 3D printers injected dielectric inks onto a layer of a build, creating electronic traces, to build electronic parts. Nano Dimension was the first company to develop such a system, and it continues to evolve the technology.  Today, it offers Additive Manufacturing Electronics (AME).

Developments in using additive manufacturing to build electronic PCBs

Recent events show the need for agility to meet market demands. Dr. Joe DeSimone, executive chairman of Carbon, discussed the unique levels of agility offered by additive manufacturing.

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Additive manufacturing meets the need for agility

A look at recent developments with Greg Elfering, Ultimaker's newly named president of Ultimaker Americas.  Ultimaker initially developed desktop 3D printers, but the company has expanded into connected 3D printers, then moved into larger systems as well as a network of 3D printing, including services

What's new with Ultimaker

Many users of 3D printing/additive manufacturing technology are concerned with its potential impact on the environment. Often the focus is on resin-based prototypes ending up in landfills and taking years to degrade. But other materials also end up as scrap, such as that from machining and similar subtractive processes.

One company has made it a mission to turn this scrap into usable metal powder for additive manufacturing (AM). The company is 6K Inc. Recently, I had a chance to interview Aaron Bent, CEO at 6K, about how they turn manufacturing scrap into additive manufacturing “gold.”

How to recycle machined metal scrap into additive manufacturing powder

The additive industry is dynamic, with new techniques introduced frequently.  Ethan Escowitz, CEO and founder of Arris Composites, for example, developed a technique called additive molding. This proprietary process combines additive manufacturing and high-volume molding technologies to create composite materials made of continuous fiber-reinforced thermoplastics.

What is additive molding

According to Pierrick Balaire, global business line leader at Intertek: “The Intertek Functional Safety mark provides Nexen a way to reduce hazards and risks to operating personnel, machinery, and surrounding environments at a time when they are facing increased demands around functional safety. We’re pleased to grant Nexen with this certification — the first of its kind in North America — and look forward to continuing to work with them and others providing the industry with high-quality products as well as peace of mind.”

In this Technology Tuesdays podcast, Dave Hein — senior vice president and engineering and chief technology officer at Nexen Group — chats with Lisa Eitel of Design World about three brake options that now have Functional Safety certification. Visit motioncontroltips.com and search on Hein to see this podcast’s show notes.

Design World Technology Tuesdays

Brakes with Functional Safety certification: Update from Nexen Group engineer Dave Hein

In this Motion Mondays podcast, Jeff Johnson of Beckhoff Automation chats with Design World’s executive editor Lisa Eitel about linear-motor conveyors (also called intelligent transport systems) as well as planar-motor systems from Beckhoff called the XPlanar.
Jeff Johnson is U.S. mechatronics products manager at Beckhoff Automation. Based in Fond du Lac, Wis., Johnson was (prior to joining Beckhoff in 2008) an applications team leader for Danaher Motion and G&L Motion Control. Visit motioncontroltips.com and search on XPlanar to see this podcast’s show notes.

Design World's Motion Mondays podcast series

Planar motors and linear transfer systems in action! Beckhoff engineer Jeff Johnson explains

The Design World podcast series features the latest in design engineering innovation from circuit design & 3D printing to automation & robotics.

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