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Author Archives: Victoria Webber

  1. How Deburring Creates Flawless Metal Parts

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    Racer Machinery International: Journey Through Generations
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    Imagine a perfectly machined gear – its teeth precisely cut, its surface a mirror reflecting the surrounding lights. But a closer inspection reveals a hidden enemy – tiny, sharp edges (burrs) clinging to its form. These unwelcome remnants are a byproduct of common metalworking processes like milling, drilling, and sawing. While these processes achieve the desired shape of the metal component, they can leave behind these imperfections. Deburring is the crucial step that removes these imperfections, transforming a good metal part into a truly exceptional one.

     

    By ensuring smooth functionality, enhanced safety, and a longer lifespan, deburring plays a vital role in delivering high-quality metal components. Often overlooked, deburring is the unsung hero of the metalworking industry, silently ensuring the quality and performance of countless parts that form the backbone of our machines, buildings, and everyday objects.

     

     

     

     

    Beyond Cosmetic Concerns: The Multifaceted Impact of Burrs

     

     

    Burrs are more than just cosmetic blemishes. These raised edges, chips, or slivers of metal can have significant consequences if left unattended. Here’s why deburring is essential for your metal parts:

    Improved Functionality: Burrs can hinder proper assembly and operation. During assembly, burrs can prevent components from fitting together seamlessly, leading to misalignment, binding, and increased friction. This can ultimately reduce a part’s efficiency and lead to premature wear and tear. Imagine a car engine where burrs on internal components cause friction and hinder smooth operation. Deburring ensures smooth, seamless interaction between components, guaranteeing proper function and optimal performance in the final product.

     

    Enhanced Safety: Sharp burrs pose a safety hazard, potentially causing cuts or abrasions during handling or assembly. Workers handling metal parts without deburring are at risk of injuries, which can disrupt production schedules and raise safety concerns. Deburring eliminates these risks, creating safe-to-touch parts that prioritize worker safety throughout the manufacturing process.

     

     

     

     

     

    Beyond Aesthetics: The Multifaceted Benefits of Deburring

     

     

    While burrs can detract from the overall appearance of a metal part, their impact goes beyond aesthetics. In some applications, a clean finish is crucial for consumer products or components with visible surfaces. Creates a professional finish that enhances visual appeal. More importantly, deburring extends the lifespan of metal components. The uneven edges created by burrs can act as stress concentration points, concentrating stress and making the part more susceptible to cracking under pressure.

     

    Deburring removes these weak points, promoting longevity and ensuring parts can withstand intended loads and stresses throughout their service life. Additionally, for parts requiring painting or other coatings, a smooth surface is essential for optimal adhesion and durability. Burrs can disrupt the coating process, leading to uneven application and potential peeling or flaking. Deburring creates a surface that allows for a strong, long-lasting coat, ensuring the aesthetics and functionality of the final product.

     

     

     

     

    A Toolbox of Solutions: Deburring Techniques

     

     

    There’s a deburring technique for every need. Metalworkers have a variety of methods at their disposal, each with its own advantages and applications:

    • Abrasive Techniques: Versatile and suitable for various parts, these methods utilize abrasive materials like sandpaper, grinding wheels, or tumbling media to wear down and smooth out burrs. This approach is ideal for general-purpose and can be automated for high-volume production.
    • Cutting Techniques: Offering precise control for delicate work, these techniques physically remove burrs using specialized tools like files, scrapers, and deburring knives. These methods are well-suited for intricate parts or areas that require a more delicate touch, ensuring minimal material removal.
    • Thermal Deburring: This method utilizes heat, often in the form of a flame or plasma torch, to melt and vaporize burrs. This technique is ideal for hard-to-reach areas or small burrs on thin materials. However, it requires careful control to avoid damaging the surrounding metal.
    • Chemical Deburring: Certain chemical solutions can dissolve or etch away burrs, particularly effective for removing small burrs from intricate parts. This method is often used for very small or delicate parts that cannot be with other techniques. However, it’s important to choose the right chemical solution for the specific metal to avoid unintended damage.

     

     

     

    Choosing the Right Deburring Method

     

     

    The ideal deburring technique depends on several factors, including the material’s hardness, part geometry, and burr size and location. By understanding the importance of deburring and the various techniques available, manufacturers can make informed decisions to ensure their metal parts function smoothly, are safe to handle, and achieve a long lifespan. Deburring may seem like a small step in the metalworking process, but its impact is undeniable. It’s the invisible guardian that ensures the quality, safety, and performance of the metal components that shape our world.

     

    From the intricate gears in a high-precision machine to the structural beams in a towering skyscraper, deburring plays a vital role in their smooth operation and long-lasting integrity. In today’s world of automation and mass production, deburring techniques have also evolved.

     

     

     

     

    The Rise of Automation: Deburring in the Modern Age

     

     

    Manual deburring, while still used for delicate parts or small-batch production, has become increasingly complemented by automated solutions. Robotic arms equipped with specialized tools can perform deburring tasks with greater speed, consistency, and precision. These automated systems can handle high-volume production runs efficiently, ensuring consistent quality control throughout the process. Additionally, advancements in technology have led to the development of innovative deburring methods like vibratory finishing and laser deburring.

     

    Vibratory finishing utilizes a combination of abrasive media and a vibrating tub to remove burrs from parts. This method is particularly effective for complex shapes and delicate components. Laser deburring, on the other hand, uses a highly focused laser beam to melt and vaporize burrs with exceptional precision. This technique is ideal for very small burrs or hard-to-reach areas.

     

     

     

     

     

     

     

  2. DED: Current Applications and Future Potential

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    The Significance of DED Additive Manufacturing: Unlocking Potential

     

     

    DED thrives on metals, making it a powerful tool.

     

    Directed Energy Deposition (DED) is rapidly transforming the manufacturing landscape. This innovative Additive Manufacturing (AM) technique utilizes a focused energy source, like a laser or electron beam, to melt and fuse materials layer-by-layer. Unlike some AM technologies limited to plastics, DED thrives on metals, making it a powerful tool for a diverse range of industries. Let’s delve into the current applications of DED and explore the exciting possibilities it holds for the future.

     

     

    Schematics of Two DED Systems. Image Credit: https://www.sciencedirect.com/

     

     

    One of DED’s greatest strengths lies in its ability to work with a wide variety of metals. This makes it a perfect fit for the demanding needs of the defense and aerospace sectors, where high-value parts are a critical concern. Imagine crafting intricate turbine blades or massive brackets for airplanes – DED enables precise manufacturing using the same materials as the original design, ensuring superior performance and structural integrity. Additionally, DED offers a cost-effective way to repair crucial components, extending their service lives and minimizing waste compared to traditional replacement methods.

    DED’s influence extends beyond defense and aerospace. The energy sector is exploring its potential for constructing vital components within power plants or refineries. Imagine constructing complex heat exchangers with optimized internal structures for maximum heat transfer efficiency. DED’s ability to create intricate geometries opens doors for designing energy components that are not only functional but also lighter and more efficient, boosting overall energy production.

     

     

    DED enables precise manufacturing using the same materials as the original design, ensuring superior performance and structural integrity.

    While applications in consumer goods are still in their early stages, DED shows immense promise for prototyping purposes. Imagine designers rapidly creating functional prototypes of new consumer products using DED. This allows for faster design iterations and efficient testing before mass production begins. Additionally,  used for small-scale production of high-performance or customized consumer goods, offering a unique advantage in today’s personalized consumer market.

     

    One of the most captivating future applications of DED lies in the creation of Functionally Graded Materials (FGMs). Unlike traditional materials with uniform properties, FGMs offer a groundbreaking approach. With DED, components can be built with material properties that gradually change across their structure. This allows for targeted optimization – for instance, a turbine blade could have a stronger base for anchoring and a heat-resistant tip for withstanding high temperatures. FGMs open doors for a new generation of components with unparalleled performance and efficiency across various industries.

    DED is poised to disrupt the development of new materials as well. Traditionally, creating custom alloys is a slow and expensive process. DED empowers researchers to experiment with different material combinations and rapidly create and test variations. Imagine developing and testing hundreds of different alloy variations in a single day! This agility can accelerate innovation in material science. Aerospace engineers can explore lighter and stronger alloys for next-generation aircraft, while the healthcare sector can develop biocompatible alloys for custom-made medical implants.

     

    DED boasts several key advantages that contribute to its growing popularity:

    • Material Master: Working with a wide range of materials, including common metal powders and wires, but also exotic materials that are difficult to process with other AM techniques.
    • Cost-Conscious Manufacturing: Commercially available feedstock, making it potentially more cost-effective than some other AM processes.
    • Smart DED Systems: Printing with Intelligence: Modern DED systems are equipped with advanced sensors that collect valuable data throughout the printing process. This real-time data allows for quality control and ensures the part meets the desired specifications. Additionally, this data is crucial for post-build analysis, helping engineers refine future printing processes for continuous improvement.

     

     

    DED transcends the limitations of traditional manufacturing. Its ability to create complex parts with a vast array of materials, coupled with the potential of FGMs and custom alloys, positions DED at the forefront of innovation. We can expect even more groundbreaking applications across various industries, shaping the future of manufacturing with stronger, lighter, and more efficient components.

     

     

     

  3. Trillium Network and Racer Machinery International

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    When Siemens North America needed a partner to meet very specific needs for its first digital twin initiative, they chose RACER Machinery International.

     

    RACER’s Chief Operating Officer Alex Vojinovich describes this opportunity as “validation of years of RACER providing quality machinery, rich in technical developments, to the market.” A year later, Siemens is promoting the success of the project, citing up to 30 per cent faster time to market and up to 25 per cent higher machine productivity, an impressive result when a huge multinational company collaborates with a 30 person Ontario manufacturer.

     

    RACER Machinery International has evolved from a small equipment repair business to a custom manufacturer of engine lathes and machinery for machine components for Thyssenkrupp GM, Magna, Martinrea, Toyota, General Dynamics, US and Canadian Defence and others. However, its success was no accident. It is the result of a founding family combining a traditional quality-centered approach with a willingness to embrace innovative technologies like additive manufacturing and digital twins.

     

    When first founded by Don Zoran Vojinovich in 1983 as Progress Machine in Cambridge, the company…operated as an engine lathe and machine repair shop, building and retrofitting Standard Modern™ Lathes.

     

    When first founded by Don Zoran Vojinovich in 1983 as Progress Machine in Cambridge, the company focused on enabling customers to maximize the functional lives of their lathes. At the time, it operated as an engine lathe and machine repair shop, building and retrofitting Standard Modern™ Lathes. Standard Modern was originally founded in Windsor in 1931 and became an industry standard for manufacturers and training facilities around the world.

     

    In 1990, Progress Machine became Racer Machinery Company and the company continued servicing lathes as well as introducing its own line of branded machinery. Having built and repaired the Standard Modern brand in the 1980s, the company seized the opportunity to buy the Standard Modern Lathe company in 2014 and move it from its location in Pennsylvania back to Ontario. Machine tools are stationary power-driven machines that shape or form metal parts. Engine lathes change the size, shape or finish of a revolving metal piece using various cutting tools. Today, RACER builds machine tools under the Phantom Machine Technology brand, manual engine Standard Modern lathes, and saws bearing the E-R Maier label. The company provides technical support in addition to building these signature products.

     

     

    According to Alex, much of RACER’s success can be attributed to its Cambridge location. Being close to Toronto, London, Windsor, and the U.S. border gives it access to markets, automotive and defense manufacturers.

     

     

    Since its founding, RACER has expanded to larger facilities a total of five times, always in Cambridge. Today, the company is run by Don and his sons Alex and Igor Vojinovich, Chief Operating Officer and Chief Administrative Officer respectively. According to Alex, much of RACER’s success can be attributed to its Cambridge location. Being close to Toronto, London, Windsor, and the U.S. border gives it access to markets, automotive and defence manufacturers.

     

    Cambridge provides RACER with a robust labour pool. However, like many manufacturers, accessing skilled workers is becoming increasingly challenging for RACER as the workforce ages. While CNC technology is taught in the trades schools, the company encourages more schools to update the curriculum to keep up with the industry’s software and technological advances. As a corporate sponsor of the McMaster Manufacturing Research Institute (MMRI), led by Dr. Stephen Veldhuis, RACER helped develop specialized courses that are offered to manufacturers by the Institute. Participants in MMRI’s training programs come from various stages in their careers, and can earn certificates in Process, Materials, or in Industry 4.0.

     

    Regardless of an applicant’s formal training, RACER describes its recruiting approach as “hiring for common sense”. If someone demonstrates they have basic skills, RACER will invest in the training required to close any gaps. Alignment with the company’s vision is as important as a skills fit. Teamwork is one of the four pillars of RACER’s vision, along with integrity, passion and excellence. Employee ideas are encouraged and the benefit of a variety of views is realized.

     

    The company founder’s commitment to quality and customer service lives on, and RACER is still known for making high quality products despite the influx of cheaper alternatives from lower cost regions. As Alex puts it, “We compete with China on quality. Ours are not cheap lathes.” Chinese competitors offer lower-cost, off-the-shelf solutions for customers less concerned with quality and durability. RACER works hard to reinforce the message that lathes are complex pieces of equipment that can be customized to meet very specific requirements. Made in Canada, by Canadian-skilled workers, using Canadian materials is RACER’s competitive advantage, offering a 20-year parts and service guarantee on its products.

     

     

    In September of 2020, Siemens chose RACER to develop CNC technology that will improve customer productivity through the use of digital twins.

     

     

     

    In addition to the proven machine tool, lathe and saw products, RACER is experiencing growth on the services side of the business as newer technology enables behind the scenes enhancements in its customers’ manufacturing processes. In September of 2020, Siemens, the long-time leading manufacturer of CNC controls, has selected RACER Machinery International, Inc. to be part of its North American “Field Experience” phase for its new revolutionary SINUMERIK ONE, the first digital native CNC. A digital twin is a computer replica of a real-world product which allows the customer to test new systems prior to manufacturing and ensuring the most productive methods are in place. RACER is piloting the new technology on all of its metal cutting platforms.

     

    RACER provides the highest level of training, service, and support in the industry. Training includes three days of programming/applications training at a local university. Additionally, the customer’s maintenance personnel are invited for the last week of assembly and run-off at our plant. After installation at the customer’s facility, RACER’s service personnel and engineers work with three groups of customer personnel, namely, maintenance, operators and high-level engineers to ensure understanding of the equipment to make in-house support as effective as possible. Additionally, a key component in RACER’s performance is the “Box in box design”, which brings to the final customer superior damping characteristics, higher speed, and higher precision feed.

     

    In addition to its Canadian and American sales, RACER also exports to Mexico, Europe, and other parts of the world. While selling expensive machine products to manufacturers in the low-cost region of Mexico seems counterintuitive, RACER saw an opportunity to help Mexican suppliers secure and retain OEM contracts by meeting rising quality standards. This risk was offset by support from EDC which provided insurance and advice that protected the company from non-paying customers.  The European market, however, remains challenging for growth as they are more confident in their own capabilities and less open to what RACER and Ontario can provide.

     

    When Don Zoran Vojinovich started Progress Machines in 1983, the focus of the company was enabling customers to maximize the functional lives of their lathes by servicing and rebuilding them. Nearly 40 years later, RACER Machinery International is a much different company with three key brands, advanced solutions and technologies, and a growing international footprint. However, they are still enabling the success of their customers and the innovation that has made Ontario the manufacturing hub it is today.

  4. The Founding Fathers of Modern Manufacturing

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    Father’s Day is a time to honor the men who shaped our lives. But in the world of manufacturing, there are also “founding fathers” whose inventions and ideas continue to influence the industry today. Here at Racer Machinery International, we recognize the pivotal role these pioneers played in laying the groundwork for modern manufacturing.

     

     

     

     

     

    Precision and Innovation: The Machining Masters

     

    Eli Whitney (1765-1825)

     

    Often credited as the “Father of American Manufactures,” Whitney’s invention of the cotton gin revolutionized the textile industry. His concept of interchangeable parts, where identical components could be used in different machines, remains a cornerstone of mass production.

     

    Richard Gatling (1818-1903)

     

    The inventor of the Gatling gun, Gatling is another crucial figure in machining history. His design, featuring a multi-barreled weapon with a rapid-fire mechanism, showcased the potential for precision engineering in firearms and beyond.

     

     

     

     

    Automation and Robotics: The Visionaries of Efficiency

     

    Joseph Engelberger (1925-2015)

     

    Nicknamed the “Father of Robotics,” Engelberger co-founded the world’s first robotics company. His work on industrial robots paved the way for automation in manufacturing, leading to increased efficiency and productivity.

    George Devol (1912-2011)

     

    Considered the “inventor of the first industrial robot,” Devol’s Unimate robot was a groundbreaking innovation. His work, alongside Engelberger’s, helped usher in a new era of automation that continues to shape modern manufacturing.

     

     

    Lean Manufacturing: The Efficiency Experts

    Kiichiro Toyoda (1894-1952)

     

     

    The son of Toyota’s founder, Kiichiro Toyoda is credited with establishing the core principles of the Toyota Production System (TPS). This system, emphasizing waste reduction, just-in-time manufacturing, and continuous improvement, revolutionized manufacturing efficiency.

     

    Taiichi Ohno (1912-1990)

     

    A key figure in implementing TPS, Ohno is known as the “Father of the Toyota Production System.” He streamlined TPS by focusing on eliminating waste (muda) in all aspects of production.

     

     

     

    These “founding fathers” of manufacturing represent a legacy of innovation, efficiency, and environmental responsibility. At Racer Machinery International, we strive to honor their pioneering spirit by delivering cutting-edge solutions that meet the highest standards of precision, automation, and sustainability.

  5. Multitasking Machining: The Future of Manufacturing

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    Ever marvel at a perfectly machined part? Complex ones often require multiple CNC machines (lathes, mills, grinding). But what if there was a way to achieve the same results with just ONE machine? Introducing multitasking machining – the future of efficient and precise part creation.

    Enter the multitasking CNC machine, a marvel of modern manufacturing. It’s essentially a Swiss Army Knife of machining, combining the capabilities of lathes, milling centers, and sometimes even grinding machines all in one. This powerhouse simplifies the process dramatically, offering a slew of benefits for CNC manufacturers.

     

     

     

     

    The Power of One

     

    Imagine this: you need to create a complex part like a drive shaft. Traditionally, you’d use a CNC lathe for shaping, a CNC machining center for drilling and tapping, and maybe even a hobbing machine for gears. With a multitasking CNC machine, you can tackle all these tasks with a single setup. This translates to:

     

     

    Reduced Labor Costs

     

    No more moving parts between CNC machines or waiting for them to be available. The multitasking machine automates the entire process, freeing up your workforce for other tasks (CNC programmer, machine maintenance, quality control).

     

     

    Space Efficiency

     

    Forget the days of needing a dedicated CNC machine for each step. Multitasking machines consolidate everything into one unit, maximizing your precious factory floor space (perfect for small machine shops).

     

     

    Improved Accuracy

     

    Traditionally, every time you move a part between machines, there’s a risk of slight variations. Multitasking machines eliminate these transfers, resulting in consistently high-precision parts (critical for aerospace, medical, and automotive industries).

     

     

     

     

    Beyond Efficiency

     

    The advantages of multitasking CNC machines go beyond just streamlining production. They open doors to a wider range of possibilities:

     

    Versatility

     

    With its diverse capabilities, a multitasking machine can handle an array of parts, making your production more adaptable (ideal for low-volume, high-mix production runs).

     

    Higher Quality

     

    The improved accuracy and reduced handling lead to consistently high-quality parts, reducing rejects and rework (essential for manufacturers with strict quality control standards).

     

    Faster Time to Market

     

    With streamlined processes, you can get your products to market quicker, giving you a competitive edge (important for staying ahead in today’s fast-paced manufacturing environment).

     

     

     

    Who Should Consider a Multitasking CNC Machine?

     

    If you’re a CNC manufacturer using multiple machines for complex parts, a multitasking machine could be a game-changer. Here are some key scenarios where it shines:

    You’re looking to reduce labor costs and improve efficiency.

    Your factory space is limited, and you need to consolidate operations.

    Maintaining consistent accuracy is critical for your parts.

    You produce a variety of complex parts in low volumes.

    You need to get your products to market quickly.

     

     

     

    As manufacturing continues to evolve, multitasking CNC machines are poised to play a central role. Their ability to simplify complex processes, reduce costs, and improve quality makes them an attractive option for businesses of all sizes. So, if you’re looking to revolutionize your production and take your game to the next level, consider embracing the power of the multitasking CNC machine.

  6. Robots vs. Cobots: What’s the Difference?

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    The world of CNC machining is witnessing a revolution driven by automation. Repetitive tasks that once hampered production, like material handling and loading/unloading, are giving way to efficient robotic solutions. But with two distinct players entering the stage – robots and cobots – a crucial question arises: what differentiates robots vs cobots in CNC machining? Let’s delve into the world of robotic automation to demystify their roles.

     

     

     

     

     

    Robots: The Powerhouse Performers

     

    Imagine a robot in a CNC shop, its powerful arm maneuvering a massive metal block with ease. Industrial robots, the heavy lifters of automation, excel at demanding tasks and high-volume production. Here’s what defines them:

    Strength and Speed: Robots possess incredible strength and speed, perfectly suited for handling large workpieces and performing repetitive tasks like welding or high-throughput material handling.

    Dedicated Workspaces: Due to their power and speed, robots often operate in dedicated areas with safety fencing, separate from human workers.

    Complex Programming: Robots require specialized programming expertise for initial setup and task configuration.

     

     

     

     

    Cobots: The Collaborative Companions

     

    Now, picture a robot working seamlessly alongside a machinist. Collaborative robots, or cobots, are designed for this safe human-robot interaction. They bring a unique advantage to CNC shops:

    Safety First: Cobots prioritize safety with features like force sensors, rounded edges, and soft padding, allowing them to work closely with humans.

    Flexible Automation: Cobots are lightweight and adaptable. Their user-friendly programming and ease of reconfiguration make them ideal for handling various parts and tasks.

    Simple Programming: Cobots often feature intuitive programming interfaces or even allow for programming by physically guiding the robot, making them user-friendly for CNC operators.

     

     

     

    Understanding the Key Differences: Robots vs Cobots in CNC Machining

     

    While robots and cobots automate tasks in CNC machining, their strengths lie in different areas. Let’s explore the key factors that differentiate them:

    Safety: Cobots are designed for close collaboration with humans, while robots require dedicated safety zones.

    Flexibility: Cobots shine in adaptability, while robots excel at repetitive, high-precision tasks.

    Ease of Use: Cobots are generally easier to program and use compared to robots.

    Cost: Cobots typically have lower upfront costs and require less infrastructure investment.

    Performance: Robots reign supreme in terms of speed and power, while cobots are well-suited for slower, precise maneuvers.

     

     

    By understanding the capabilities of robots and cobots, CNC shops can gain valuable insights into optimizing their operations. This knowledge empowers them to make informed decisions about automation solutions, regardless of their focus on high-volume production or intricate, small-batch jobs. As the world of CNC machining embraces automation, both robots and cobots offer solutions waiting to revolutionize the industry.

  7. Get to know Barb Wilmer: Director of Sales Canada/Mexico

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    The world of CNC machine sales has long been known for being a boys’ club. But at Racer, we’re rewriting the script with Barb Wilmer at the helm as our Director of Sales for Canada and Mexico. For the past seven years, Barb has defied expectations, shattered stereotypes and built a remarkable career driven by her dedication to client success and exceptional service.

     

    Earning the nickname “CNC Precision Princess,” Barb’s approach is a winning combination of dedication and genuine care for her clients. In this interview, we get down to business with Barb, exploring her journey, her insights into the ever-evolving CNC industry, and the valuable advice she has for those interested in this field.

     

     

     

    Can you describe a specific client interaction that has been particularly rewarding for you? Why?

    One of the most rewarding moments in my career was working with a university professor.  He was thrilled to have a Canadian-made CNC machine in his program and couldn’t wait to show it off to his students and clients.  It was a pleasure collaborating with him, attending events, and showcasing the machine to potential customers.

    What are some of the biggest challenges you’ve faced in your role? How did you overcome them, and what did you learn from the experience?

    Balancing the demands of a male-dominated field with family responsibilities can be tough.  However, I’ve learned to be proactive and keep pushing forward.

     

     

    Looking back on your career, what advice would you give to your younger self about pursuing a career in sales?

    To my younger self, I’d say: stay focused, avoid distractions, and take more business courses.  Consider pursuing an MBA!

     

    Do you have any mentors or trusted advisors who have played a role in your success? If so, how have they influenced your approach to sales?

    In 2007, I was hired by a man who saw potential in me, even though I had no experience in the steel industry.  He became my mentor, taking me under his wing and teaching me invaluable lessons.  He greatly influenced my professional growth and career path.

     

     

    What excites you most about the CNC machine industry? Are there any specific technological advancements you find particularly interesting?

    The CNC machine industry is a dynamic and exciting field that constantly evolves with advancements in technology, materials, and automation.  I’m particularly interested in additive manufacturing and eager to learn more about its potential.

     

    Have you witnessed any inspiring examples of how CNC machines are being used to create positive change in Canada or Mexico? (e.g. in manufacturing, education, healthcare)

    Canadian companies are leveraging CNC machines to produce high-quality, precision components for various industries like aerospace, automotive, and healthcare. This strengthens Canada’s manufacturing sector, creates jobs, and drives economic growth.

    In Mexico, CNC machines play a crucial role in their thriving automotive industry and medical device manufacturing.  These machines enable the production of intricate parts for cars, implants, prosthetics, and surgical instruments, ultimately improving healthcare outcomes and patient care.

     

     

    What advice would you give to someone interested in learning more about CNC machines and their potential applications?

    Start by familiarizing yourself with different types of CNC machines (milling, lathes, routers, etc.) and common industry terminology.  Explore online courses, hands-on practice if possible, and learn about CAD/CAM software.

     

    What is your greatest accomplishment?

    My greatest accomplishment is balancing motherhood and a successful career while creating a stable and loving home environment for my family.  As a young single mom who started at the bottom, I’m proud to be happily married and living my best life in a leadership role.

     

     

    Thank you, Barb, for sharing your story and inspiring us all to push boundaries!

  8. How Digital Twins are Saving Supply Chains

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    In today’s interconnected world, supply chains face constant disruptions.  From port closures to pandemics, these disruptions can cripple businesses.  However, a revolutionary technology is emerging to combat this vulnerability: digital twins. Virtual replicas of physical systems, offering real-time insights and unprecedented control.  Once confined to specific industries, they’re now transforming supply chain management for companies of all sizes.

     

     

     

     

     

    Illuminating the Path: Real-World Applications

     

    Leading the charge is Siemens, a global manufacturing giant.  By deploying digital twins across their vast network, they gain crucial real-time data on material movement.  This foresight allowed them to predict and navigate potential disruptions during the COVID-19 pandemic, avoiding costly bottlenecks and ensuring uninterrupted production.

    Digital twins go beyond just monitoring.  Companies like BMW leverage them to simulate entire production processes, identifying potential defects before they occur.  This proactive approach minimizes costly rework and guarantees exceptional product quality.

     

     

     

     

    Navigating Uncharted Waters: Embracing Agility

     

    The recent Suez Canal blockage serves as a stark reminder of unforeseen disruptions.  Fortunately, companies are embracing digital twins as an agile solution.  Inspired by industry resources like PixelPlex’s blog on “Digital Twins in Supply Chain,” organizations are proactively building resilience.

    Airbus, an aerospace leader, utilizes digital twins to analyze engine data.  This allows them to predict maintenance needs, leading to cost-effective and proactive servicing.  By analyzing potential outcomes and adjusting routes in real-time, businesses can mitigate delays, safeguard operations, and navigate uncertainty with confidence.

     

     

     

    Foresight is Power: Modeling for Success

     

    Digital twins empower businesses to model potential disruptions, from supplier delays to port closures. This foresight allows for strategic planning to ensure business continuity. Companies can implement strategies like alternative sourcing, inventory adjustments, and rerouted shipments – all before disruptions hit.

     

    The benefits of digital twins extend beyond the physical supply chain.  They provide valuable insights into market dynamics, consumer behavior, and preferences.  Manufacturing giant Caterpillar leverages this power to analyze customer data, resulting in highly targeted marketing campaigns leading to a 175% increase in website traffic and a 25% lead boost.

    Furthermore, digital twins enable precise demand forecasting. Businesses can adjust promotional activities, pricing strategies, and inventory management with laser focus, ensuring they adapt to customer demands and maintain a competitive edge.

     

     

     

     

    The Digital Twin Revolution: A Call to Action

     

    Companies like Siemens, Airbus, BMW, and Caterpillar are testaments to their transformative power.  As the world of supply chain management continues to evolve, staying informed about digital twins is crucial.  Resources like PwC reports and Forbes articles offer valuable insights into this game-changing technology.

    By embracing the digital twin revolution, businesses can build resilient and adaptable supply chains, ensuring they not only weather unforeseen challenges but also thrive in an ever-changing global landscape.

  9. Lightweight Spacecraft: The CNC Advantage

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    How can we reach farther and explore the vast unknown of space? The answer lies in building lightweight spacecraft. Every ounce saved is a game-changer, allowing us to carry more fuel, essential supplies, or even groundbreaking scientific equipment on our missions. This relentless pursuit of weight reduction is crucial for venturing beyond our immediate solar system and pushing the boundaries of human exploration. CNC machining offers a revolutionary solution, enabling the creation of incredibly precise, lightweight spacecraft components. This innovative technology provides a powerful tool for engineers, allowing them to design and build the next generation of spacecraft, opening up a new chapter in humanity’s journey among the stars.

     

     

     

     

     

    CNC Machining: Sculpting Strength from Lightness

     

    CNC machining, or Computer Numerical Controlled machining, utilizes computer-controlled tools to precisely remove material from a solid block. This allows for the creation of complex shapes with minimal waste, leading to significant weight reduction. But it’s not just about removing material; CNC machining excels at working with high-strength, low-weight metals like titanium and aluminum alloys. Imagine a bridge built with intricate trusses, miniaturized and made of metal – that’s the concept behind lattice structures. CNC machining can create these 3D honeycombs, offering incredible strength while minimizing material usage. They can be customized for strength in specific directions, further optimizing weight savings. Recent spacecraft designs have incorporated CNC-machined lattice landing legs and interstage structures, significantly reducing weight without compromising strength.

    This design freedom extends beyond intricate structures. CNC machining allows engineers to translate their Computer-Aided Design (CAD) models directly into manufacturing instructions. The software can analyze a design and suggest areas for material removal without compromising strength. This level of precision enables the creation of incredibly lightweight yet functional spacecraft components.

     

     

     

     

    A Case Study: The Falcon Heavy Takes Flight

     

     

    A prime example of CNC machining’s impact is the SpaceX Falcon Heavy. This launch behemoth boasts impressive capabilities, partly due to its lightweight design. A crucial element is the interstage, connecting the first and second stages. Traditionally, bulky steel or aluminum cylinders were used, adding significant weight and limiting payload capacity.

    By employing CNC machining for the Falcon Heavy’s interstage, SpaceX engineers achieved a dramatic weight reduction. Lightweight, CNC-machined aluminum offered significant savings compared to steel. Additionally, intricate lattice structures, strategically placed for launch forces, provided exceptional strength while minimizing material usage.

     

     

     

    The Future of Lightweighting: Beyond the Horizon

     

    As space exploration pushes boundaries, the demand for even lighter and more efficient spacecraft will only grow. The future of CNC machining in this arena is brimming with exciting possibilities:

    Advanced Materials: Imagine even lighter, stronger materials specifically designed for CNC machining, pushing the limits of spacecraft design.

    Multi-Material Additive Manufacturing: Combining the precise cutting of CNC machining with the limitless shaping of 3D printing could create revolutionary spacecraft parts with exceptional functionality.

    In-Situ Manufacturing: Picture a Moon base with a CNC machine, churning out replacement parts or building structures. This concept, known as in-situ resource utilization (ISRU), allows missions to create tools and components directly on celestial bodies, enabling longer missions and permanent outposts.

     

     

    CNC machining’s ability to craft lightweight, high-strength components is revolutionizing spacecraft design. As technology progresses, advancements in materials, integration with 3D printing, and even in-situ manufacturing on celestial bodies promise an exciting future where CNC machining plays a key role in pushing the boundaries of space exploration.

     

  10. Digital Twins vs. Traditional CAM

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    In the ever-evolving world of CNC machining, traditional Computer-Aided Manufacturing (CAM) methods have long been the industry standard. But with the rise of Industry 4.0, a new challenger has emerged: digital twin technology. While both methods aim to create precise parts through CNC machines, their approaches differ significantly. Let’s delve into the key distinctions between digital twins and traditional CAM for CNC programming.

     

     

     

     

    Traditional CAM: A Reliable Workhorse

     

    Traditional CAM programming relies on manually creating G-code instructions that dictate the movements of the CNC machine. Programmers write these codes based on the Computer-Aided Design (CAD) model of the part and the capabilities of the specific machine. This tried-and-true approach offers several advantages:

     

     

    Direct Control: Programmers have complete control over every aspect of the machining process, allowing for fine-tuning.

    Familiarity: Many experienced machinists are well-versed in traditional CAM methods, reducing the learning curve for implementation.

    Lower Upfront Costs: Traditional CAM software might have a lower initial investment compared to some digital twin solutions.

     

     

    However, traditional methods also have limitations:

    Time-consuming Process: Manually creating and testing G-code programs can be a lengthy process, especially for complex parts. This can lead to production bottlenecks.

    Prone to Errors: Human error during programming can lead to costly mistakes and rework, impacting production efficiency and budget.

    Limited Optimization: Traditional CAM offers minimal opportunities for program optimization to reduce cycle times or material waste, hindering overall productivity.

     

     

     

     

    Digital Twins: A Virtual Powerhouse

     

     

    Digital twin technology introduces a virtual replica of the CNC machine, workpiece, and machining process. This virtual environment allows for a more holistic approach to CNC programming, offering significant advantages:

    Simulation and Optimization: Digital twins enable simulating the entire machining process before running it on the actual machine. This allows for identifying and rectifying potential collisions (improving safety), optimizing toolpaths for efficiency (reducing cycle times), and minimizing material waste (lowering production costs).

    Real-time Monitoring: Sensor data from physical machines can be integrated with the digital twin, enabling real-time monitoring of machine health and performance. This predictive maintenance capability helps prevent unexpected downtime and equipment failures.

    Improved Training: Digital twins can be used to create realistic simulations of CNC operations. This provides a safe and cost-effective environment for training new operators and upskilling the existing workforce, addressing the CNC skills gap.

     

     

    While digital twins offer significant advantages, there are also considerations:

    Learning Curve: Implementing and utilizing digital twin technology requires an initial investment in learning new software and potentially hiring personnel with specialized skills.

    Cost: Digital twin solutions may have a higher initial cost compared to traditional CAM software, potentially impacting smaller shops with limited budgets.

    Data Integration: Integrating sensor data from physical machines with the digital twin can require additional infrastructure and expertise, adding complexity to implementation.

     

     

    Choosing the Right Tool for the Job

     

     

    The best approach – traditional CAM or digital twins – may depend on your specific needs. Here’s a quick guide:

    Simple parts with experienced programmers: Traditional methods may suffice for simpler parts and shops with a skilled workforce.

    Complex parts, high-volume production, or a focus on optimization: Digital twins offer significant advantages for complex parts, high-volume production environments, and shops prioritizing efficiency and cost reduction.

    Hybrid Approach: Many shops are adopting a hybrid approach, using digital twins for complex or new processes while maintaining traditional methods for simpler tasks. This allows them to leverage the strengths of both approaches.

     

     

     

    The Future of CNC Machining is Digital

     

     

    Digital twin technology represents a significant leap forward in CNC programming. While traditional CAM methods will likely remain relevant for specific applications, the benefits of digital twins are undeniable. As technology continues to evolve and costs become more accessible, we can expect digital twins to play an increasingly important role in shaping the future of CNC machining, driving advancements in efficiency, quality, training, and overall productivity.