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.

Trillium Network and Racer Machinery International

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.

OEM Suppliers: What It Means Buying Direct

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Industry 4.0 and RACER: Driving Manufacturing Transformation

In today’s fast-evolving manufacturing landscape, the term “OEM suppliers” often takes center stage. It’s an acronym you’ve likely come across frequently, but do you fully understand what it means, especially when it comes to buying directly from the manufacturer?

In this blog, we aim to demystify OEM suppliers and shed light on the advantages and considerations when purchasing products directly from the source.

In the world of manufacturing, being the trusted OEM supplier means not just

providing tools, but building the foundation for innovation and precision.

OEM Unveiled

OEM stands for “Original Equipment Manufacturer.” In essence, it refers to a company that designs and manufactures a product or component that is then used in another company’s final product. This concept is widespread across various industries, including automotive, electronics, and machinery. But what does it entail when you, as a consumer, buy directly from the OEM?

Advantages of Direct OEM Purchasing

Quality Assurance: When you buy directly from the OEM, you can be more confident in the quality of the product. You’re getting the genuine article, designed and crafted by the experts who know it inside out. This is especially crucial in industries like manufacturing, where precision and reliability are paramount.

Customization Possibilities: OEMs often offer customization options to tailor products to your specific needs. This means you can get a product that perfectly fits your requirements, whether it’s a CNC machine or an OEM tool.

Direct Support: Dealing directly with the manufacturer means you have a direct line of communication for any inquiries, support, or technical assistance you may need. This can lead to quicker issue resolution and enhanced customer satisfaction.

Transparent Information: OEMs can provide you with in-depth product information, including specifications, maintenance guidelines, and warranty details. This transparency empowers you to make informed decisions.

Cost Efficiency: By eliminating intermediaries like retailers or distributors, buying directly from the OEM can often result in cost savings. This is particularly beneficial for businesses looking to optimize their budgets.

Considerations for Direct OEM Purchases

Product Knowledge: While buying from the OEM offers numerous advantages, it also means you need to have a solid understanding of the product and its technical aspects. Be prepared to invest time in learning about the product to make the most of your purchase.

Maintenance and Support: Understand the after-sales support and maintenance services provided by the OEM. Ensure that you have access to the necessary resources and expertise to keep your equipment running smoothly.

Lead Times: Depending on the complexity and customization of the product, lead times for direct purchases from OEMs may vary. Plan accordingly to avoid delays in your operations.

Racer Machinery International: Your Trusted OEM Partner

As an industry leader in CNC machines and OEM tools, Racer Machinery International exemplifies the advantages of buying direct from the manufacturer. Our commitment to quality, customization, and customer support ensures that you receive the best possible solutions for your manufacturing needs.

When you choose Racer as your OEM partner, you gain access to a world of precision engineering, innovative technology, and a dedicated team ready to assist you at every step of the journey. With us, OEM is more than just a buzzword; it’s a commitment to excellence and a promise of reliability.

When buying direct from the manufacturer, like Racer Machinery International, you’re not just purchasing a product; you’re investing in quality, customization, and a partnership that ensures your success. Demystify OEM and experience the difference it can make in your manufacturing endeavors.

A successful outcome at Euromold 2007 in Frankfurt, Germany

Germany was the stepping stone for RMI as the company branches off into the global market. With the success of Euromold 2007, RMI plans to attend many more international exhibitions in 2008. Visit our news & events page for upcoming events and annoucments.

Join us at Houstex Southwest Manufacturing Event

Join us at Eastec – Eastern States Exposition, West Springfield, Massachusetts May 16th to May 18th 2017

Join us May 16th – May 18th at Eastec in Springfield, MA.

You can find us at booth #1152.

“With more than 500 exhibitors, complimentary conference sessions, industry keynotes and much more, EASTEC is an event dedicated to keeping northeast manufacturers competitive. It’s where manufacturing ideas, processes and products that make an impact in the northeast region, are highlighted through exhibits, education and networking events. The event offers a unique chance to connect with resources that can solve your company’s most pressing problems, improve productivity and increase profits…”

Come visit us at our booth for new special promotions.

Find our more information at www.easteconline.com

Join us at MFG4 Aerospace – Defense – Medicial

Join us February 28th – March 2th at Houstex in Houston Texas.

You can find us at booth #1222.

“As an industry-leading Southwest manufacturing event, HOUSTEX attracts suppliers, distributors and machinery builders from throughout North America. With aisle after aisle of exhibitors and products to investigate, you’re sure to find technologies that can transform your business and industry. HOUSTEX is the premier manufacturing event in Texas….”

Come visit us at our booth for new product launches in 2017 as well as a special show promotion.

Find our more information at www.houstexonline.com

Join us at Expo Maq Machine Tools Show

Join us May 3rd – 5th at MFG4 in Hartford Connecticut.

You can find us at booth #1651.

“Mfg4 surpasses the traditional manufacturing technology event by delivering content and suppliers mandated by industry. Mfg4 is an event for industry developed by industry, with an emphasis on industry-specific solutions with attention to cross-collaboration…”

The Mfg4 exhibit focuses on “…aerospace, defense (including arms) and medical device industries have much in common. All three are challenged by long project lifecycles, stringent government regulations, mission-critical quality control and a subsequent need for cutting-edge technology…”

Find our more information at www.mfg4event.com

Join us at AeroDef® 2016

Join us April 12th – 15th 2016 in Poliforum Leon Mexico.

You can find us at booth #1826.

“With over 16,000 people attendance from all over the country.

EXPOMAQ took place in its second edition. One of the most important shows of the year, where high technology machinery, industrial and users people met at Poliforum Leon.

With the participation of 200 national and international exhibitors representing 300 brands, EXPOMAQ is the only exhibition of machinery, peripherals and industry services where worldwide makers and distributors from the Construction, Management for Cargo Storage and Machine Tools sectors can get in touch.

Find our more information at expomaq.org.mx

Launch of Racer’s new brand identity

Join us February 9th and 10th at AeroDef® in Long Beach California.

You can find us at booth #213.

“AeroDef® Manufacturing is the leading exposition and technical conference for the aerospace and defense manufacturing industry. Produced by the SME, in partnership with industry OEMs, our mission is to foster innovation across the extended enterprise to reduce costs, expedite production times and maintain manufacturing competitiveness in the global economy.

AeroDef® showcases the industry’s most advanced technologies across an innovative floor plan designed to facilitate interaction and business relationships between exhibitors and buyers looking for integrated solutions…”

Find our more information at www.aerodefevent.com

Launch of our RACER multi-brand website

Big change for RACER! Racer Machinery International Inc. is thrilled to announce the launch of our new brand identity. A new image but the same company.

You will being noticing new branding through our stationary, products and swag coming in the next couple weeks. This new look represents the future of Racer Machinery International Inc. as we look forward to a more modernized look while maintaining the experience and wisdom gained over the years.

We hope you like our new colors and look.