March 16, 2018
AM refers to methods that generate three-dimensional structures layer by layer. Each AM technology is compatible with the specific form of the raw input material, which may be in liquid, powder and sheet form. AM processes are not subject to the constraints associated with traditional manufacturing methods and provide significant opportunities for the design of novel geometries and complex structures, such as cellular structures in particular. Cellular structures possess a number of properties compared to solid structures. For example, the design freedom offered by AM may be used to enhance the strength-to-weight ratio of structural components by transforming solid geometry into a cellular structure or space-filling hollow sections of the model with a cellular structure. The cellular structure within the model may be useful in distributing the loads evenly compared to a hollow model while conforming to the geometric boundaries of the object. This article discusses some of the basic concepts behind the metallic lattice structures manufactured using selective laser melting (SLM)…
March 16, 2018
Established in 1886, Varley is one of Australia’s oldest, most advanced engineering and manufacturing companies. The group manufactures and sells world-class custom emergency service, health, education and rescue vehicles; defence ambulances and arms storage facilities; and industrial and recreational electric vehicles. Its electric vehicles — sold under the EMC Electric Vehicles brand name — include golf carts, resort vehicles, industrial materials-handling vehicles, and utility carts, as well as parts and accessories for each vehicle type. Facing strong competition in the electric vehicle marketplace, Varley needed to find a way to differentiate its range of vehicles and related products. Following a market review that included researching competitors in the US, the company embarked on a digital transformation project — at the centre of which was the creation of an eCommerce option to help stay ahead of the competition. “Varley has five or six key competitors in Australia within the electric vehicle marketplace alone,” says Dean Wiggins, Marketing Coordinator at Varley Group. “So, it’s important to stay a step…
March 9, 2018
As a longstanding industry leader and innovator in the world of metalworking, Iscar has taken the IQ concept of machining intelligently even further by applying logical improvements to tool development. The result is the LogIQ range of tooling solutions that both predicts and fulfils customer needs. LogIQ represents a smart logical progression in a series of strategic moves to implement Industry 4.0 standards while ensuring continuity and stability. Industry 4.0 directives – to integrate interoperability, technical task assistance and decentralised decision-making into factory practices – challenge machining centres to review their operations and adopt procedures to meet these objectives. Machining logically responds to this need. Iscar provides the tools to make it happen. LogIQ applications have created new tool families, upgraded existing lines, and inspired innovative product ranges to maximise equipment utilisation and optimise performance. Listening to customer concerns and staying ahead of market developments, Iscar’s product managers, research & development (R&D) engineers and designers have combined their expertise and experience to develop highly effective and logical tool solutions that meet today’s machining centre demands. In an industry where…
March 9, 2018
In his best-selling 2000 book, Malcolm Gladwell defined ‘The Tipping Point’ as “the moment of critical mass, the threshold, the boiling point”. By that definition, direct metal printing (DMP) is standing on the precipice, as it moves rapidly from prototyping to production for mission-critical, risk-averse applications in defence and aerospace, where nothing is left to chance. An example of this mainstream acceptance is a long-term partnership between 3D Systems and Thales Alenia Space to leverage DMP for aerospace components. Based in Toulouse, France, Thales Alenia Space is one of the leading aerospace suppliers in the world, with revenues topping €2bn in 2014. The company has 7,500 employees in eight countries, specialising in space telecommunications, navigation, Earth observation, exploration and orbital infrastructures. The collaboration between Thales Alenia Space and 3D Systems can be seen in the production of antenna brackets (190mm x 230mm x 290mm) for a geostationary telecommunications satellite. DMP is now qualified and fully available for Thales Alenia Space’s titanium aerospace applications. Today, for certain products like the satellites, 80%…
March 9, 2018
The new Lincoln Spirit 400 machine – now operating in the company’s 400sqm plate-processing facility – was specified to deliver industry-best standards of cut quality on standard and specialty steels, including stainless steels and heavy-duty chromium carbide protective plates up to 60mm thick. According to TW Woods’ Managing Director Tom Woods, high-quality, wear and impact-resistant materials are now in high demand as coal and mineral processing plants place new emphasis on long-life products that avoid delays and breakdowns as mines step up production. The same quality, traceability and accountability standards are being required by private and state organisations involved in the energy, marine, oil & gas and defence sectors, where safety and durability are paramount. The investment in state-of-the-art plasma cutting technology has also been complemented by the installation of a new Truflow spray booth and bake oven to deliver best-quality protective finishes for customers in industries including defence, energy, manufacturing, mining, minerals-processing, materials-handling, metals, process engineering, and water and…
March 9, 2018
In October Penguin Composites had a major win for the business and for Tasmanian manufacturing when it signed an three-year, $8m contract with Thales Australia to produce bonnets and other components for the Hawkei protected mobility vehicle. The deal represents the company’s first major defence related contract and it is expected to create around 15 jobs at its factory in the town of Penguin. Christopher Pyne, the Federal Minister for Defence Industry, congratulated Penguin Composites on the contract and said it would provide a significant boost to Tasmania’s share of the nation’s defence investment. “This contract will not only create new jobs in Tasmania, it will also involve the upskilling of existing personnel to help deliver this work,” said Minister Pyne. “This is a textbook example of how Australian small-to-medium enterprises are building their capabilities and contributing to our sovereign defence industry capability.” Thales signed a $1.3bn contract in October 2015 to supply 1,100 Hawkei vehicles and more than 1,000 trailers, and is now ramping up for low-rate production.…
February 23, 2018
In this report, certain generic words such as product and others are used. However it should always be understood that, while manufacturing terminology may be used, the ideas described are equally applicable to service organisations. They may also cover specific elements of a business process, rather than simply the whole business. Many people have the impression that mass customisation is about mass production, and through some magical process allows an unlimited number of variations to be offered to the customer. This is wrong. Mass customisation is about tailoring the offering to the customer, while retaining the lower costs per item that are offered by mass production. This allows SMEs to complete with larger enterprises. Mass customisation is also highly data-driven. Consequently, it is relevant to the ongoing developments in the field of Industry 4.0. From pull to push, and back again Before industrialisation, everything was craft production,…
February 23, 2018
Following many years working in the sheet metal industry, Jon Flynn founded Wildcat Industries around 10 years ago. Based in Dandenong, Victoria, the business now employs 20 people across four divisions: high-tolerance sheet metal work; architectural facade work; the manufacture of high-tech wood and gas flue systems; and most recently, Wildcat wood-fired pizza ovens. While the architectural division services clients throughout Australia, the sheet metal work is predominantly Melbourne-based. Wildcat offers custom perforated panels to the architectural, building, construction, interior design and landscaping industry. Flynn already had extensive experience dealing with Applied Machinery having, in his own words, “virtually bought every single piece of equipment to date” from them. “The Applied Machinery people look after me as though they are part of my business,” says Flynn. “The service, support and warranty are very important for me and Applied excel in this area. So the decision to buy a Yawei fibre laser from Applied Machinery was both a…
February 16, 2018
For the majority of manufacturers, like gas, electricity and water, compressed air will be an indispensable utility to their operation. However, unlike gas, electricity and water, compressed air is more often than not produced the conventional way – via a compressed air system that the manufacturer actually owns. Here, the manufacturer not only pays for the utility itself (the compressed air produced), but at some point in time will have had the capital outlay for the purchase of the compressed air equipment, as well as the ongoing costs to service and maintain the compressed air system. Compressed air contracting presents a viable alternative to investing in, and maintaining your own compressed air system. Here, the end user simply purchases the compressed air they use, in the same way they would purchase gas, electricity or water. And, they can immediately enjoy the advantages…
February 8, 2018
The Montmorency-based aerospace and defence company has been able to win lucrative global contracts and create new local jobs thanks to support from the State Government. As part of the Future Industries Manufacturing Program, Lovitt Technologies has taken on five new workers and acquired advanced manufacturing technology, including a next-generation computer to create precision aerospace components. The cutting edge technology has allowed the company to extend and secure major new contracts with clients in the aerospace industry such as Boeing and Lockheed Martin. Lovitt Technologies was established in 1954 to manufacture tooling for Australia’s automotive industry. Over the ensuing six decades it has evolved continuously, anticipating the eventual decline of Australian car-making and acting decisively by branching into fields as diverse as communications, defence and food & beverages. Primarily, however, the company has developed a strong niche in the field of aerospace over the last 20 years. Today, aerospace components account for around 95% of the company’s…
February 1, 2018
The Thai Government understands that manufacturing will be a key driver of the country’s long-term economic growth and has been encouraging companies to establish facilities in their territories through tax and other incentives. As a result, the country today has flourishing automotive and aerospace sectors that require suppliers. SK Precision has around 50 people working two shifts servicing their traditional market of cutting carbide tools and PCD tools. “We have been operating for over 20 years and know the local Thai market intimately,” says Tibordee Srikul, President of SK Precision. “We saw an opportunity in the tap grinding segment as until now companies could only source taps from overseas suppliers and that means longer lead times of up to three months and higher cost. Our customers want just-in-time products so they can reduce stock and inventory costs. Having a local supplier who can deliver taps in a short period of time helps them achieve a more efficient supply chain. “Taps are…
January 26, 2018
Based in Tullamarine, Ferraro is a tight-knit family-run business that supplies more than 25 varieties to some of Australia’s leading food manufacturers including Arnotts, Paddy’s Pies and Goodman Fielder. As production of shredded mozzarella, shredded parmesan and grated parmesan increased, Ferraro needed larger volumes of nitrogen and carbon dioxide gas, which resulted in a new solution to support its modified atmosphere packaging (MAP) process. “Since moving to BOC, we’ve had no gas supply issues and can confidently increase our cheese production knowing that we have the right gas solution,” says John Ferraro, the company’s owner. “We don’t change for the sake of change – but BOC’s offer was competitive and they have really looked after us.” The challenge Ferraro had outgrown its existing gas system from a previous supplier, and now required more nitrogen and carbon dioxide gas flows and larger vessels to support increasing quantities of cheese packs being produced using a MAP process. “We have a single chamber and double chamber machines that need gas all day long,” says Ferraro.…
January 26, 2018
South Australian-based car battery handle supplier Rope & Plastic Group had a successful business in Australia and the United States before the automotive industry’s decline. However, the company has now begun manufacturing clotheslines. According to owner John Sutton the transition was an obvious choice. “We were supplying car battery company Exide with handles, cases and lids, so it was a very lucrative business,” he explained. “In the meantime about five or six years beforehand we got involved with a company called Mrs Peggs Clotheslines, and started to manufacture, warehouse and distribute clotheslines in China. “About the same time that Exide decided to close down their manufacturing operations, Mrs Peggs came to us and said they were going to take back the business and run it themselves. We had a double whammy.” With the automotive industry offering no real future, Sutton decided to draw on the company’s experience in clothesline manufacturing to design and manufacture his own washing line. The venture was assisted by a $200,000 grant through the SA…
