Flex-N-Gate to Build $95M Plant in Detroit to Supply Ford

BOTW-50w  Source:  Today’s Motor Vehicles

Flex-N-Gate owner Shahid Khan says his company will invest $95 million in construction and capital costs for a Detroit-area facility that will supply parts to Ford Motor Co. Potential additional investment in the project could push the project to at least $100 million. Khan says the project will create at least 400 and up to 650 new jobs in Detroit over the next three years; at full capacity, up to 750 total jobs could be added.”

Read More:  Flex-N-Gate to Build $95M Plant in Detroit to Supply Ford

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Automotive Supplier in Alabama Purchases Heat Treatment System from Can -Eng Furnaces

CAN-ENG Furnaces International Limited has been contracted by a large Canadian-based Tier 1 Automotive Supplier located in Alabama to design, manufacture and commission an automated T-7 Heat Treatment System for the processing of high integrity aluminum automotive structural castings. CAN-ENG is a global expert in the design of thermal processing solutions for high pressure die castings (HPDC) and aluminum automotive structural components.  CAN-ENG’s technology was chosen for this new light-weighting project because it offers inherent part handling features that reduce floor space requirements and energy consumption. The technology also provides predictable mechanical properties and maintains the dimensional stability of the casting.

The T-7 cell includes Robotic Handling, a Solution and Age Furnace with CAN-ENG’s Precision Air Quench (PAQ ™) technology, and controls integrated into a Level II SCADA system.  CAN-ENG’s PAQ™ system offers a unique combination of recirculating air chambers, distribution nozzles, dampers and directional ductwork.  Analysis of CFD modelling by CAN-ENG’s R and D Center ensures that the Precision Air Quench System (PAQ™) delivers controlled quench media to the casting, leading to repeatable and uniform mechanical properties and accurate dimensional results.  CAN-ENG’s T-7 heat treatment system is integrated with up and down stream processing operations, reducing W.I.P inventories.  It is scheduled to be commissioned in the summer of 2016 with a second phase to follow in 2017.

Automotive Supplier in Alabama Purchases Heat Treatment System from Can -Eng Furnaces Read More »

Pratt & Whitney Searching for Products, Services to Ramp Up Monthly Engine Production

BOTW-50w  Source:  Manufacturing Engineering

“In 2010 P&W delivered about 55 engines a month. In 2017, that number grows to about 100 engines a month. And in 2024, it continues to climb to about 158 engine deliveries a month, she said.

“And I’m doing that with 20-year-old technology and 20-year-old manufacturing processes and a very well-seasoned workforce” that adds significant complexity to the digital manufacturing transformation of the East Hartford, CT-based firm, Hagerty  said during a panel talk on best practices.

“So the challenges ahead of me are steep.”

In an interview with Smart Manufacturing magazine after the panel discussion, Hagerty said she is “fresh into the exploratory phase” to find products and services her firm needs. She has mapped out her requirements.

“Now, I’m reaching out to the service providers” and scheduling visits to firms using products and services that might well work for Pratt & Whitney.”

Read More:  Pratt &Whitney Searching for Products, Services to Ramp UP Monthly Engine Production

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UPS Launching On-Demand 3D Printing Manufacturing Network

UPS will launch a distributed, on-demand manufacturing network that links its global logistics network with 3D printers at The UPS Store in more than 60 locations around the U.S. and Fast Radius’ On Demand Production Platform and 3D printing factory in Louisville, Kentucky. The integration into one additive manufacturing and logistics solution this summer will make 3D printing accessible to more potential users, enabling them to realize the convenience and cost-savings this technology offers.

Further strengthening UPS’s distributed, on-demand manufacturing offering, SAP today announced an agreement with UPS to create an end-to-end industrial solution. SAP’s extended supply chain solutions will be integrated with UPS’s on-demand manufacturing solution and global logistics network to simplify the industrial manufacturing process from digitization, certification, order-to-manufacturing and delivery.SAP made its announcement at the SAPPHIRE NOW conference.

“UPS is a leader in bringing industrial-strength 3D printing to reality. By building this disruptive technology into our supply chain models, we also bring new value to our manufacturing customers of all sizes,” said Stan Deans, president, UPS Global Distribution & Logistics. “Additive manufacturing technology is still developing rapidly so ‘manufacturing as a service’ is a smart approach for many companies.”

Customers will visit the Fast Radius website (formerly CloudDDM) to place their 3D printing orders, which will be directed to the optimal manufacturing or The UPS Store location based on speed, geography, and the product quality the customer requires. Orders can be shipped as early as same day. While participating The UPS Store locations are all in the U.S., companies globally could utilize the network and place orders.

By integrating SAP’s extended supply chain software with the UPS additive manufacturing solution and logistics network, manufacturing companies of all sizes will be able to access on-demand industrial manufacturing with the touch of a button. SAP customers will be able to digitize and simplify the production part approval process through SAP and their orders can be seamlessly routed to UPS for production and delivery.

The on-demand network created will benefit customers of all sizes:

  • Manufacturers wanting to reduce inventory for slow-moving parts
  • Manufacturers with short production runs where the cost to create the mold or tooling could make these orders too expensive for traditional manufacturing
  • Manufacturers and retailers of custom/semi-custom goods as additive manufacturing allows cost-effective customization of goods
  • Industrial designers and engineers who want high quality rapid prototypes delivered as fast as one day
  • Entrepreneurs, start-ups and manufacturers who don’t currently have access to 3D printers or have limited capital and time and will use 3D printing for rapid prototyping and manufacturing of initial production runs

“Fast Radius plans to continue enhancing its production platform and to globally expand its manufacturing capabilities in 3D printing (plastics and metals), CNC machining and rapid injection molding,”said Rick Smith, co-founder and CEO of Fast Radius.  “With this distributed, on-demand manufacturing network, UPS customers will be able to get their products to market faster and more cost-effectively because parts can be produced exactly in the quantity they need and when they need them. The potential of on-demand manufacturing is here today.”

The UPS Store was the the first nationwide retailer to offer 3D printing services in-store. “Connecting all The UPS Store locations into a larger network provides more opportunity for new customers to access our printers and gives customers added flexibility to match their requirements with the appropriate UPS location,” said Daniel Remba, Small Business Technology Leader for The UPS Store, Inc.

For more information about 3D printing at UPS, please visit www.ups.com/3Dprinting.  UPS is a minority investor in Fast Radius through the UPS Strategic Enterprise Fund (SEF).  The UPS SEF is a corporate venture capital group that focuses on developing critical partnerships and acquiring knowledge returns from its investments in information technology companies and emerging market-spaces.

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3D Printing, Ultrasonic Milling Medical Orthopedic Devices

BOTW-50w  Source:  Today’s Medical Developments

“Our Austofix product design engineers, working with IPAS, were able to innovate within a flexible design and manufacturing process. This environment was key to our ability to take the prototype to market within such a short timeframe,” he said. “There are key components of the plate manufactured using 3D printing, this enabled us to create a complex design without the costs associated with traditional manufacturing. It also enabled us to bring the device to market quickly.”

Austofix has a number of products including a range of stainless steel and titanium surgical nails, which it exports to the Middle East and China.”

Read More:  3D Printing, Ultrasonic Milling Medical Orthopedic Devices

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Saudi Aramco Signs to Set Up High-End Forging & Casting Manufacturing Facility

Saudi Aramco has signed a Memorandum of Understanding (MoU) with GE (NYSE: GE) and Cividale SpA of Italy to build the Middle East and North Africa’s first-of-its-kind high-end forging & casting manufacturing facility that will serve the region’s maritime and energy industries.

Marking a joint investment of over US$400 million (SAR1.5 billion), the new facility, to be located in Ras Al-Khair under the Royal Commission of Jubail and Yanbu industrial area, aims to establish a high-value supply chain that boosts exports and economic competitiveness. Set to be operational in 2020, the plant will create 2,000 quality jobs in the Kingdom and catalyze the growth of Saudi small and medium enterprises (SMEs).

The MoU follows a preliminary partnership between Saudi Aramco and Cividale, a leading European producer in the steel and cast iron sector, to conduct feasibility studies for forging and casting manufacturing services in the Kingdom. GE has come on board to extend its expertise and investment in developing the world-class manufacturing plant through a joint venture between the three entities.

The Forging & Casting Manufacturing Facility complements plans by Saudi Aramco to develop several industrial projects in the Kingdom including a maritime project focused on building, maintenance, repair and overhaul (MRO) of offshore platforms, jack-ups, offshore service vessels and commercial tankers.

Saudi Aramco is also working with its partners to develop an onshore rig manufacturing facility for providing new build and MRO services to onshore rigs and systems; an engine manufacturing project for the manufacturing, maintenance and repair of diesel engines, manufacturing and repair of marine pumps; and an Energy Industrial City to accelerate manufacturing industries in the oil and gas sector.

The Forging & Casting Manufacturing Facility will serve all these projects in addition to providing the best-in-class services and technologies to downstream & other industries across the region and global markets. It will also support the ongoing emphasis of the government, under Saudi Vision 2030, to develop the mining sector of the Kingdom by creating a domestic source-market for various raw materials & supplies that go into the production line.

Abdallah I. Al-Saadan, Senior Vice President, Finance, Strategy & Development, Saudi Aramco, said: “The MoU reflects our ambition to create a robust supply chain that builds positive synergies in the oil and gas manufacturing sector. This builds on our deep commitment to support the goals of Saudi Vision 2030 to promote economic and industrial diversification in the Kingdom and boost localized manufacturing.”

Rami Qasem, President & CEO, GE Oil & Gas, Middle East, North Africa & Turkey said: “For the Forging & Casting Manufacturing Facility, we will leverage our already strong expertise in ‘Made in Saudi’ manufacturing. Together with our partners, we will actively engage Saudi SMEs to support the plant’s operations, and train & hire Saudi professionals, adding further value to the economy. By building a domestic forging and casting production unit, Saudi and regional customers can achieve greater operational efficiencies in product procurement, repair and service support.”

Antonio Valduga, President of Cividale, added: “The feasibility assessment study underlines the strong potential for a world-class manufacturing facility for forging and casting services in the Kingdom. Developing a full-fledged facility through the joint partnership will position Saudi Arabia as a technology and services hub for specialized equipment and services.”

The collaboration is a strong example of the public-private partnerships that the government fosters under Saudi Vision 2030 to develop local manufacturing capabilities that add significant value to the economy.

Saudi Aramco Signs to Set Up High-End Forging & Casting Manufacturing Facility Read More »

Automotive Engineers Look at Honing after Heat Treating

BOTW-50w Source:  Manufacturing Engineering

“Another dramatic change in the process itself is the move away from first hobbing a gear, then shaving it and then heat treating it. Hobbing is a multipoint cutting process that rotates both tool and workpiece in precise relations to each other. It is used to rough cut multiple gear teeth at once. “Today, automakers are hobbing gears, heat treating them and then grinding them post-heat treat. This provides a harder, more robust gear. Post-heat treat finishing of these gears eliminates distortion or changes of geometry in that gear set. The tolerance requirement after grinding is pretty critical,” he said.”

Read More:  Automotive Gears and their Opportunities and Challenges

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Magna Announces New Aluminum Casting Facility in the UK

Magna International Inc. today announced it will build a new world-class aluminum casting facility in Telford, United Kingdom, to support Jaguar Land Rover, the UK’s leading vehicle manufacturer.

The new facility is expected to be approximately 225,000 square feet and will create up to 295 jobs at full capacity. Working with the UK Trade & Investment and the Automotive Investment Organization, along with financial support from the UK Government’s Regional Growth Fund, helped to secure this project. Construction is expected to start in the autumn of 2016.

Once production begins in 2018, the facility will use Magna’s innovative high-pressure vacuum die casting process to produce a number of advanced lightweight aluminum castings– a key building block in the next generation all-aluminum and multi-material vehicle architectures.  By using these types of castings, Magna helps automakers deliver maximum strength and stiffness and minimum weight, ultimately achieving better fuel economy, safety and handling.

“We are excited to work closely with Jaguar Land Rover in the development of this project which will bring the most advanced structural casting technologies to the UK,” said John Farrell, President of Cosma International, an operating unit of Magna International.   “As lightweighting continues to be a key technology driver, we are uniquely positioned to help automakers achieve optimal weight savings throughout the vehicle architecture.”

Magna, through its Cosma International operating unit, is one of the world’s premier suppliers providing a comprehensive range of body, chassis and engineering solutions to automakers around the world.

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Automotive Aluminum Extrusion Market Grows

BOTW-50w  Source: Today’s Motor Vehicles – May/June 2016

Automotive Aluminum Extrusion Market Grows Read More »