<a href="https://www.fcmore.cl/">FC More Integral</a> is a leading engineering firm based in Chile that specializes in comprehensive solutions for the mining industry. The company manufactures, offers maintenance and repairs components of mining equipment. FC More Integral provides its services to major mining businesses, including Cerro Colorado, Collahuasi, Lomas Bayas (a Glencore company), Finning-CAT, and Komatsu, Minera Escondida, Minera Centinela and Sierra Gorda.With a strong commitment to quality, FC More Integral has established itself as a trusted partner for complex projects across Latin America. The company’s team brings together multidisciplinary expertise, enabling it to deliver tailored solutions that meet each client’s unique challenges.<h2>Legacy inspection techniques are no longer effective for Latin America’s booming mining sector</h2>In the mining industry, maintaining and repairing large-scale equipment is a critical challenge, especially when it comes to the integrity of components and assemblies. Traditional visual inspections and manual 3D measurement techniques can be prone to human error, resulting in overlooked issues that lead to costly component failures and fleet downtimes.According to Robert Valenzuela, Manager of Engineering, Administration and Quality at FC More Integral, there was—and still is—a growing need in the Latin American mining sector for more accurate and reliable methods to evaluate, repair, and improve parts to ensure equipment performance and operational efficiency.The team at FC More Integral wanted to find a better approach, using the latest metrology technologies, to improve component inspections, designs, redesigns, manufacturing and quality control.<h2>Transforming 3D measurement challenges into market opportunities</h2>The FC More Integral started exploring different 3D scanning solutions. They settled on two Creaform solutions: the&nbsp;<a href="https://www.creaform3d.com/en/handyscan-3d-silver-series-professional-3d?aw_campaign=20.90.1.0-%5bBRANDED%5d-Search-Canada-EN%5bCB%5d&network=g&aw_device=c&keyword=handyscan%20silver&creative=696797456081&matchtype=p&gad_source=1&gclid=CjwKCAjwxY-3BhAuEiwAu7Y6s_kTPWwwT3s0CI-LbT6HZZSJivU99BqPjkgRqaJwqO1UZs21Z8OMIxoCJLoQAvD_BwE">HandySCAN 3D|SILVER metrology-grade 3D scanner</a> and the&nbsp;<a href="https://www.creaform3d.com/en/metrology-solutions/optical-measuring-systems-maxshot-3d">MaxSHOT 3D optical coordinate measuring system</a>.“Our customers use HandySCAN 3D|SILVER to carry out 3D measurements on smaller components and the MaxSHOT 3D to scan large components over 5 meters—and up to 30 meters,” explained Ismael Mandiola at Talentum Digital. “The results are always accurate, reliable and repeatable.”The ultimate goal was to set up a brand-new and patented service, FC Scan, using Creaform’s technologies. In addition to improving the company’s in-house workflows, the HandySCAN 3D|SILVER and MaxSHOT 3D are now leveraged to provide FC More Integral’s customers with on-site assessments.“With FC Scan, customers can obtain a range of possibilities, from a simple initial structural diagnosis to deformation or failure identification to an entire inspection cycle, which generates a real three-dimensional image of how the component is today,” Robert said. That data makes carrying out maintenance and repair work easier and more precise. FC Scan customers appreciate the higher quality of repairs, reduced lead times and minimized downtimes.Another bonus is part archiving for future reference. “We can provide customers with complete models of various components and assemblies—information that was previously unavailable to many mining companies,” he mentioned.FC More Integral’s experts are thrilled with the MaxSHOT 3D and HandySCAN 3D|SILVER. They have had a tremendously positive impact on the company’s processes and customer inspections.

The FC More Integral started exploring different 3D scanning solutions. They settled on two Creaform solutions: the HandySCAN 3D|SILVER metrology-grade 3D scanner and the MaxSHOT 3D optical coordinate measuring system.

Mining engineering firm opens new service segment thanks to 3D scanners

A comprehensive technical analysis of PCB prepreg and core materials, examining their distinct material properties, manufacturing implications, and selection criteria for multilayer PCB design. 

PCB Prepreg vs Core Materials: Engineering Guide to Laminate Selection and Properties

Digital fabrication engineers are now working toward expanding the display capabilities of other everyday objects. One avenue they’re exploring is reprogrammable surfaces — or items whose appearances we can digitally alter — to help users present important information, such as health statistics, as well as new designs on things like a wall, mug, or shoe. Researchers from MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL), the University of California at Berkeley, and Aarhus University have taken an intriguing step forward by fabricating “<a href="https://hcie.csail.mit.edu/research/portachrome/portachrome.html">PortaChrome</a>,” a portable light system and design tool that can change the color and textures of various objects. Equipped with ultraviolet (UV) and red, green, and blue (RGB) LEDs, the device can be attached to everyday objects like shirts and headphones. Once a user creates a design and sends it to a PortaChrome machine via Bluetooth, the surface can be programmed into multicolor displays of health data, entertainment, and fashion designs.<iframe width="640" height="360" src="https://www.youtube.com/embed/eQcwTSWOzR8?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>To make an item reprogrammable, the object must be coated with photochromic dye, an invisible ink that can be turned into different colors with light patterns. Once it’s coated, individuals can create and relay patterns to the item via the team’s graphic design software, or use the team’s API to interact with the device directly and embed data-driven designs. When attached to a surface, PortaChrome’s UV lights saturate the dye while the RGB LEDs desaturate it, activating the colors and ensuring each pixel is toned to match the intended design.Zhu and her colleagues’ integrated light system changes objects’ colors in less than four minutes on average, which is eight times faster than their prior work, “Photo-Chromeleon.” This speed boost comes from switching to a light source that makes contact with the object to transmit UV and RGB rays. Photo-Chromeleon used a projector to help activate the color-changing properties of photochromic dye, where the light on the object's surface is at a reduced intensity.“PortaChrome provides a more convenient way to reprogram your surroundings,” says Yunyi Zhu ’20, MEng ’21, an MIT PhD student in electrical engineering and computer science, affiliate of CSAIL, and lead author on a paper about the work. “Compared with our projector-based system from before, PortaChrome is a more portable light source that can be placed directly on top of the photochromic surface. This allows the color change to happen without user intervention and helps us avoid contaminating our environment with UV. As a result, users can wear their heart rate chart on their shirt after a workout, for instance.”<h2>Giving everyday objects a makeover</h2>In demos, PortaChrome displayed health data on different surfaces. A user hiked with PortaChrome sewed onto their backpack, putting it into direct contact with the back of their shirt, which was coated in photochromic dye. Altitude and heart rate sensors sent data to the lighting device, which was then converted into a chart through a reprogramming script developed by the researchers. This process created a health visualization on the back of the user’s shirt. In a similar showing, MIT researchers displayed a heart gradually coming together on the back of a tablet to show how a user was progressing toward a fitness goal.PortaChrome also showed a flair for customizing wearables. For example, the researchers redesigned some white headphones with sideways blue lines and horizontal yellow and purple stripes. The photochromic dye was coated on the headphones and the team then attached the PortaChrome device to the inside of the headphone case. Finally, the researchers successfully reprogrammed their patterns onto the object, which resembled watercolor art. Researchers also recolored a wrist splint to match different clothes using this process.Eventually, the work could be used to digitize consumers’ belongings. Imagine putting on a cloak that can change your entire shirt design, or using your car cover to give your vehicle a new look.<h2>PortaChrome’s main ingredients</h2>On the hardware end, PortaChrome is a combination of four main ingredients. Their portable device consists of a textile base as a sort of backbone, a textile layer with the UV lights soldered on and another with the RGB stuck on, and a silicone diffusion layer to top it off. Resembling a translucent honeycomb, the silicone layer covers the interlaced UV and RGB LEDs and directs them toward individual pixels to properly illuminate a design over a surface.This device can be flexibly wrapped around objects with different shapes. For tables and other flat surfaces, you could place PortaChrome on top, like a placemat. For a curved item like a thermos, you could wrap the light source around like a coffee cup sleeve to ensure it reprograms the entire surface.The portable, flexible light system is crafted with maker space-available tools (like laser cutters, for example), and the same method can be replicated with flexible PCB materials and other mass manufacturing systems.While it can also quickly convert our surroundings into dynamic displays, Zhu and her colleagues believe it could benefit from further speed boosts. They'd like to use smaller LEDs, with the likely result being a surface that could be reprogrammed in seconds with a higher-resolution design, thanks to increased light intensity.“The surfaces of our everyday things are encoded with colors and visual textures, delivering crucial information and shaping how we interact with them,” says Georgia Tech postdoc Tingyu Cheng, who was not involved with the research. “PortaChrome is taking a leap forward by providing reprogrammable surfaces with the integration of flexible light sources (UV and RGB LEDs) and photochromic pigments into everyday objects, pixelating the environment with dynamic color and patterns. The capabilities demonstrated by PortaChrome could revolutionize the way we interact with our surroundings, particularly in domains like personalized fashion and adaptive user interfaces. This technology enables real-time customization that seamlessly integrates into daily life, offering a glimpse into the future of ‘ubiquitous displays.’”Zhu is joined by nine CSAIL affiliates on the paper: MIT PhD student and MIT Media Lab affiliate Cedric Honnet; former visiting undergraduate researchers Yixiao Kang, Angelina J. Zheng, and Grace Tang; MIT undergraduate student Luca Musk; University of Michigan Assistant Professor Junyi Zhu SM ’19, PhD ’24; recent postdoc and Aarhus University assistant professor Michael Wessely; and senior author Stefanie Mueller, the TIBCO Career Development Associate Professor in the MIT departments of Electrical Engineering and Computer Science and Mechanical Engineering and leader of the HCI Engineering Group at CSAIL.

When Nikola Tesla predicted we’d have handheld phones that could display videos, photographs, and more, his musings seemed like a distant dream. Nearly 100 years later, smartphones are like an extra appendage for many of us.

A portable light system that can digitize everyday objects

An overview of Flip chip technology, its inception, manufacturing process, advancements and performance optimization techniques.

Flip Chip Technology: Advanced Semiconductor Packaging for Next-Generation Electronics

It happens all the time, legacy equipment functions as intended but doesn’t offer today’s remote monitoring capabilities. Facility management and staff know that capturing performance data from their equipment would enable better decisions but often fear it’s difficult to add the technology. That may have been true in the past, but today – with Banner’s Snap Signal plug-and-play products – it’s easier than you may think. This guide will walk you through a simple approach to upgrading legacy equipment and gaining new insights into your operation.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730079732912-1730079732912.png" class="fr-fic fr-dib"><h2 id="isPasted">1. Identifying Actionable Data Locked Inside Your Equipment</h2>Have you ever looked at the sensor on your conveyor, or tower light on your case packer and considered how much information it could potentially provide you with? At Banner, we call this “actionable data.” Photoelectric sensors may be currently used to trigger various steps of the process on your machine, but they can also be a source of measuring overall equipment effectiveness (OEE). Once your data is unlocked, each time a product passes a sensor, the data becomes actionable. The same could be true for tower lights, which are commonly used to notify staff whether the machine is operating correctly, is out of materials, or is stopped for some reason. While this indicator provides local benefits, think how helpful the data would be to someone who was trending the downtime of all machines based on the tower light status. Comparing downtime among machines can help drive your continuous improvement efforts by aiming your projects at the underperforming machines.Traditional approaches to IIoT may require removing all existing sensors and other control devices and adding new. Not only is this expensive, but it generates waste from removing components that are working well. And it introduces risk, as you’re making large changes to equipment that could create unnecessary downtime. Another approach that is often considered is accessing the data inside the PLC or HMI on the machine. However, these devices are often locked down after the machine build, and making changes could pose further risk to the performance and uptime of the machine. At Banner Engineering, we take a less invasive approach by tapping the data from the devices you already have installed by creating an “overlay network” that operates alongside your existing device infrastructure.<h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730101897087-Screenshot+2024-10-28+at+8.49.33%E2%80%AFAM.png" style="width: 100%px;" class="fr-fic fr-dib"></h2><h2 id="isPasted">2. Unlocking Actionable Data</h2>Start by looking at the devices you have on your machines and consider whether the data is useful or needed. In the bottling example above, not every sensing point may be valuable, but some certainly will be. Also, look beyond sensors. Do your control panels have indicator lights that tell operators if something is wrong? This is actionable data. You can begin monitoring this machine data to trend how often a particular condition presents itself and then make a plan to improve it.Unlocking this data from existing devices is usually as simple as adding a splitter connection to “listen in” on the signals. For example, the bottling application’s photoelectric sensor – being used by the existing control system – likely has an M12 connector. If not, a field-wireable one can be easily added. This connector makes it easy to use a splitter cable to begin monitoring the signal. It is important to point out that with this method, you are not interrupting anything, you are simply listening in. With the splitter connected to the sensor, one branch of the splitter stays connected to the the PLC and the other branch goes to the new Snap Signal overlay network.Snap Signal is a portfolio of modular IIoT hardware and software that converts existing sensor signals to a unified protocol and then brings the data to an edge device to monitor machine conditions in the cloud or distribute the data to a SCADA control system or PLC. Snap Signal products are easily deployable and deliver actionable machine data from across your factory floor. Snap Signal helps minimize disruptions when upgrading equipment. Your existing control system architecture remains unchanged. Alternative methods like upgrading your PLC typically require significant down time and present the possibility of problems upon re-commissioning, but that isn’t the case with Snap Signal.<h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730101908786-Screenshot+2024-10-28+at+8.49.58%E2%80%AFAM.png" style="width: 100%px;" class="fr-fic fr-dib"></h2><h2 id="isPasted">3. Adding New Sensors to Unlock Additional Machine Data</h2>During your assessment of existing devices, you may realize there are points you want to monitor that don’t currently have sensors installed. For example, you may realize that monitoring the vibration and temperature of an electric motor could give you insights into when it may need service or replacement. You can quickly add a vibration &amp; temperature sensor and connect it into the overlay network. This is a simple problem to solve using your new overlay network from Snap Signal, as there’s no need to integrate these I/O points with your PLC.<h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730102023324-Screenshot+2024-10-28+at+8.50.20%E2%80%AFAM.jpg" style="width: 100%px;" class="fr-fic fr-dib"></h2><h2 id="isPasted">4. Simplifying Equipment Data with Unified Protocols</h2>Industrial equipment and control systems often come with a variety of communication protocols, making it difficult to monitor existing equipment. The Snap Signal family of products unifies these into a single communication protocol allowing you access to existing device data and any new sensors you have added which you need to monitor.Snap Signal makes this easy by offering a portfolio of in-line signal converters. These devices take signals like 0-10Vdc analog and convert them to a serial protocol. The converters require little to no configuration and install quickly via M12 connectors on either end. Building your overlay network involves identifying the signal types you have, so you can find the corresponding converters to capture the data and get it streaming. Once the signals are on a common serial protocol, you can bring them all together by creating cable networks with tees and M12 connectors.The industrial controller moves the data to a location it can be consumed. Locations you might send data to include cloud dashboards, SCADA systems, and HMIs. Banner’s Snap Signal IIoT portfolio includes a DXMR90 controller, which has the ability to connect to several serial networks and push data out via a single Industrial Ethernet port. The DXMR90 can perform logic, math, and other functions. Configurating the device is accomplished using Banner’s free software, and scripting can be performed using MicroPython for even more advanced functionality.<h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730102043503-Screenshot+2024-10-28+at+8.50.41%E2%80%AFAM.png" style="width: 100%px;" class="fr-fic fr-dib"></h2><h2 id="isPasted">5. Providing Your Organization with Actionable Data</h2>Now that you have access to all this actionable data, here are 5 real-world applications where you can begin using it immediately:<ol><li>Use sensor data to monitor the level of raw materials and schedule refills. Rather than having machine operators call in for more materials, let the machine tell the operators when they need to act. Use a cloud dashboard to view all the new data you have and create alerts when more materials are needed. <a href="https://www.bannerengineering.com/us/en/solutions/iiot-data-driven-factory/increase-machine-uptime0.html?utm_campaign=snap-signal&utm_medium=pdf&utm_source=snap-guide&utm_content=cloud-dashboard">Click Here to Read More.</a></li><li>Monitor Overall Equipment Effectiveness (OEE). Use sensor data from input, reject, and output lines, along with machine uptime, to provide insights by monitoring a cloud dashboard that can help identify machines which are performing well or poorly. <a href="https://www.bannerengineering.com/us/en/solutions/iiot-data-driven-factory/measure-throughput-and-oee-on-case-sealer.html?utm_campaign=snap-signal&utm_medium=pdf&utm_source=snap-guide&utm_content=monitor-oee">Click Here to Read More</a></li><li>Predict when hydraulic power units will need maintenance by monitoring a cloud dashboard containing vibration, temperature, and motor current data. <a href="https://www.bannerengineering.com/us/en/solutions/iiot-data-driven-factory/monitor-hydraulic-power-units.html?utm_campaign=snap-signal&utm_medium=pdf&utm_source=snap-guide&utm_content=remote-monitoring">Click Here to Read More</a></li><li>Monitor tank levels remotely. Snap Signal products connect sensors of all signal types to bring tank level data onto your industrial network or to the cloud. <a href="https://www.bannerengineering.com/us/en/solutions/iiot-data-driven-factory/monitor-tank-level-remotely-in-a-snap.html?utm_campaign=snap-signal&utm_medium=pdf&utm_source=snap-guide&utm_content=monitor-tank-levels">Click Here to Read More</a></li><li>Monitor the condition of dust collection systems. Monitor vibration and temperature, boiler temperatures, level, and differential pressure. Then bring this data to a Banner DXM and the option of aggregating in a cloud dashboard. <a href="https://www.bannerengineering.com/us/en/solutions/iiot-data-driven-factory/condition-monitoring-of-dust-collection-system--.html?utm_campaign=snap-signal&utm_medium=pdf&utm_source=snap-guide&utm_content=dust-collection">Click Here to Read More</a></li></ol>The move to a smart factory – which was once a daunting prospect – has become easier with the use of Snap Signal products, from Banner Engineering. Snap Signal is brand-agnostic, and flexible enough to be implemented at any point along your data-flow chain and is an ideal solution for both modernizing legacy equipment and integrating with new machine builds. Increase productivity and unlock your factory’s true potential with Snap Signal – a hardware and software tool-kit for your IIoT evolution. <a href="https://www.bannerengineering.com/us/en/lp/snapsignal/snap-signal-guide-form.html?srsltid=AfmBOopef7Gq13YBKeqW0so-JI-dRjrUy8RWmuLVpMh9LxWWGgQgCJpW">Banner </a>products and solutions have been trusted for over 50 years and are designed and built to meet and exceed industry standards.

Unlocking Data from Your Existing Equipment is Easier Than You Think

The 5-Step Guide to Modernizing Your Factory

Machines like the Stratasys Fortus 450mc can process high-temp 3D printer filament (credit: Stratasys)

High-temp 3D printer filaments are challenging to print, but they can be used to make vital end-use parts like automotive components.

High-Temp 3D Printer Filament: Material and Hardware Considerations

Polylactic acid (PLA), a versatile bioplastic derived from renewable resources, tends to be seen as the greenest of common thermoplastic 3D printing materials. It is marketed as a relatively safe, non-toxic material that is biodegradable after use.Indeed, this plant-based polymer offers a potential alternative to conventional petroleum-based plastics, addressing the critical need for biodegradable materials in various engineering applications. The importance of such materials extends beyond mere waste reduction; they play a crucial role in promoting circular economy principles and mitigating the environmental impact of plastic pollution. However, as environmental concerns over all forms of manufacturing have intensified, the biodegradability of PLA has become a point of discussion &nbsp;for engineers and researchers alike.In simple terms, used PLA filament cannot simply be thrown into your garden compost heap, but it is biodegradable under specific conditions. This article looks at the science behind biodegrading PLA, as well as practical considerations for discarding scrap 3D printer filament.<h2 dir="ltr">The Molecular Makeup of PLA: A Closer Look</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728575443981-polylactic_acid_structure.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="pla">The chemical structure of PLAPolylactic acid (PLA) is a biopolymer with a unique molecular structure that sets it apart from traditional petroleum-based plastics. Its backbone formula is (C3H4O2)n. At its core, PLA is composed of lactic acid monomers, which are derived from renewable plant sources such as corn starch or sugarcane.[1] These lactic acid molecules undergo a polymerization process to form the long chains of PLA.Unlike petroleum-based plastics, which are derived from non-renewable fossil fuels, PLA's plant-based origins contribute to its sustainability profile. The production of PLA typically involves fermenting plant starches to produce lactic acid, which is then polymerized through various methods, such as direct condensation or ring-opening polymerization of lactide.[2]Key properties of PLA relevant to its biodegradability include:<ul><li dir="ltr">Presence of hydrolyzable ester bonds</li><li dir="ltr">Higher hydrophilicity compared to conventional plastics</li><li dir="ltr">Low <a href="https://www.wevolver.com/article/pla-melting-point" target="_blank">glass transition temperature</a></li><li dir="ltr">Susceptibility to enzymatic degradation</li><li dir="ltr">Stereocomplex formation capability (between L- and D-lactide units)</li></ul>These properties contribute to PLA's ability to break down under specific environmental conditions, making it an attractive option for biodegradable applications in various engineering fields.<h2 dir="ltr">PLA Biodegradability vs. Other Filaments</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728575468036-3d_printer_filament_spools.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="abs pla">ABS and other synthetic plastics do not compost easily like PLAThe molecular structure of Polylactic acid (PLA) differs significantly from petroleum-based 3D printing plastic like ABS and PETG, which directly influences its biodegradability potential.ABS is a terpolymer consisting of three monomers: acrylonitrile, butadiene, and styrene. The acrylonitrile provides chemical resistance, butadiene adds toughness, and styrene gives rigidity and processability. ABS has a complex structure, with strong intermolecular forces and cross-linked chains that resist environmental degradation. The butadiene component especially contributes to ABS's durability and its resistance to microbial attack. This results in ABS being highly resistant to biodegradation, often persisting for centuries in landfills.PETG is a glycol-modified version of PET, with ethylene glycol incorporated into the polymer chain to improve flexibility. The polymer consists of repeating terephthalate units, and the addition of glycol inhibits crystallization, making PETG more amorphous and easier to process. PETG’s structure, like ABS, is resistant to biodegradation due to its strong ester bonds and aromatic rings, which are stable in most environmental conditions. This makes PETG durable but not biodegradable. On the other hand, both ABS and PETG can be recycled in many locations.Recommended reading: <a href="https://www.wevolver.com/article/pla-vs-abs" target="_blank">PLA vs ABS: Which Filament Should One Use?</a><h2 dir="ltr">PLA Biodegradability: Fact or Fiction?</h2>Biodegradability, in the context of plastics and polymers, refers to the material's ability to break down into natural substances such as water, carbon dioxide, and biomass through the action of naturally occurring microorganisms. For Polylactic acid (PLA), this process is not just theoretical but a demonstrable reality under specific conditions.PLA biodegradation occurs through two primary mechanisms: hydrolysis and microbial action. Hydrolysis, the initial step, involves the breaking of ester bonds in the PLA polymer chain by water molecules. This process reduces the molecular weight of PLA, making it more susceptible to microbial attack. Subsequently, microorganisms present in the environment can metabolize these smaller PLA fragments, converting them into biomass, CO2, and water.[3]The biodegradation of PLA is heavily dependent on environmental conditions. Optimal PLA biodegradation typically requires:<ul><li dir="ltr">Temperatures above 58°C (136°F)</li><li dir="ltr">Relative humidity above 70%</li><li dir="ltr">Presence of specific microorganisms capable of metabolizing PLA</li><li dir="ltr">pH levels between 5.5 and 8.0</li><li dir="ltr">Adequate oxygen levels for aerobic biodegradation</li></ul>These conditions are commonly found in industrial composting facilities but are unlikely to occur in home composting setups or natural environments, which explains why PLA may not biodegrade readily in all situations. In fact, in many everyday disposal scenarios, PLA may not biodegrade any faster than conventional plastics, underscoring the importance of proper waste management and disposal practices for this material.The stages of PLA biodegradation can be outlined as follows:<ol><li dir="ltr">Moisture absorption: PLA begins to absorb water from its environment.</li><li dir="ltr">Hydrolysis initiation: Water molecules start breaking the ester bonds in PLA.</li><li dir="ltr">Molecular weight reduction: The polymer chains break into smaller fragments.</li><li dir="ltr">Microbial colonization: Microorganisms begin to colonize the PLA surface.</li><li dir="ltr">Enzymatic degradation: Microbes secrete enzymes that further break down PLA.</li><li dir="ltr">Assimilation: Microorganisms consume the small PLA fragments.</li><li dir="ltr">Biomass and gas production: The consumed PLA is converted into biomass, CO2, and water.</li></ol><h3 dir="ltr">How Long Does PLA Take to Biodegrade?</h3>The biodegradation rate of Polylactic acid (PLA) varies depending on environmental conditions. Under optimal industrial composting conditions, PLA can biodegrade to a significant reduction in mass in around 30 to 60 days. However, in less ideal environments, the process can take much longer. In landfill or cold home composting setups, PLA often degrades no faster than plastics derived from fossil fuels. Biodegradation times are heavily influenced by temperature, humidity, microbial activity, pH levels, and aerobic conditions.<h2 dir="ltr">What Should You Do With Scrap PLA Filament?</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728575482055-colorful_plastic_scraps.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="scrap">Scrap filament can be composted at an industrial facilitySince PLA is a bio-based and biodegradable polymer, one might assume that the material is suitable for home composting, but this is generally not the case due to the high temperatures required for biodegradation. However, the compostable plastic can be sent to an industrial composting facility.&nbsp;Depending on where you live, you may be able to put PLA scraps in with other organic waste to be collected by a municipal waste organization. Generally, it depends on whether organic waste in the area goes through a&nbsp;Biomethanization process prior to composting or not. PLA is not suitable for this process, so areas that send organic waste for Biomethanization will not accept PLA. If this is the case for your area, you can try to find a commercial or industrial composting location independently.If composting is not a feasible option, recycling PLA is another route. Scrap PLA cannot generally be mixed into regular plastic recycling streams, but can be sent to special facilities for recycling. Incineration is another option. Putting scrap PLA with general waste for landfill should be a last resort, as the plastic will degrade extremely slowly in those conditions.Recommended reading: <a href="https://www.wevolver.com/article/pla-recycling" target="_blank">PLA Recycling: Can PLA 3D Printer Filament be Recycled?</a><h2 dir="ltr">PLA's Environmental Footprint: Beyond Biodegradability</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728575493924-biodegradable_cup_label.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="pla cup">End-of-life is not the only environmental concern regarding PLAPolylactic acid (PLA) is often touted as an environmentally friendly alternative to traditional plastics due to its biodegradability. However, a comprehensive analysis of its environmental footprint requires examining its entire life cycle, from production to disposal. The life cycle of PLA begins with the cultivation of raw materials, typically corn or sugarcane. These crops undergo fermentation to produce lactic acid, which is then polymerized into PLA. The polymer is processed into various products, used by consumers, and finally disposed of or recycled.Compared to traditional plastics, PLA generally has a lower environmental impact. Its production requires less fossil fuel and generates fewer greenhouse gas emissions. However, the exact environmental benefits can vary depending on the specific production processes and energy sources used.While PLA production emits less CO2 than traditional plastic production, it is not carbon-neutral. The fermentation process and energy used in manufacturing contribute to greenhouse gas emissions. However, the plants used as raw materials absorb CO2 during growth, partially offsetting these emissions. The net climate impact depends on factors such as agricultural practices, processing efficiency, and end-of-life management.Land use for PLA raw material production is a significant concern. The cultivation of corn or sugarcane for PLA competes with food production and can lead to land-use changes. This competition could potentially impact food security and biodiversity. However, research is ongoing into using agricultural waste or non-food crops as PLA feedstocks, which could mitigate these concerns.<h2 dir="ltr">Conclusion</h2>Polylactic acid (PLA) represents a significant advancement in biodegradable materials, offering a potential solution to the persistent problem of plastic pollution. Its ability to break down under specific conditions, particularly in industrial composting facilities, sets it apart from traditional plastics. Proper disposal and composting practices are crucial for realizing the full environmental benefits of PLA. Without appropriate end-of-life management, PLA may not biodegrade efficiently, potentially contributing to waste accumulation.&nbsp;<h2 dir="ltr">Frequently Asked Questions</h2>Q: How long does it take for PLA to biodegrade in a home compost bin?A: PLA biodegradation in (cold) home compost bins is ineffective, with the plastic taking potentially hundreds of years to degrade at ambient temperatures. Industrial (hot) composting facilities are required to compost PLA effectively.Q: Can PLA be recycled with other plastics?A: PLA should not be mixed with other plastics for recycling. It requires specific recycling processes different from those used for conventional plastics. Mixing PLA with other plastics can contaminate the recycling stream.Q: How does the strength of PLA compare to traditional plastics?A: PLA's strength can be comparable to some traditional plastics like polystyrene, but it's generally less durable than other common filaments like ABS. Its mechanical properties can be enhanced through various techniques such as blending with other polymers or adding reinforcing fibers.Q: Is PLA production more energy-efficient than traditional plastic production?A: PLA production typically requires less energy than the production of petroleum-based plastics, though exact figures depend on specific production methods and energy sources.<h2 dir="ltr">References</h2>[1] Fatchurrohman N, Muhida R. <a href="https://jitekin-upiyptk.org/ojs/index.php/Teknologi/article/view/101" target="_blank">From Corn to Cassava: Unveiling PLA Origins for Sustainable 3D Printing</a>. Jurnal Teknologi. 2023 Dec 31;13(2):87-93.[2] Hu Y, Daoud WA, Cheuk KK, Lin CS.<a href="https://pubmed.ncbi.nlm.nih.gov/28773260/" target="_blank">&nbsp;Newly developed techniques on polycondensation, ring-opening polymerization and polymer modification: Focus on poly (lactic acid)</a>. Materials. 2016 Feb 26;9(3):133.[3] Elsawy MA, Kim KH, Park JW, Deep A.<a href="https://www.sciencedirect.com/science/article/pii/S1364032117307876" target="_blank">&nbsp;Hydrolytic degradation of polylactic acid (PLA) and its composites</a>. Renewable and Sustainable Energy Reviews. 2017 Nov 1;79:1346-52.

As one of the few thermoplastic 3D printing materials derived from natural sources, PLA is often assumed to be the most eco-friendly. But is that true?

Is PLA Biodegradable? What To Do With Scrap Filament

Centurion Performance &amp; Engines is an Illinois-based manufacturer of custom performance engines and parts. It is also a custom tuning and install body shop in high demand.Founded in 2009, the company has a research and development department equipped with an array of advanced tools, including a machining center with a SolidWorks station. This comprehensive setup enables the team to design and test the unique combinations of systems and parts that set their products apart, achieving levels of functionality never seen before. Many components and ideas tested here are subsequently integrated into other builds, driving continuous improvement and innovation for customers.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727935731270-IMG_4466-1536x1152.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">The challenge: Hand fabrication makes production scalability difficult</h2>Centurion Performance &amp; Engines prides itself on making superior-quality products for its discerning clientele. However, due to increasing demand and an uptick in the complexity of the components to be developed, the Centurion team realized that fabrication experts could no longer rely on manual processes alone.The conventional fabrication processes were slow and difficult to replicate accurately, preventing team members from producing consistent, high-quality parts and assemblies. This was especially true when it came to implementing organic surfaces to design composite panels that mate properly together and create new power systems that could fit into existing engine compartments.<a href="https://www.creaform3d.com/blog/pun5th75ef_wp/wp-content/uploads/IMG_4451-scaled.jpg" target="_blank"> </a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727935746178-IMG_4451-1152x1536.webp" style="width: 100%px;" class="fr-fic fr-dib">Moving from prototype to production was particularly challenging due to difficulties in visualizing the entire system, such as an engine bay, without a digital representation. This led to a lot of back-and-forth between teams and longer lead times.Many innovative projects remained in the conceptual stage because the cost and time associated with manually developing the systems were prohibitive. Recognizing the importance of accurate equipment for successful prototype parts, Centurion Performance &amp; Engines was motivated to explore more viable and efficient solutions.“Having already worked with a customer on a reverse engineering project with a CMM, I knew that a metrology-based solution was key to developing successful prototypes,” explained Tim Slater, the company’s president. “Having seen 3D scanning technologies in action, it became very and immediately clear this was a direction we needed to go.”<h2>The solution: HandySCAN BLACK Elite and VXmodel outperform in terms of 3D scanning accuracy and post-processing speed</h2>Tim tested multiple 3D measurement products. “After much difficulty in post-processing scans, which led to inaccuracies in the data, and realizing how much time and effort was spent manipulating the scan so that I could complete a post-process to satisfaction, I decided to try the metrology-grade HandySCAN BLACK Elite,” he said. “It was a decision that came after a year and a half of frustration and lack of acceptable results.”The engineering team were impressed with the results. “The accuracy of the raw 3D scans combined with the power of Creaform’s VXmodel post-processing software gave us the speed and extremely high-quality renderings we simply couldn’t get with the other equipment we tried. The ease of scanning is great, and the software is brilliant.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727935773373-CowlingExitScan-1536x800.webp" style="width: 100%px;" class="fr-fic fr-dib">Creaform’s technology transformed Centurion Performance &amp; Engines’ time to market and production capacity. Using the HandySCAN BLACK Elite, teams could quickly and accurately scan components and existing engine compartments, allowing for precise design and integration of new power systems that met customers’ exacting standards. The ability to quickly create and test prototypes significantly reduced development time.For instance, Tim was able to design, manufacture, and test a new part for their race team’s airplane within 48 hours—a process that traditionally would have taken much longer.“After completing nearly two months of non-stop work modifying our race team’s first airplane, test flights were completed satisfactorily with three days remaining before needing to leave for the racing event. An area left unfinished was a large clearance hole that was cut in the bottom of the engine cowling to fit the new performance exhaust system,” he described.“Knowing this large hole was a major drag contributor, I set out to create a part to close it off and direct the engine cooling air appropriately and efficiently out the bottom of the aircraft. &nbsp;On a Tuesday afternoon, I scanned the bottom of the cowling and surrounding area. Then, I sat on the computer for a couple of hours processing the scan, designing the part, and then the mould to create the part. &nbsp;At about 11 p.m., I was at our facility, piecing together the appropriate pieces of urethane tooling board to machine out the mould. &nbsp;At about 5 a.m., the machining was complete. I returned late in the morning to prepare the mould for laying up the carbon fibre part. Once the part was laid up and in a vacuum bag, I set a timer for 24 hours. Thursday late morning, I removed the part from the mould and transported it to the aircraft for trimming and installation. The part was fitted, installed, exhaust extended, and heat shields in place by about 9 pm that evening after barely 2 days from the start of the project.”<h2>The results: Greater production output and new market opportunities</h2>Implementing HandySCAN BLACK Elite and VXmodel generated impactful business benefits for Centurion Performance &amp; Engines.Tim mentioned that “the ability to visualize and fit components digitally before fabrication saved a tremendous amount of time and energy. The ROI comes from the ability to produce and sell multiples of a part—with unbeatable accuracy—thanks to extremely high-quality scanning that results in excellent tooling.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727935781624-IMG_1688-1152x1536.webp" style="width: 100%px;" class="fr-fic fr-dib">He emphasized the importance of counting on a 3D scanning solution with a powerful and integrated post-processing software module. “The capabilities of VXmodel are far and above others I have used. I see all sorts of pretty scans people make with inexpensive handheld scanners. Nevertheless, the ability to pull accurate and consistent data off of the scan is where VXmodel shines. Its surfacing tools and the ability to send the files and scans directly into SolidWorks is nothing short of phenomenal.”Creaform’s 3D scanner and scan-to-CAD software also created additional market opportunities for Tim’s business, allowing it to offer new services and product applications that were previously not feasible. “Since we bought HandySCAN BLACK Elite and VXmodel, we’ve been off to the races,” Tim concluded. “I have the confidence in the 3Dscanner, data and software to tackle any development or prototype project!

Creaform’s technology transformed Centurion Performance & Engines’ time to market and production capacity. Using the HandySCAN BLACK Elite, teams could quickly and accurately scan components and existing engine compartments, allowing for precise design and integration of new power systems

Revolutionizing Custom Engine Fabrication with HandySCAN BLACK Elite & VXmodel

<a href="https://www.apsx.com/" target="_blank" rel="noopener noreferrer">APSX machines</a> provide a strategic advantage for manufacturers looking to achieve sustainability and cater to small-batch production, particularly for niche markets. Here’s how they contribute to these areas:1. Sustainability through Resource OptimizationAPSX machines are engineered to support sustainable manufacturing practices by incorporating features that minimize resource consumption and waste generation. Here are the key aspects that enhance sustainability:<ul type="disc"><li>Precision Engineering with Minimal Waste: APSX machines employ advanced CNC machining techniques and high-precision controls that optimize material usage. These machines reduce excess material usage, leading to less waste and more efficient use of raw materials.</li><li>Energy-Efficient Operations: The machines are equipped with energy-efficient drives and smart motor controls that reduce power consumption during idle periods and optimize energy use during production. This efficiency lowers the overall carbon footprint of manufacturing processes.</li><li>Reduced Tooling and Maintenance Requirements: APSX machines often require fewer tool changes and less maintenance compared to traditional manufacturing setups. This results in a lower consumption of consumables and extends the lifespan of parts, contributing to less industrial waste and a more sustainable production environment.</li><li>Support for Eco-Friendly Materials: These machines can handle a wide range of materials, including biodegradable and recycled composites, supporting the use of eco-friendly alternatives. Manufacturers can experiment with sustainable materials without compromising on quality or precision.</li></ul>2. Small-Batch Production for Niche MarketsAPSX machines are particularly well-suited for small-batch production, making them an ideal solution for niche markets that demand high customization and lower production volumes. Here’s how APSX machines help:<ul type="disc"><li>Flexible Production Capabilities: APSX machines are designed with versatility in mind, allowing manufacturers to quickly switch between different product configurations without the need for extensive retooling. This flexibility is crucial for producing small batches of customized products or catering to specific client requirements.</li><li>Cost-Effective for Low-Volume Runs: Traditional manufacturing equipment often incurs high setup costs, making small-batch production economically unfeasible. APSX machines, with their lower upfront costs, modular configurations, and minimal setup requirements, enable manufacturers to achieve profitability even with low-volume runs.</li><li>Shorter Lead Times: With advanced CNC and additive manufacturing capabilities, APSX machines reduce production times and enable rapid prototyping, making it easier to test and validate new designs. This agility is essential for niche markets that value speed and flexibility in meeting unique customer needs.</li><li>Customization with High Precision: Niche markets often require highly specialized products with unique specifications. APSX machines can execute complex geometries and fine detailing with high accuracy, ensuring that even small production runs meet the exact standards of quality and design.</li></ul>3. Supporting Sustainable Product DevelopmentAPSX machines allow businesses to experiment and iterate on sustainable product designs with minimal material investment. This makes it easier for companies to refine eco-friendly product offerings without incurring the high costs typically associated with traditional prototyping and production methods. For manufacturers targeting environmentally-conscious markets, this capability supports the development of products that align with sustainability goals.4. Enabling On-Demand ManufacturingIn niche markets, demand can be unpredictable and fluctuate widely. APSX machines enable an on-demand manufacturing model, where production is initiated based on real-time orders rather than maintaining high levels of inventory. This approach minimizes overproduction and reduces inventory waste, further contributing to sustainable practices.#injectionmolding #cncmachining #prototyping #sustainability&nbsp;

APSX machines provide a strategic advantage for manufacturers looking to achieve sustainability and cater to small-batch production, particularly for niche markets.

Sustainability and Small-Batch Production with APSX Machines

CMOS and CCD sensors both convert light into electronic signals, with CMOS using pixel-level transistors for faster, energy-efficient processing, while CCD transfers charge across the chip for superior image quality but with slower speed and higher power consumption.

CCD vs CMOS Image Sensors: A Comprehensive Guide for Engineering Professionals

Murata Digital Transformation (MDX) was launched with the goal of driving both business and IT, in order to realize Murata's long-term concept, "Vision 2030." In this article, executive officer Fumiyuki Suchi (Corporate Unit, Business Engineering &amp; Information System Group) explains the company's strategy for engaging with DX and transforming a wide range of fields including business models, value chains, and core competencies.<h2 id="isPasted">1. Aiming for a high-cycle organization where people and data are connected</h2>Murata launched MDX as a company-wide initiative. According to Suchi, the foundation for this was based on three Ds: "Diversity &amp; Decision Making Process," "Definition," and "Digital."<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMjIzODYwMjM2LW11cmF0YSBhLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Autonomous and decentralized organizational management, and the three DsSuchi:&nbsp;"We want to implement digital transformation with digitization and digitalization as drivers. We will optimize decision-making processes based on diverse mutual understanding and cooperation that goes beyond individuals, teams, organizations, and sites ('Diversity &amp; Decision Making Process'), and then redefine KGIs/KPIs and how organizations should function ('Definition')."Describing transforming business models through DX as "extremely difficult," Suchi continues, "we're first focusing on a high-cycle organization where people and data are connected."Suchi:&nbsp;"A high-cycle organization is an organization where the cycle of establishing, trying, and verifying a hypothesis and then moving on to the next hypothesis is accelerated and spirals up, allowing for agile decision-making. In order to make that possible, we aim to build a data infrastructure that allows multiple people to access the same data at the same time, so that information can be connected between management, sites, customers, and suppliers, allowing us to autonomously make use of information and data to establish policies focused on collectiveness."<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMjIzODg3Mzg4LW11cmF0YSBiLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">A high-cycle organization where people and data are connected<h2 id="isPasted">2. Connecting all business processes for comprehensive and efficient optimization</h2>According to Suchi, the company will focus on Value Provided &amp; Business Model, Holistic Value Chain, and Enhancement of Core Competencies, as specific MDX initiatives.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1723224029515-img4-003-en.jpg" style="width: 100%px;" class="fr-fic fr-dib">MDX overall diagramSuchi:&nbsp;"Value Provided &amp; Business Model means launching new businesses outside of conventional standard businesses and specific application businesses, that are more focused on solving problems, and implementing transformation. Holistic Value Chain will be crucial in using digital to enhance this three-layer portfolio."The demand chain starts with customers and the market, while the engineering chain is rooted in manufacturing processes such as product development and manufacturing, and the supply chain extends from raw material and part procurement to sales. Holistic Value Chain is the process of connecting all of these and optimizing processes.Suchi:&nbsp;"One of Murata's strengths has been our ability to meet the needs of customers with superior technology and a willingness to bounce ideas off each other. However, this is not enough now. We need to also compete on being able to deliver quickly without loss. We will need to connect all business processes and aim for comprehensive and efficient optimization."According to Suchi, the company will aim to Enhance Core Competencies in order to realize Holistic Value Chain.Suchi:&nbsp;"Manufacturing is Murata's greatest strength, and it's in this area that we will promote the use of cyberphysical systems, the utilization of materials informatics (MI) in developing technologies, and the use of digital in marketing and promotion. We will create a high-cycle organization that enables more sophisticated decision-making, by visualizing and linking operations in the areas of Value Provided &amp; Business Model, Holistic Value Chain, and Enhancement of Core Competencies. We want to promote MDX in a way that encompasses all of this."<h2>3. Building a digital infrastructure focused on autonomy, collectiveness, and evolution</h2>Building a next-generation digital infrastructure will serve as the foundation for bringing more sophisticated decision-making, based on Value Provided &amp; Business Model, Holistic Value Chain, and Enhancement of Core Competencies. Suchi: "The goal is not simply to build infrastructures for data and applications and promote DX."<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMjIzOTM2Mjk5LW11cmF0YSBkLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Next-generation digital infrastructure conceptSuchi:&nbsp;"Our keywords for the next-generation digital infrastructure are Autonomy, Collectiveness, and Evolution. Autonomy means that people on site autonomously use digital to bring about transformation and create new value. In order for that to happen, we will build a data infrastructure that provides data governance functionality to ensure that data is used safely and securely. That's Collectiveness."Autonomy has been an important value at Murata for some time.Suchi:&nbsp;"The improvements being made at all of our sites are based on autonomy. However, as an organization expands, it tends to become more vertically aligned with regard to businesses and functions. This also means that the company becomes weaker horizontally across organizations. This is why we think it's so important to press forward with Holistic Value Chain while also considering the proper balance between Autonomy and Collectiveness, and to promote collaboration between business divisions and sites."Evolution means making use of the latest technologies, such as application programming interface (API) linking and virtualization technology.Suchi:&nbsp;"In Europe, suppliers and customers are connected to the same data infrastructure or cyberphysical system, and the pace of business continues to increase. We want to introduce the latest technology and enhance our infrastructure linked with external services and applications, so that we won't be left behind by global trends like this."<h2>4. Business and IT driven by each employee undergoing DX</h2>According to Suchi, creating environments for employees to autonomously engage in DX is also important for MDX.Suchi:&nbsp;"For example, we're preparing environments at Murata and providing ChatGPT, so that people can get familiar with digital. We're also implementing a range of policies to democratize IT, such as establishing a cloud utilization promotion organization to make it easier for people to use the latest information technology safely, establishing a digital architecture consultation service for people to get answers to their questions, and enhancing security against cyber attacks and information leaks."The company is now implementing several policies, and Suchi stresses the importance of sharing information.Suchi:&nbsp;"In addition to presenting our vision of MDX, it's important to share information and show employees how things will change and how it will benefit them. That's why we launched our new portal site. Employees can access this information and begin using digital to solve problems and build success stories. We believe that, by taking the lead in promoting DX, employees will transform themselves and then drive business and IT."Although the company has launched MDX as a company-wide challenge and continues to promote initiatives, Suchi is quick to clarify that MDX is just one means of realizing what Murata wants to be for "Vision 2030."Suchi:&nbsp;"'Vision 2030' calls for four management transformations: Management that creates a continuous cycle of social value and economic value, autonomous and decentralized organizational management, change-responsive management based on hypothetical thinking, and DX promotion. MDX is just one means of accomplishing this. The use of digital will be crucial for expanding our three-layer portfolio and four business opportunities (communications, mobility, environment, and wellness), and for accelerating our results cycle. By 2030, we will realize MDX to the point where it has a definite effect, and will also realize a high-cycle organization where people and data are connected."

In this article, executive officer Fumiyuki Suchi explains the Murata's strategy for engaging with DX and transforming a wide range of fields including business models, value chains, and core competencies.

Strategies and challenges for accelerating digital transformation

<section>You've poured your heart and soul into this project. Late nights fueled by coffee and determination have finally paid off. Your new electronic system prototype sits on your desk, a testament to your engineering expertise. It functions flawlessly, exceeding all expectations. Now comes the moment of truth: transitioning your prototype into a full-scale production run.This final hurdle can feel exhilarating, but also nerve-wracking. Unlike the controlled environment of prototyping, production introduces a complex web of factors outside your direct control. Contract manufacturers (CMs), material availability, and unforeseen manufacturing challenges can all conspire to derail your first production build. The result? Delays, wasted resources, and a sinking feeling in the pit of your stomach.This article aims to equip you with the knowledge to navigate these potential pitfalls. By understanding the most common roadblocks and implementing proactive solutions, you can significantly increase your chances of a successful first production run.<h2> </h2><h2>8 Common Roadblocks on the Path to Production Success</h2><h3>Communication Breakdown: The Perils of Information Silos</h3>Effective communication is paramount in the transition from prototype to production. The absence of a centralized information hub can lead to misinterpretations, delays, and increased costs.Digital manufacturing platforms provide a robust solution by consolidating design files, assembly instructions, and other critical documentation. This centralized repository ensures that all stakeholders, from engineers to factory floor technicians, possess identical and up-to-date information. By eliminating the potential for discrepancies caused by disparate communication channels, organizations can significantly reduce errors and streamline the production process.Moreover, digital platforms facilitate real-time collaboration and knowledge sharing. Engineers can provide timely clarifications, and technicians can offer valuable feedback on assembly challenges. This iterative approach fosters continuous improvement and enhances the overall product quality. By investing in a digital manufacturing platform, companies can bridge communication gaps, mitigate risks, and improve operational efficiency.<h3>Subjective Acceptance Criteria: Creating A Foundation for Quality</h3>Precisely defined acceptance criteria are essential for achieving consistent product quality. Vague or subjective standards can lead to inconsistencies between production units, increasing the likelihood of defects and rework.Establishing clear, objective, and measurable criteria for both electrical and mechanical aspects of the assembly process is crucial. For instance, instead of relying on subjective terms like "good solder joints," engineers should specify precise metrics such as solder joint height, fillet shape, and the absence of voids.Look for a CM that can manage your prototypes as well as your production. By working with the contract manufacturer (CM) early on in the prototype phase, it is possible to identify potential failure points that may adversely affect future production runs and develop robust acceptance criteria. Bringing your production CM into your process earlier allows engineers to gain valuable insights into the feasibility of design specifications and make necessary adjustments to ensure manufacturability. This proactive approach reduces the risk of costly rework and delays during production when they can really hurt.<h3>Bill of Materials Bottlenecks: Mitigating Supply Chain Risks</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMTIwOTg1ODk2LTE3MjMxMjA5ODU4OTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="1uniubn849384s" class="fr-fic fr-dii">A rigid BOM can create significant hurdles in the face of component shortages or supply chain disruptions. Consequently, engineers should prioritize component selection based on availability and identify suitable alternatives. Maintaining a flexible BOM allows for rapid adjustments in response to changing market conditions or unforeseen supply chain challenges.Furthermore, accurate lead time estimation is critical for effective production planning. Partnering with a CM that offers BOM kitting and a digital platform offering comprehensive lead time analysis can provide valuable insight into potential supply chain bottlenecks. By proactively addressing these challenges, organizations can minimize production delays and smoothly transition from prototype to full-scale manufacturing.<h3>Tolerance Trap: Navigating Design and Manufacturing Variability</h3>Tolerance accumulation is a common pitfall in product design and manufacturing. Even minor variations in component dimensions can have a significant impact on assembly fit and functionality. To prevent tolerance-related issues, engineers must carefully analyze component tolerances and their cumulative effect on the overall product. Statistical process control (SPC) techniques can be employed to assess the potential impact of manufacturing variability on product performance.Additionally, close collaboration with the CM during the design phase is essential for identifying and mitigating tolerance-related risks. By involving manufacturing experts early in the process, engineers can gain valuable insights into the achievable tolerance levels and make necessary design adjustments for manufacturability. This proactive approach helps prevent costly rework and delays caused by tolerance-related assembly issues.<h3>Quality Assurance Challenges: From Specification to Implementation</h3>A comprehensive quality specification plan is the cornerstone of a successful production run. This document outlines precise quality expectations for both the assembly process and individual components. By clearly defining these requirements, engineers minimize ambiguity and reduce the likelihood of defects. Incorporating visual and x-ray inspection criteria for incoming materials further strengthens the quality assurance process.A well-structured quality plan also includes robust quality control procedures. These procedures should specify inspection points, acceptance criteria, and corrective actions for non-conforming products. By implementing a rigorous quality control system, organizations can identify and address quality issues early in the production process, preventing costly rework and scrap. Moreover, a data-driven approach to quality management enables continuous improvement through process optimization and defect prevention.<h3>Manufacturing Mismatch: Optimizing Contract Manufacturer Selection</h3>Selecting the right contract manufacturer (CM) is critical for production success. A CM that lacks the necessary capabilities or expertise can lead to significant challenges, including production delays, quality issues, and increased costs.As a precaution, engineers should carefully evaluate potential CMs based on their track record, equipment, and experience with similar products. Conducting pilot runs or pre-production builds at the selected CM can provide valuable insights into the manufacturer's capabilities and identify potential issues before full-scale production. Look for a partner with the capacity and willingness to prioritize your needs. This means finding a company with readily available capacity for when business is booming that will also prioritize your smaller orders when necessary.Additionally, establishing clear communication channels and expectations with the CM is vital to a smooth production process. By diligently selecting and managing the CM, organizations can increase the likelihood of a successful production launch.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMTIwOTg1MjAxLTE3MjMxMjA5ODUyMDEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="2iirou8493ijnww" class="fr-fic fr-dii"><h3>Reliance on Tribal Knowledge: Safeguarding Production Continuity</h3>Traditional reliance on the expertise of specific individuals can create vulnerabilities within the manufacturing process. When key personnel are unavailable, the risk of production disruptions increases significantly. Reduce this risk by working with a CM offering a robust, centralized knowledge repository.A digital platform that houses comprehensive design information serves as a single source of truth, ensuring alignment between design inputs and outputs. This platform provides a clear roadmap for all manufacturing personnel, eliminating the potential for deviations from the original design intent. By digitizing and standardizing manufacturing processes, organizations reduce reliance on individual expertise and enhance overall production efficiency.Further, a digital platform facilitates knowledge sharing and collaboration among team members. It enables real-time access to information, enabling rapid problem-solving and decision-making. This collaborative approach fosters a culture of continuous improvement and reduces the risk of knowledge loss due to employee turnover.<h3>Miscommunication Minefield: Effective Communication Strategies</h3>Effective communication is essential for preventing misunderstandings and delays throughout the product development and production process. Engineers should avoid making assumptions about the CM's understanding of design changes or requirements. Instead, they should implement a formal change management process that clearly communicates modifications to the CM.Regular communication and collaboration between the engineering and manufacturing teams are also crucial for ensuring alignment and addressing potential issues proactively. By fostering an open and transparent communication environment, organizations can minimize miscommunication and improve overall project efficiency. Additionally, using clear and concise language in all project documentation helps to reduce ambiguity and prevent misunderstandings.<h2>Partnering for Success: How MacroFab Can Help</h2>By following these best practices and partnering with a reliable CM like MacroFab, you can significantly reduce the risk of production build failure. MacroFab offers a suite of services specifically designed to address the challenges faced by electrical engineers transitioning prototypes to production, including<ul><li>Digital Manufacturing Platform: Streamline communication and make sure everyone is on the same page with MacroFab's digital manufacturing platform. Upload design files, BOMs, and assembly instructions to a secure and centralized location. You can manage team permissions so that each member of your team has access to the information they need.</li><li>DFM Expertise: MacroFab's engineers can analyze your design for manufacturability, identifying potential tolerance issues and suggesting improvements to streamline the production process. This can save you time and money by avoiding costly design revisions later in the development cycle.</li><li>Pre-Vetted North American Manufacturing Network: MacroFab’s manufacturing network offers a wide range of capabilities and ready manufacturing capacity for any job. You can rest assured that your project will be produced on the factory line with the specific expertise necessary to best manufacture it.</li><li>Seamless Communication: MacroFab prides itself on clear and consistent communication throughout the entire manufacturing process. Your named project manager will be your point of contact, ensuring you are kept informed of every step along the way.</li><li>Rapid Prototyping: MacroFab offers rapid prototyping services to help you refine your design and identify potential issues before committing to a full production run. This allows you to iterate quickly and minimize the risk of problems during the first production build.\</li><li>Complete Transparency: MacroFab provides real-time production tracking and detailed cost breakdowns, allowing you to stay in control of your project budget and timeline.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMTIwOTg2MDYzLTE3MjMxMjA5ODYwNjMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="3j9w088493075" class="fr-fic fr-dii">By leveraging MacroFab's comprehensive suite of services and industry expertise, you can navigate the complexities of transitioning your prototype to production with confidence. MacroFab understands the challenges faced by electrical engineers and is committed to providing the tools and support necessary to ensure your project's success.</section><h4>Ready to turn your innovative design into reality?</h4><a href="https://factory.macrofab.com/quick_quote/?utm_source=www.macrofab.com&utm_medium=referral" target="_blank">GET AN INSTANT QUOTE NOW</a>

A digital platform containing comprehensive design information can aid this process, as it acts as a single source of truth, ensuring alignment between design inputs and outputs. 

8 Steps to a Smooth First PCBA Production Run

What is CNC turning? This digital manufacturing technology, different from CNC milling in a few important ways, is used to make rounded or cylindrical parts with a high level of precision.

What is CNC Turning? Process, Advantages, Applications

Titanium, known for its formidable strength and lightweight properties, is one of the most important materials in metal 3D printing. When formulated as an additive manufacturing powder, titanium offers a broad range of capabilities within fields such as aerospace, medical, and automotive.&nbsp;3D printing titanium allows for the creation of complex, bespoke parts that leverage the desirable material properties of titanium — biocompatibility, high strength, and beyond — in previously unworkable geometries. The use of titanium with advanced metal 3D printing technologies like direct metal laser sintering can propel industries toward more innovative, efficient, and sustainable practices.This article looks at the basics of 3D printing titanium, discussing key additive manufacturing technologies, printable titanium alloys, and common applications.<h2 dir="ltr">Why Titanium 3D Printing Offers Huge Potential</h2>Titanium has turned metal 3D printing into a high-value opportunity for manufacturers. Known for its superb strength-to-weight ratio, titanium is a cornerstone in sectors such as <a href="https://www.wevolver.com/article/from-jet-engines-to-satellites-3d-printing-and-aerospace" target="_blank">aerospace</a> and automotive engineering, enabling the creation of components that are not only lighter and stronger but also more durable.[1]Biocompatibility is another standout feature of titanium, making it a preferred material in medical applications.[2] It is used extensively for implants and prosthetic devices that need to interact harmoniously with the human body while offering longevity and resistance to wear in a biological environment. This compatibility is essential for patient safety and the reliability of medical devices.Furthermore, titanium's inherent high corrosion resistance ensures that products last longer even under harsh conditions, such as during exposure to saltwater or corrosive chemicals.[3] This makes it invaluable in industries like marine engineering and chemical processing where material longevity is as crucial as its strength.On a technical level, titanium's mechanical properties include high fatigue resistance and excellent fracture toughness, allowing it to withstand rigorous operational demands. Its thermal stability also stands out, maintaining structural integrity across a wide range of temperatures, which is pivotal in high-temperature applications in aerospace and automotive manufacturing.Recommended reading: <a href="https://www.wevolver.com/article/metal-manufacturing-processes-compared-machining-forging-casting-powder-additive-extrusion" target="_blank">Metal manufacturing processes compared: machining, forging, casting, powder, additive, extrusion</a><h2 dir="ltr">Titanium 3D Printing Processes</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720070163301-3d_printed_tool.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="Titanium parts">Titanium parts can be made with various 3D printing technologiesTitanium 3D printing technology is dominated by two main technologies: direct metal laser sintering (DMLS) — otherwise known as laser powder bed fusion (L-PBF) or Selective Laser Melting (SLM) — and electron beam melting (EBM). The former is more widespread than the latter, with a greater number of 3D printer manufacturers.Other titanium 3D printing technologies include binder jetting, in which titanium is deposited along with an adhesive binder that is then burned away during post-processing, and direct energy deposition (DED).<h3 dir="ltr">Titanium DMLS</h3>DMLS uses a precise, high-power laser to fuse titanium powder into a solid structure. The process begins with a layer of titanium powder spread over the build area. A laser beam then selectively melts the powder by tracing the predefined path of the object’s cross-section, fusing the titanium particles together and to the layer below. This method allows for the creation of highly complex geometries, which are otherwise difficult to achieve with traditional manufacturing techniques. The primary challenge in DMLS is managing the high melting point of titanium alloys, which requires a very powerful laser and careful control of the energy input to avoid defects like warping or residual stresses.Manufacturers of laser-based systems for titanium 3D printing include EOS, Colibrium Additive (formerly GE Additive), and Nikon SLM Solutions (formerly SLM Solutions).<h3 dir="ltr">Titanium EBM</h3>EBM, on the other hand, utilizes a high-energy electron beam under vacuum to melt the titanium powder. This beam scans across a bed of titanium powder, melting and solidifying the material layer by layer according to the digital design. EBM is particularly effective at managing the reactive nature of titanium because the vacuum environment prevents oxidation, which is a common issue when titanium is heated in an air atmosphere. The electron beam can also be adjusted dynamically in terms of focus and power, allowing for precise control over the melting process, which is crucial for maintaining material properties and structural integrity.Manufacturers of EBM systems for 3D printing titanium include Colibrium Additive (formerly GE Additive) and Mitsubishi subsidiary TADA Electric.<h2 dir="ltr">Industries Using Titanium 3D Printing</h2>Titanium 3D printing has been a game-changer in several sectors, driving innovation and efficiency with its unique properties. While virtually all industrial sectors can use titanium 3D printing, three of the most important are aerospace, automotive, and medical.<h3 dir="ltr">Aerospace</h3>In the aerospace and aviation industry, titanium’s strength-to-weight ratio enables the production of complex components that are both lighter and more durable than those made with traditional materials. For instance, leading aerospace manufacturers use titanium 3D printing — often powder bed fusion process — to create parts for jet engines and airframes, resulting in aircraft that are not only more fuel-efficient but also capable of withstanding the extreme stresses of flight.[4]<h3 dir="ltr">Automotive</h3>In the automotive sector, the ability to print metal parts with titanium has led to the development of customized, high-performance vehicle parts. Manufacturers can produce lightweight yet robust printed parts like gears and brackets, which contribute to overall vehicle weight reduction and enhanced performance. This application is crucial in the context of electric vehicles, where efficiency and battery range are significantly improved by reducing the vehicle's weight.<h3 dir="ltr">Medical</h3>The medical industry benefits particularly from the biocompatibility of titanium. 3D printing with titanium allows for the production of tailored implants and prosthetics that fit patients with unprecedented precision. These corrosion-resistant, biocompatible implants are not only stronger and more durable but also integrate better with human tissue, which improves the recovery process and overall outcomes for patients. Titanium surgical instruments and machine components can also be printed.<h2 dir="ltr">Titanium Alloys for 3D Printing</h2>Titanium is a mainstay of metal additive manufacturing because, despite its hugely desirable material properties, it is not especially difficult to print. In fact, it is much better suited to 3D printing than other processes like CNC machining.Material manufacturers make titanium powders tailored for 3D printing. These metal powders are engineered for uniform particle size and shape, improving flowability and packing density in the print bed. This enhancement leads to smoother, more detailed prints and strengthens the mechanical properties by reducing inclusions and porosity.Most titanium 3D printing applications use titanium alloys — metal materials containing titanium alloyed with other elements — instead of pure titanium. The type of titanium alloy used depends on the specific 3D printing application. Some common varieties are shown in the table below.<div dir="ltr" align="center"><table><tbody><tr><td style="width: 16.434%;">Alloy</td><td style="width: 11.3579%;">Grade</td><td style="width: 47.9695%;">Description</td><td>Applications</td></tr><tr><td style="width: 16.434%;">Ti-6Al-4V</td><td style="width: 11.3579%;">5</td><td style="width: 47.9695%;">The most common and important titanium alloy for 3D printing, with excellent strength-to-weight, corrosion resistance, and biocompatibility</td><td>Aerospace components, automotive components, surgical instruments, medical implants</td></tr><tr><td style="width: 16.434%;">Ti-6Al-4V-ELI</td><td style="width: 11.3579%;">23</td><td style="width: 47.9695%;">This purer titanium alloy has an “extra-low interstitial,” making it slightly weaker than Grade 5 but better for biomedical applications</td><td>Surgical instruments, medical implants</td></tr><tr><td style="width: 16.434%;">Ti-6Al-2Sn-4Zr-2Mo</td><td style="width: 11.3579%;"> </td><td style="width: 47.9695%;">A near-alpha titanium alloy with high strength and excellent corrosion resistance</td><td>Aerospace components, aviation components, marine components</td></tr><tr><td style="width: 16.434%;">Ti-5Al-5V-5Mo-3Cr</td><td style="width: 11.3579%;"> </td><td style="width: 47.9695%;">A beta titanium alloy with high strength and toughness that shows promise in 3D printing due to its poor machinability</td><td>Industrial components</td></tr></tbody></table></div><h2 dir="ltr">Technical Challenges</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720070176687-industrial_machine_interior.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="Titanium printing">Titanium printing requires skilled industrial operatorsTitanium 3D printing, highly valued for its exceptional properties like high strength and lightweight, confronts several engineering challenges. One such challenge is the stringent requirement for temperature control. Titanium’s high melting point necessitates precise thermal management during the printing process. Inconsistent temperature can lead to material stress and deformation, which are detrimental in applications requiring high precision such as aerospace components and surgical implants.Ensuring material sintering uniformity is another critical technical hurdle. The quality of titanium prints heavily depends on the uniformity of the sintering process. Variations can introduce weak points that compromise the structural integrity, making the parts unsuitable for high-stress applications. This challenge is particularly pronounced in the production of complex geometries where even minor faults can lead to catastrophic failures.The need for specialized support structures is also a notable challenge. These supports are essential to combat gravity and thermal distortion during printing but removing them without damaging the intricate parts requires meticulous techniques. The precision necessary in this step is crucial for industries like automotive and biomedical, where even minute imperfections can render a part unusable.<h2 dir="ltr">The Cost of 3D Printing Titanium</h2><ul><li dir="ltr">Titanium 3D printer costs: $250,000–$1,000,000</li><li dir="ltr">Titanium powder costs: $300–$600 per kilogram</li><li dir="ltr">Titanium parts from service provider: Approx. 2–3x raw material cost</li></ul>Titanium 3D printing is transformative in high-stakes industries like aerospace and healthcare but comes with substantial initial costs. Industrial-grade DMLS systems, for example, can cost six or seven figures. The production of titanium powder, essential for 3D printing, is costly due to the need for high purity and fine particle consistency, processes that are both energy-intensive and technologically demanding. These costs are further compounded by the environmental impact of titanium extraction and processing, which often involves extensive safety and regulatory compliance.Despite the high initial investment, sectors that demand exceptional material properties find significant long-term value. Aerospace applications, for example, benefit from reduced aircraft weight leading to lower fuel costs and increased range, while medical implants from titanium offer longevity that decreases the need for repeat surgeries, dramatically improving patient care and reducing healthcare costs. Alternatively, using a 3D printing service for one-off parts and prototypes is more feasible and cost-effective for smaller companies, though lead times will naturally be longer than in-houe printing.&nbsp;Operational savings are palpable when considering the longevity and reduced maintenance needs of titanium parts. These benefits, combined with ongoing advancements in 3D printing technology that promise to lower production costs, enhance the economic case for titanium in these critical fields. As efficiencies in titanium powder production improve, we can expect broader adoption in other industries, leveraging titanium’s unique properties more economically.Recommended reading: <a href="https://www.wevolver.com/article/metal-injection-moulding" target="_blank">An Advanced Guide to Metal Injection Molding</a><h2 dir="ltr">Conclusion</h2>Titanium 3D printing stands at the forefront of technological innovation, enhancing industries from aerospace to medicine. The suitability of titanium for powder-based additive processes, coupled with the inherently desirable properties of certain titanium alloys, makes titanium 3D printing a valuable proposition for many sectors. As the technology evolves, ongoing advancements in material science and engineering are expected to lower costs and expand applications, making titanium 3D printing even more accessible and impactful.<h2 dir="ltr">Frequently Asked Questions</h2>What makes titanium ideal for 3D printing in aerospace applications?Titanium's high strength-to-weight ratio allows for the production of lightweight, durable components that reduce overall aircraft weight and enhance fuel efficiency.How does titanium's biocompatibility benefit medical 3D printing?Titanium is non-toxic and not rejected by the body, making it perfect for medical implants that require long-term interaction with human tissue.What are the main challenges in 3D printing with titanium?Key challenges include managing the high melting point of titanium, ensuring uniform material sintering, and the costs associated with specialized printing equipment.Can titanium 3D printing be used for mass production?While currently more suited to bespoke designs and prototypes due to cost and complexity, ongoing advancements are likely to enable more widespread use in mass production.<h2 dir="ltr">References</h2>[1] Boyer RR. <a href="https://link.springer.com/article/10.1007/bf00705316" target="_blank">Titanium for aerospace: rationale and applications</a>. Advanced Performance Materials. 1995 Oct;2:349-68.[2] Baltatu MS, Tugui CA, Perju MC, Benchea M, Spataru MC, Sandu AV, Vizureanu P. <a href="https://www.revistadechimie.ro/pdf/40%20BALTATU%204%2019.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Biocompatible titanium alloys used in medical applications</a>. Rev. Chim. 2019 May 15;70(4):1302-6.[3] Mountford Jr JA. <a href="https://onepetro.org/NACECORR/proceedings-abstract/CORR02/All-CORR02/114526" target="_blank">Titanium-properties, advantages and applications solving the corrosion problems in marine service</a>. InNACE CORROSION 2002 Apr 7 (pp. NACE-02170). NACE.[4] Śliwa RE, Bernaczek J, Budzik G. <a href="https://www.scientific.net/KEM.687.199" target="_blank">The application of direct metal laser sintering (DMLS) of titanium alloy powder in fabricating components of aircraft structures</a>. Key Engineering Materials. 2016 May 21;687:199-205.

In metal additive manufacturing, titanium powders have some of the most high-value applications, from aerospace manufacturing to patient-specific medical implants.

3D Printing Titanium: Best Processes, Alloys, Applications

Discover the latest advancements in PCBA manufacturing and how they are transforming the electronics industry. Learn about foundational concepts, innovative technologies, real-world applications, and challenges in this comprehensive guide.

PCBA Manufacturing: Revolutionizing Modern Electronics Assembly

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