<p id="isPasted">Designing medical parts? Just as there are countless types of medical procedures, there are also countless types of polymers on the market today. Which ones are best for your medical application? Great question. We’ll attempt to provide some guidance in this design tip, but it’s important to start with the following caveat: The term “medical grade” is ambiguous at best. &nbsp;</p><p><a href="https://www.protolabs.com/en-gb/industries/medical/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Medical" target="_blank" rel="noopener noreferrer">Medical device</a> manufacturers must understand and comply with a slew of standards, but for the purposes of this discussion, ISO 10993 takes the lead role. It has nearly two dozen parts, of which four pertain specifically to material selection; of these, ISO 10993-13 is probably the most relevant to polymers.&nbsp;</p><p>Unfortunately, there’s no catalogue or book that lists which polymers meet which standards, or even which polymers are biocompatible. Compounding matters is the sheer number of resins, pellets, powders, and bulk forms like rod and sheet from which to choose, each with multiple manufacturers that may or may not meet the necessary&nbsp;<a href="https://www.protolabs.com/en-gb/resources/design-tips/manufacturing-tool-kit-for-the-medical-industry/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Manufacturing Tool Kit for the Medical Industry" target="_blank" rel="noopener noreferrer">medical device requirements</a>. Where one might provide medical-grade ABS, the other produces ABS suitable for LEGOs and power tool housings. &nbsp;</p><p>Of course, one blog post can’t cover all you need to know about medical grade plastics, so don’t forget you can look at the stats on our <a href="https://www.protolabs.com/en-gb/materials/comparison-guide/?category=plastic&utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-medical-plastics-1224" title="Comparison Guide" data-anchor="?category=plastic" target="_blank" rel="noopener noreferrer">materials comparison page</a>. All that said, here are six essential polymers to keep in mind for your next medical parts project.&nbsp;</p><h3 id="isPasted">Comparing Plastics for Medical Parts&nbsp;</h3><p>Generally, medical device designers and manufacturers should look for polymers that are resistant to corrosion, chemical attack, and high temperatures. These should be non-absorbent and inert, and able to withstand repeated sterilisation cycles in an autoclave. Of course, they shouldn’t react with bodily fluids and human tissue, cause irritation, or create skin sensitivities. Did we mention strength and durability? All of this might seem like a very tall order, but the good news is that a healthy handful of polymers check at least most of these boxes. &nbsp;</p><h5 id="isPasted"><strong>PC</strong>&nbsp;</h5><p>Oftentimes, an optically transparent polymer is needed for medical procedures, and polycarbonate is the material of choice. It checks all the usual boxes in terms of toughness, dimensional stability, heat and chemical resistance, and sterilizability. You won't find it inside the human body, but PC is typically used when it's necessary to see blood, drugs, and other fluids flowing through a device. Many of Protolabs' medical customers will 3D-print their designs from PC-like materials such as Acura 5530 or PerFORM, then go on to machined or injection-moulded polycarbonate as production needs increase. &nbsp;</p><h5 id="isPasted">UHMW-PE&nbsp;</h5><p>Since we’re discussing orthopedic implants, here’s another important polymer to keep in mind: ultra-high molecular weight polyethylene. If you’ve had a knee or hip replacement, chances are good that you have some of this stuff inside you. UHMW-PE is an extremely dense, low-friction member of the polyethylene family. If you’re looking for some machined medical components (or wear-resistant machinery parts), UHMW-PE has excellent impact strength and abrasion resistance, and here again, is eminently biocompatible. And for slightly less demanding applications, “regular” polyethylene (PE) and high-density polyethylene (HDPE) are good, all-around polymers for a wide range of medical applications, especially for single-use products and the PPE gear that’s become so prevalent over the past few years. &nbsp;</p><h5 id="isPasted"><strong>PEI</strong>&nbsp;</h5><p>Like PEEK, polyetherimide borders on super-polymer territory. Better known by its trade name Ultem, PEI is a rigid, semitransparent, and heat-resistant 180°C polymer that is amber in colour and boasts great tensile strength. Because it also has high dielectric characteristics and resistance to flame, it is widely used in electronic components, medical or otherwise. We machine and injection mould PEI into various shapes, with potential uses including handles for surgical instruments, medical device enclosures, insulators, electrical connectors, and more. Lastly, PEI is readily sterilised via autoclaving and gamma radiation. &nbsp;</p><h5 id="isPasted"><strong>PSU</strong>&nbsp;</h5><p>Another amber-coloured polymer is PSU, short for polysulfone. Recognised for its toughness and rigidity at elevated temperatures, PSU is less strong than PEI but more impact resistant. It might be machined or moulded into filter housings, catheter ports, surgical instrument trays, and sizing devices for use during heart valve replacements. Polysulfone is said to be one of the few polymers able to withstand more than 1,000 cycles of steam sterilisation (as can PEEK and PSU’s even more impact- and heat-resistant cousin, polyphenylsulfone, or PPSU).&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519080624-1734519080624.png" class="fr-fic fr-dib" style="width: 806px;"></p><p><em>This medical component from IDEXX Laboratories, Inc. is part of an instrument that veterinarians use to test blood and urine.</em></p><p><em><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519116565-1734519116565.png" style="width: 808px;" class="fr-fic fr-dib"></em><em>Moluded part manufactured with medical-grade liquid silicone rubber.</em></p><h5 id="isPasted"><strong>PEEK</strong>&nbsp;</h5><p>Polyetheretherketone is a great place to start. Long considered an “engineering-grade” thermoplastic, PEEK enjoys broad use in the medical industry. Orthopedic surgeons use it for trauma fixation, spinal implants, and replacement joints, while dentists use it in crowns and bridges. PEEK is both lightweight and strong, is radiopaque (meaning it appears on x-rays), and maintains its strength and dimensional stability at high temperatures. And seeing that PEEK is often inserted into the human body for extended periods of time, it goes without saying that it’s biocompatible and sterilisable. Protolabs routinely CNC machines and plastic injection moulds PEEK into mechanical components such as gears, bearing surfaces, and manifolds, as well as a host of medical parts. &nbsp;&nbsp;</p><h5 id="isPasted"><strong>Silicone</strong>&nbsp;</h5><p>The stuff of weatherproofing adhesive and cooking utensils, silicone is also an excellent choice for many medical components. Silicone is available in various hardness levels, from soft and stretchy like a rubber band or rigid like a tire tread. It withstands temperatures from sub-zero to oven hot 55°C to 210°C, is hydrophobic (repels water), resistant to solvents and acids, and has good vapour permeability, making it a favourite for prosthetic devices. Protolabs 3D-prints a variety of medical components, including seals, gaskets, and surgical models, and injection moulds all manner of prototypes and end-use production parts using liquid silicone rubber (LSR). You can even 3D print in silicone, a great option for prototyping parts using this material for complex parts or prior to moving to injection moulding for production quantities. In addition, there’s also an optical grade of liquid silicone rubber, OSLR, which enjoys superior refractive and light transmission properties compared to its PC or PMMA (acrylic) alternatives. It is therefore popular for use in lenses and lighting applications, or anywhere that a clear, non-yellowing, heat- and chemical-resistant biocompatible polymer is needed. &nbsp;&nbsp;</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519177098-1734519177098.png" class="fr-fic fr-dib"></p><p><em>An operator removes a silicone part from the LSR press. Due to the elasticity of silicone parts, manual removal is necessary.</em></p><h3 id="isPasted">More Options to Consider&nbsp;</h3><p>Those six medical-grade polymers are just the starting point. We’d be remiss if we didn’t mention PTFE, better known as Teflon, a super-lubricious polymer used in everything from catheters and stents to heart-lung machines. Impact and chemical-resistant acrylonitrile butadiene styrene (ABS) is sometimes used to replace metal structural components in medical equipment, as is acetal (you might know it as Delrin), while polyvinyl chloride (PVC) might be considered a flexible version of polycarbonate in certain applications. Polyethylene terephthalate (PET) resists attacks by microorganisms, making it just as suitable for soft drink containers as it is for wearable sensors. Polypropylene (PP)—although considered a commodity plastic—finds widespread use in specimen bottles, prescription containers, and disposable hypodermic syringes (it’s also a great option for parts that would benefit from a living hinge). &nbsp;</p><p>As with any manufacturing application, choosing the best material for a medical device comes down to its physical, chemical, and electrical requirements, not to mention its operating environment. There’s also manufacturability to consider and all the design rules that go along with that. And at the end of the design and prototyping process waits the FDA approval ordeal. It can be a confusing landscape to navigate, which is why we encourage you to upload a file, get a quote, and give us a call to discuss your options. We've helped countless others who were once in your shoes. &nbsp;</p>

Safety and longevity are key to this list of medical-grade plastics.

Plastics for Medical Devices and Applications

<p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://fast.wistia.net/embed/iframe/ia348qtpqn" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>&nbsp;</span></p><p id="isPasted"><a href="https://www.protolabs.com/en-gb/resources/insight/" title="Insight" target="_blank"><strong>Protolabs’<em>&nbsp;Insight</em> video series</strong></a></p><p>Our <em>Insight</em> video series will help you master digital manufacturing.</p><p>Every Friday we’ll post a new video – each one giving you a deeper <em>Insight</em> into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.</p><p>So join us and don’t miss out.</p><h3 id="isPasted">Insight: Optical LSR</h3><p>Transcript</p><p>Hi, it’s Friday, which means it’s time for another Insight video.</p><p>This week I’m going to light up your world with optical liquid silicone rubber – wow.</p><p id="isPasted">But let’s start with some history. When taken as a whole, the history of plastic revolves around finding new ways to replace other materials. Back in the 19<sup>th</sup> century this started with cutting out ivory and tortoiseshell and as our technology has got better and better, we’ve been able to switch even more materials to cheap and tough, reliable plastics.</p><p id="isPasted">One of the latest examples of this lies in liquid silicone rubber – or LSR – which is starting to replace glass in many optical applications, including lens covers and light pipes.</p><p>In many ways, this is a revelation. Glass has seemed like the ideal shell for lightbulbs ever since they were being designed by Edison, and for a very good reason. It is almost perfectly transparent, inexpensive, has a defined manufacturing process, and is more or less impervious to the considerable heat generated by incandescent light elements.</p><p>However, this waste heat – and therefore waste electricity – is the very reason why those incandescent bulbs are dying off. LEDs are a bit more expensive to produce at the moment, but they more than make up for their initial cost with energy efficiency and long life.</p><p>And while glass could be used to enclose, cover, or direct them, optical LSR is a better choice in almost every way. But why is this?</p><p>Well, let’s kick off with the basics.</p><p id="isPasted">Optical LSR is almost as transparent as the best glass, it doesn’t discolour or lose transparency with age or exposure to UV, and it’s significantly lighter than glass. It’s optically and mechanically stable at up to 150 degrees, which is more than enough to cope with any heat put out by LEDs.</p><p>As you can probably guess, all of these are huge benefits.</p><p id="isPasted">On top of that, LSR is far more flexible than glass, which reduces the chance of breakage, but is still decently stiff. This stiffness is particularly valuable in applications like vehicle lenses where lights can be exposed to a variety of vibrations and blows.</p><p>It’s also nicely scratch and crack-resistant, which helps preserve both its physical integrity and optical properties. Don’t get me wrong, you could cut a part made of optical LSR if you went at it with a razor, but if you were to drag it across the ground or other rough surface it would probably conform to the surface as it was dragged and come out the other side in pretty much the same state that it started.</p><p id="isPasted">By the way, this flexibility, it’s decent temperature resistance and UV stability all make it ideal for outdoor applications.</p><p>That’s a lot of good reasons why optical LSR is a good material for your finished design. Let’s take a quick breather while we can, though, because next up I’m going to run through the reasons why it’s also good to work with from a design perspective.</p><p>Are you ready?</p><p>Right, first of all, LSR moulding is an optimised process that uses less manufacturing space and energy than a glass manufacturing facility, which allows for prototype and low-volume production runs.</p><p>Its low viscosity allows easy flow within a mould, which gives the designer much greater freedom when creating fine features. With LSR you can get away with much thinner walls than could normally be produced in other resins.</p><p id="isPasted">Next, it cools without creating significant sink or internal stresses. This dimensional stability allows accurate production of lenses, which is rather important in optical applications.</p><p>The material can also be moulded within a polished mould without the use of secondary polishing processes saving time and money in production.</p><p id="isPasted">The somewhat rubbery consistency of LSR means that shapes with small undercuts and negative draft that would be unacceptable in a more rigid material may be able to be safely unmoulded and treated as bump-offs or pickouts.</p><p>Finally, its flexibility allows you to combine a lens with a seal to reduce assembly cost and inventory control, and to cut out the need for seams in the assembly.</p><p>Okay, that was a lot of information.</p><p>To recap, optical LSR is a thermosetting material that is absolutely ideal for many optical applications. In terms of clarity it’s second only to glass, it can withstand heat in proximity to high-output LEDs and work just fine in a range of ambient temperatures.</p><p id="isPasted">It’s flexible enough for rough duty, outdoor, and automotive use, allows for very flexible design including accurate replication of fine features and can support both thick and thin walls.</p><p>You know, I think that’s probably about enough for today. But we’ll be back next week with another video, so be sure to check back in then.</p>

Optical LSR is a transparent and flexible thermoset material that is increasingly replacing glass in various optical applications. Discover more about it in this Insight video.

What is Optical Liquid Silicone Rubber (LSR) ?

<p id="isPasted">What started out in 1928 as a blacksmith and carriage smithy is now, 94 years later, a modern, customer-focused vehicle manufacturing company in the heart of Switzerland. These days, <a rel="noopener noreferrer" href="https://sutter-fahrzeugbau.ch/" target="_blank">Sutter AG Lungern Fahrzeugbau</a> specializes in the development and manufacture of 3-side tippers of up to 40t, loading bridges for all trucks and vans, box bodies, tipping bodies, quick-change systems, special vehicles, maintenance and repairs of bodies and trailers.</p><p>Before purchasing the Creaform 3D scanner, engineers at Sutter spent about 5% of their working time manually measuring certain components with complex geometries to fit them to vehicles. These are mainly aluminum covers, underride guards, crane mounting elements, and other vehicle mounted components that are tailored to the requirements of the vehicle or the customer’s wishes. Before, these parts used to be manufactured without the possibility of double-checking them prior to the time of final assembly, as it was not possible to check the geometries on the vehicle itself. Apart from the extended amount of time it took to develop the components, the effort and expense required to have them modified and adapted by qualified metal workers for their final place of use was enormous.</p><h2><strong>Requirements for a new measuring system and implementation</strong></h2><p>Sutter often has to deal with large scanning areas, such as truck chassis zones, where the distance between the individual components is important, yet the measurement accuracy must remain high. The crucial requirement in purchasing the measurement system was therefore accuracy.</p><p>One of the key factors in choosing <a href="https://www.creaform3d.com/en">Creaform Go!SCAN SPARK</a> was the ability to purchase not just a product, but a complete service. This included the purchase of consumables for the use of the scanner, a laptop, support for the work on site, after-sales service in case of maintenance, repairs, and questions.</p><p>The implementation of Creaform’s 3D measurement solutions was very intuitive, as it did not require a new process to be defined, only for an existing one to be replaced. In practice, the manual measurement process was simply replaced by 3D scanning. This not only provided the design department with more measurement data, but also allowed them to check the actual dimensions and geometries of vehicle components during development (a double-check).</p><p>Since Sutter AG is a small company, the entire process from 3D scanning to ordering raw materials for manufacturing the components, such as sheet metal, is handled by one of the engineers in the engineering department. A single two-day training session by a Creaform technician made it possible for Sutter to be fully operational and independent right from the start.</p><h2><strong>Truck add-on parts: Teamwork between Creaform Go!SCAN SPARK, engineering department and workshop</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989230571-dji_0032-scaled.jpg" style="width: 100%px;" class="fr-fic fr-dib"></strong></p><p id="isPasted">Sutter AG handles a multitude of diverse projects. As an example, we would like to show how the design, manufacture, and assembly of a customized tool box on an existing truck chassis for the transport of construction machinery was created in cooperation between the workshop and the engineering department.</p><p>Due to current delivery bottlenecks at the vehicle manufacturer, the “construction machine taxi” project was created under tight time constraints. This meant the engineering department had to do a lot of advance preparation using CAD designs. When the vehicle arrived, an advanced design status was achieved very quickly and the workshop itself built some additional attachment holders for tool boxes.</p><p>Another application Sutter has found for the technology is to ensure traceability in the archive in accordance with the ISO9001 standard. It was therefore decided to scan the additional mounting bracket with the <a href="https://www.creaform3d.com/en">Creaform Go!SCAN SPARK.</a></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989245859-sutter_bild1.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Area with additional mounting bracket for toolboxes to be scanned</span></span></span></p><p>Although the additional mounting bracket has a wide variety of surface finishes, colors, and geometries, it took very little time to scan and the amount of material required (targets and matting spray) was very low.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989265416-sutter_bild2.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3D scan of the truck chassis with additional elements mounted by Sutter in the VXmodel software</span></span></span></p><p>With the help of the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" id="isPasted">VXmodel</a> export function, everything could be imported directly into Solidworks and traced very quickly. This was mostly done using the measurement function, the creation of geometry (such as profiles, planes, and cylinders) in VXmodel, and then with the direct transfer of the geometries into Solidworks.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989299882-reverse-engineering.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Reverse engineering in Solidworks</span></span></span></p><p>Where possible, purchased parts were replaced with 3D data from parts suppliers. However, this does not happen as a rule, since missing 3D models are often replaced by mesh bodies from 3D scans. This method of working also increases the quality and completeness of the company’s own database of purchased parts.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989337664-sutter_bild3.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CAD view of the scanned areas with traced toolbox holders and purchased part (hydraulic tank)</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989357772-sutter_bild4.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">CAD view with bridge (main design, manufactured by the engineering department), hydraulic tank (from 3D data from parts supplier), and toolboxes (holders built by the workshop and redesigned through reverse engineering</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989372499-sutter_bild5.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Finished body</span></span></span></p><h2 id="isPasted"><strong>How the Go!SCAN SPARK with VXmodel has improved processes and practices at Sutter AG</strong></h2><p>Apart from the main requirement of accuracy already mentioned before, there have been several improvements at a practical level:</p><ul><li>The space analysis in the planning of bodies, but also of additional units and attachments, has been greatly simplified.</li><li>The accuracy of measurements and the production of raw parts have been increased.</li><li>Quality management has been improved and it is now possible to track completed and similar projects.</li><li>The waste rate of raw parts has been reduced or brought to zero.</li><li>The assembly and adaptation time by the workshop has been reduced, which avoids the need for highly trained employees (the objective is a plug &amp; play strategy).</li></ul><p>In terms of software, the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module">VXmodel software module</a> used by Sutter enables the data to be scanned, processed, and aligned with the correct coordinate system quickly and easily, and finally exported directly to the Solidworks CAD drawing program. The biggest advantage is definitely the possibility to export the raw data directly into the Solidworks format. There, the data can be used for CAD comparisons or as an aid for designing further parts.</p><p>All these factors have led to considerable improvements in internal processes and shared practices in the execution of projects.</p><h2><strong>Future areas of application</strong></h2><p>Sutter’s central idea is to gradually increase the use of the <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d">Creaform 3D scanner</a> in order to spread the technical and practical benefits across all industries and product types.</p><p>Burim Shala, Technical Manager at Sutter comments: “Another step we would like to take as a company is to scan purchased standard components for which there are no 3D models, so that we can plan and design our products with even more detail and precision. We would like to use the 3D scanner mainly for preliminary clarifications so that we can design earlier in the manufacturing process. In a nutshell, I would say that Creaform measurement solutions help us keep the focus on the ‘golden triangle’.”</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733989405049-golden-triangle.png" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Blue triangle. At the top corner is says “Quality,” at the bottom left corner “Time,” at the bottom right corner “Cost.”</span></span></span></p>

The use of the Go!SCAN SPARK and VXmodel leads to significant improvements in the internal processes when carrying out projects at the Swiss company Sutter AG.

Vehicle manufacturing company increases design quality with 3D scanners

<p dir="ltr" id="isPasted">The two day <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven?creative=713450062759&keyword=hexagon%20live%20eindhoven&matchtype=e&network=g&device=c&gad_source=1&gclid=Cj0KCQjw99e4BhDiARIsAISE7P-jq9--x4A0TeKGXvQPXSR46iJ28I8bV7tNL3-yyfjZcLlvv_LBpE4aAsuEEALw_wcB">Hexagon LIVE event</a> at the Brainport Industries Campus in Eindhoven was an unforgettable convergence of technology, engineering, and innovation, showcasing cutting-edge solutions driving the future of manufacturing. This year’s conference, themed around accelerating smarter manufacturing, brought together experts to discuss transformative solutions in digital workflows, sustainability, and precision engineering. The event emphasized how innovation can meet the demands of modern industries, bridging cutting-edge technologies with practical applications across sectors.</p><p dir="ltr">Throughout the event, Wevolver was reporting live on our social media channels from the center of the action on Day 1, which saw an engineering marvel in the form of Max Verstappen’s 2021 championship-winning car, showcased by Oracle Red Bull Racing and the grand opening of Hexagon's brand new 400 square meters Experience Center. We also spoke to Jan Klingen, VP EMEA North of Hexagon's Manufacturing Intelligence Divison about how to reach the younger generation of engineers and Erik Josefsson, CEO of R-evolution, Hexagon's sustainable innovation and green-tech investment subsidiary about how their Green Cubes can accelerate biodiversity and rainforest conservation worldwide.&nbsp;</p><p dir="ltr">If you missed tuning in on the day or you would like to rewatch the interviews, they are now available on-demand in our curated YouTube playlist, offer insights into key discussions, live demonstrations, and interviews with experts. For those who missed the action, don’t miss your chance to catch up on the industry-shaping innovations revealed at Hexagon LIVE!</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/videoseries?si=Lhd341sSJ5qxATtE&amp;list=PLnGQIAOr1q_N-g5DgT-VhKJGS8PLEpEfr&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" title="YouTube video player" 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" style="width: 560px; height: 450px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h2 dir="ltr" id="isPasted">A Decade of Collaboration: How Hexagon’s technologies underpin Red Bull Racing’s success</h2><p dir="ltr">For over a decade, <a href="https://www.redbullracing.com/int-en" target="_blank" rel="noopener noreferrer">Oracle Red Bull Racing</a> has collaborated with Hexagon to revolutionize their engineering processes. Wevolver spoke with Morgan Maia, Senior Technical Partnership Manager at Oracle Red Bull Racing about the partnership and how Hexagon’s technologies underpin Red Bull’s success both on and off the track.</p><h2 dir="ltr">Inauguration of Hexagon’s New Experience Center</h2><p dir="ltr">Day 1 of Hexagon LIVE marked the grand opening of Hexagon’s state-of-the-art Experience Center. This 400-square-meter space is a hub of manufacturing innovation, offering visitors hands-on demonstrations of the latest technologies and direct access to industry experts. As the first of its kind in Europe, the center is designed to inspire and educate, showcasing solutions ranging from digital workflows to cutting-edge automation tools, emphasizing Hexagon’s commitment to shaping the future of manufacturing. Wevolver spoke to Jan Klingen, VP EMEA North of Hexagon's Manufacturing Intelligence Divison and Stephen Chadwick, President of EMEA North of Hexagon's Manufacturing Intelligence Divison about the significance of this grand opening.</p><h2 dir="ltr">A R-evolutionizing Approach to Rainforest Conservation</h2><p dir="ltr" id="isPasted"><a href="https://r-evolution.com/" target="_blank" rel="noopener noreferrer">R-evolution</a>, Hexagon's sustainable innovation and green-tech investment subsidiary had a significant launch of their own with their new initiative of <strong>Green Cubes</strong>, an innovative solution leveraging digital technology for rainforest conservation. These Green Cubes are a cutting-edge platform combining Hexagon's expertise in sensor technology, data analytics, and AI to monitor and protect critical ecosystems in real time. Wevolver spoke to Erik Josefsson, CEO and Stina Langenius, Business Designer how these cubes can contribute to preserving one of the planet's most vital resources.&nbsp;</p>

Wevolver was at the center of action during the Hexagon LIVE in Eindhoven, reporting live on cutting-edge tech and smarter manufacturing solutions, interviewing experts and exploring innovation in digital workflows, sustainability, and precision engineering. Watch the livestream on demand here!

Highlights from Hexagon LIVE 2024: Watch the livestream on demand

<p>Digital light synthesis (DLS) is the signature technology of digital manufacturing company <a rel="noopener noreferrer" href="https://www.carbon3d.com/" target="_blank" id="isPasted">Carbon</a>. It allows for the rapid 3D printing of plastic parts in production-grade materials. DLS technology uses light to set the 3D shape of printed parts, then parts undergo a thermal-curing process that brings them to their final material properties. By combining these processes, Carbon’s additive manufacturing technology is able to blend the speed and design freedom of light-curing 3D printing processes with superior plastic material properties typically not possible with 3D printing.</p><h3 id="isPasted">Designing for Carbon’s 3D Printing Technology</h3><p>Many of the same tactics used to mitigate warping in&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-carbon-3dp-1224" title="Injection Molding" target="_blank" rel="noopener noreferrer">injection moulding</a> apply to 3D printing as well. Maintaining uniform wall thicknesses, adding radii to interior corners, and building support ribs all help with the dimensional stability of Carbon parts and lessen part warpage.</p><p>Carbon’s technology excels at lattice-type geometries, but struggles with large cross sections caused by bulky, thick parts. Avoid thick walls and ideally stay under 2.54mm wall thickness. Try hollowing parts, adding lattices or honeycombs, or adding holes to remove material unnecessary to the functionality of the part.</p><p>Surfaces 45 degrees and steeper from the draw plane typically do not require supports. Marching walls up and over at 45 degrees instead of hard 90-degree angles will typically make a part build more accurately and require less supports. Once again, adding a radius to internal and external corners often mitigates or even removes the need for supports on many parts.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733222222556-image+cw.jpg" style="width: 544px;" class="fr-fic fr-dib"></p><p><em>Build platform (1), UV curable resin (2), dead zone (3), oxygen permeable window (4), projector (5).</em></p><p><em>Along these lines, here are important size and design considerations when using Carbon:</em></p><p><em><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733222328102-1733222328102.png" style="width: 692px;" class="fr-fic fr-dib"></em></p><h3 id="isPasted">Carbon DLS vs. Stereolithography</h3><p>Carbon’s technology is a “vat photopolymerisation” 3D printing process, which places it in the same technology family as <a href="https://www.protolabs.com/en-gb/services/3d-printing/stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-1224&utm_content=wevolver-carbon-3dp-1224" title="Stereolithography" target="_blank" rel="noopener noreferrer">stereolithography (SLA)</a>. Fundamentally, this means it builds parts by curing liquid photopolymers into a solid by selectively exposing them to light. That said, Carbon differs from SLA in a number of ways:</p><ul><li>Carbon emits light via a digital light projection (DLP) chip similar to how a projector casts an image on a screen. This is in contrast to how SLA draws features, which is at a single point of space at a time with a laser. The implications of this are that Carbon can print much faster (just as you can stamp an image faster than you can draw it) but this does come with a trade-off for accuracy and surface finish.</li><li>Carbon technology essentially builds “upside down” in relation to conventional SLA. To facilitate this, Carbon emits the light used for curing through a clear pane at the bottom of the resin vat. Once again, this is a trade-off. Building this way allows Carbon to build faster but it also requires stronger supports.</li><li>There are other systems that print parts “upside down” like Carbon, but Carbon has a unique twist in that the pane the light passes through is also oxygen permeable. This is important because the liquid photopolymer will not cure into a solid if it is saturated with oxygen. Normally systems like this need to physically pull the parts off this pane as they are effectively glued to each layer, but Carbon is able to do so without being so rough on the parts. The oxygen prevents the resin immediately off the glass from curing, allowing the part to raise off without having to physically rip from the pane on every layer. This enhancement not only significantly improves the print speed but also reduces the supports required.</li><li>Historically, vat photopolymerisation materials were not known for their durability nor longevity. Since the technology fundamentally creates parts with light, the materials were naturally light-sensitive. Parts made via SLA are typically sensitive enough to UV light that they may discolour in just a few hours of exposure to sunlight. However, Carbon found a singular solution to this problem. The technology’s unique resins combine aspects of not just photopolymers but also two-part urethanes. This means Carbon parts require a thermal cycle after they are built to reach their final properties, but makes them much more durable.</li><li>Finally, in terms of usage, Carbon parts can be used for both functional prototypes and end-use production parts. Typically SLA parts are cheaper and more accurate for rapid prototyping, but Carbon offers additional material properties that SLA does not. Carbon materials are much more durable, UV resistant, and chemical resistant than SLA materials. If the prototypes see demanding environments, then Carbon may be the best option.</li></ul><h3>Carbon DLS vs. Multi Jet Fusion</h3><p>Both Carbon and&nbsp;Multi Jet Fusion&nbsp;(MJF) are well suited for functional prototypes and low-volume production, so when should you use one or the other? Here are some elements to consider:</p><p><strong>Materials.</strong> The materials offered by the two technologies are quite different. &nbsp;MJF prints parts in nylon 11, 12 and TPU. These nylon materials are both moderately stiff and flexible, and have impressive impact resistance. At Protolabs, we offer four Carbon materials— including rigid polyurethane and flexible polyurethane. The rigid polyurethane is similar to MJF’s material in stiffness, but offers superior flexibility. The flexible polyurethane is less stiff but offers tremendous flexibility and is similar to moulded polypropylene in its material properties.&nbsp;</p><p><strong>Holes, slots, channels.</strong> Though the minimum feature size of both technologies is similar (at about 0.5mm), Carbon is much better at forming “negative spaces” like holes, slots, and channels. This is because of the powder used in MJF, and the media is difficult or impossible to remove from small gaps. If the part design has several holes or complex channels, it is likely a better fit for Carbon.</p><p><strong>Part size.</strong> At Protolabs factory, Carbon can produce larger parts than MJF. If the part is larger than 284 mm x 380 mm x 380 mm it may be necessary to print it via DLS because it may be too large for the MJF platform, alternatively our network may be able to support.</p><h3>Applications for Carbon DLP 3D Printing Technology</h3><p>Carbon is one of the best technologies available for 3D printing plastic parts for low-volume production. Non-bulky parts with moderate-to-high complexity are typically good candidates for this technology. Though critical features can be “dialled-in” for improved tolerances, Carbon has looser tolerances than injection moulding so the candidate parts should not require overly tight tolerances.</p><p>Carbon is frequently used for intricate designs that are challenging to mould and durable 3D-printed components for end-use applications. Some recent high-profile products that Carbon has produced include its work with <a href="https://www.carbon3d.com/resources/case-study/made-with-carbon-dls" target="_blank" rel="noopener noreferrer">Adidas and its AlphaEdge 4D running shoe</a>, <a href="https://www.carbon3d.com/resources/case-study/made-with-carbon-dls" target="_blank" rel="noopener noreferrer">a Riddell football helmet</a>, <a href="https://www.carbon3d.com/resources/case-study/made-with-carbon-dls" target="_blank" rel="noopener noreferrer">and a high-performance bike saddle for cyclists.</a> Carbon parts also are used regularly in medical and dental industries.</p><p><br></p>

Tips on how to design for Carbon’s additive manufacturing technology, and how Carbon stacks up against stereolithography and Multi Jet Fusion 3D printing.

Create Production Parts with Carbon 3D Printing

<p dir="ltr" id="isPasted">Plastic injection molding is the most common production process for simple plastic parts with thin walls. It is fast, cheap, and ideal for mass production. However, an injection molding machine is a complex piece of equipment, and the process is prone to a few specific problems that can lead to part defects.</p><p dir="ltr">Injection molding defects can significantly impact the quality and performance of manufactured products — or render them completely unusable and destined for the scrapheap. This can in turn lead to increased production costs, reduced efficiency, and compromised product reliability. For manufacturers, addressing these issues is key to maintaining quality standards and ensuring customer satisfaction.</p><p dir="ltr">Understanding plastic injection molding defects involves identifying their causes, diagnosing their presence, and implementing preventive measures. This article looks at some of the most common injection molding defects, examining why they occur and how to prevent them.</p><h2 dir="ltr">What Are Injection Molding Defects?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733143119052-yellow_black_plastic_parts.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="parts"><span class="fr-inner">Because they are made quickly and affordably, molded parts can exhibit defects</span></span></span></p><p dir="ltr">Injection molding defects are imperfections or anomalies that occur during the manufacturing process of molded products. These defects can manifest in various forms, such as surface blemishes, structural inconsistencies, or dimensional inaccuracies. They can undermine the functionality, aesthetics, and durability of the finished products, often leading to increased waste and production costs.[1]</p><p dir="ltr">Proactively identifying and mitigating defects can save resources, reduce operational costs, and lead to high-quality parts. By prioritizing defect management, manufacturers can enhance their competitiveness and foster sustainable production practices.</p><h2 dir="ltr">Common Types of Injection Molding Defects</h2><p dir="ltr">Injection molding is a highly efficient manufacturing process, but it is not without its challenges. Defects can arise at various stages of production, affecting the functionality, aesthetics, and overall quality of the final product. Below are some of the most frequent defects encountered in injection molding, along with their causes and implications:</p><h3 dir="ltr">Sink Marks</h3><p dir="ltr">These are shallow depressions or dimples that form on the surface of molded parts, often around thicker sections of material. Sink marks occur when the material inside the part cools and shrinks unevenly, pulling the surface inward. They are commonly caused by insufficient packing pressure, inadequate cooling time, or poor mold design features such as inconsistent ribs.[2]</p><h3 dir="ltr">Warping</h3><p dir="ltr">Warping is the unwanted bending or twisting of molded parts after ejection from the mold. It is primarily caused by uneven cooling rates across the part, leading to residual stresses that distort the shape. Warping can also result from improper material selection, as some polymers are more prone to shrinkage and deformation than others.</p><h3 dir="ltr">Short Shots</h3><p dir="ltr">A short shot happens when the molten material does not completely fill the mold cavity, resulting in incomplete or missing sections of the part. This defect is often caused by inadequate injection pressure or obstructions within the mold. It can also occur if the mold is poorly vented, preventing the material from flowing freely.</p><h3 dir="ltr">Flash</h3><p dir="ltr">Flash is an excess layer of material that seeps out of the mold cavity along the mold parting line or around ejector pins. This defect can occur if the mold is not clamped tightly enough or if the clamping force is uneven. Flash can also result from excessive injection pressure or worn mold components that allow material to escape.</p><h3 dir="ltr">Burn Marks</h3><p dir="ltr">Burn marks are darkened or charred areas on the surface of molded parts, typically caused by trapped air overheating during the injection process. These marks are usually found near sharp corners, flow path ends, or areas where air cannot escape the mold cavity. Factors contributing to burn marks include high injection speeds, insufficient venting, or improper gate design.</p><h3 dir="ltr">Flow Lines</h3><p dir="ltr">Flow lines are visible streaks or patterns on a molded part’s surface, caused by the cooling and solidification of material as it flows through the mold. These defects are often linked to inconsistent injection speeds, material temperature, or poor mold design. Although flow lines are typically cosmetic, they can indicate potential weaknesses in the part.</p><h3 dir="ltr">Delamination</h3><p dir="ltr">Delamination refers to the peeling or separation of surface layers on a molded part, resulting in a flaky or brittle texture. This defect is sometimes caused by contamination of the material, such as moisture or foreign particles. It can also occur if incompatible materials or additives are used together or if the material experiences excessive shear stress during molding.</p><h3 dir="ltr">Jetting</h3><p dir="ltr">Jetting appears as wavy, worm-like lines on the surface of molded parts, caused by irregular material flow of the molten plastic. This defect occurs when molten material is injected too quickly or at an improper angle, leading to turbulence rather than smooth filling. Jetting can also result from incorrect gate design or insufficient mold temperature. Proper flow rate and gate positioning can help mitigate this issue.</p><h3 dir="ltr">Voids</h3><p dir="ltr">Voids are small cavities or air pockets that form inside molded parts, often reducing their structural integrity. They typically occur due to uneven cooling, excessive material shrinkage, or trapped air during the molding process. Poorly designed runners or gates and insufficient holding pressure can exacerbate the issue. Adjusting cooling profiles and improving mold venting can help prevent voids.</p><h3 dir="ltr">Knit Lines</h3><p dir="ltr">Knit lines, also known as weld lines, are visible seams where two flow fronts of molten material meet but fail to fully fuse. This defect is often caused by insufficient material temperature or pressure, long flow paths, or improper gate placement. While sometimes purely cosmetic, knit lines can compromise strength. Enhancing material flow and optimizing mold design can reduce their occurrence.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/the-pros-and-cons-of-3d-printing-low-run-injection-molds" target="_blank"><em>The pros and cons of 3D printing low-run injection molds</em></a></strong></p><h2 dir="ltr">Root Causes of Injection Molding Defects</h2><h3 dir="ltr">Material-Related Causes</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733143131103-colorful_plastic_pellets.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="injection molding materials"><span class="fr-inner">Some injection molding materials are more defect-prone than others</span></span></span></p><p dir="ltr">The type and quality of plastic materials used in injection molding play a role in determining the success of the process. Factors such as moisture content, contamination, and material compatibility can directly influence the occurrence of defects.</p><ul><li dir="ltr"><p dir="ltr"><strong>Moisture Content</strong>: Excess moisture in raw molding materials can lead to defects like voids, bubbles, or delamination in the finished product. Certain plastics, such as polycarbonate and nylon, are hygroscopic and require proper drying before use to prevent moisture-related issues.</p></li><li dir="ltr"><p dir="ltr"><strong>Contamination</strong>: Foreign particles or impurities in the material can cause surface blemishes, inconsistent textures, or reduced structural integrity. For instance, contamination with incompatible polymers or dust can result in brittle or uneven parts.</p></li><li dir="ltr"><p dir="ltr"><strong>Material Selection</strong>: Some materials are simply more prone to certain defects than others. For example, polypropylene may exhibit sinking, fiber-filled plastics may warp, and moisture-filled nylon can sputter and create various defects.</p></li></ul><h3 dir="ltr">Process-Related Causes</h3><p dir="ltr">The parameters used during the injection molding process also greatly affect the quality and consistency of the final product. Variations in temperature, pressure, and injection speed can introduce defects if not carefully controlled.</p><ul><li dir="ltr"><p dir="ltr"><strong>Temperature</strong>: Inconsistent or incorrect material temperatures can lead to issues such as burn marks, short shots, or material degradation. For instance, excessive melt temperature can cause thermal degradation, resulting in discoloration or reduced material strength.</p></li><li dir="ltr"><p dir="ltr"><strong>Pressure</strong>: Insufficient or excessive injection pressure (back pressure and/or holding pressure) can lead to defects. Low pressure may cause short shots or incomplete filling of the mold cavity, while excessive pressure can lead to flash or damage to the mold.</p></li><li dir="ltr"><p dir="ltr"><strong>Injection Speed</strong>: The speed at which material is injected into the mold impacts the flow and cooling dynamics. High injection speeds may trap air within the mold, causing burn marks, while low speeds can lead to flow lines or incomplete filling.</p></li></ul><h3 dir="ltr">Design-Related Causes</h3><p dir="ltr">Product and mold design are important factors in the success of the injection molding process. Poor design choices can lead to a variety of defects, impacting both the structural integrity and aesthetic quality of the molded part.</p><ul><li dir="ltr"><p dir="ltr"><strong>Wall Thickness</strong>: Uneven or excessively thick walls can cause defects such as sink marks, warping, or voids. For example, parts with inconsistent wall thickness may cool unevenly, leading to residual stresses and dimensional inaccuracies.</p></li><li dir="ltr"><p dir="ltr"><strong>Rib Design</strong>: Improper rib placement or dimensions can result in defects like sink marks or weld lines. Ribs that are too thick relative to the surrounding walls can create localized shrinkage, causing surface imperfections and weakened structural areas.</p></li><li dir="ltr"><p dir="ltr"><strong>Gate Location</strong>: The placement of gates in the mold affects the flow of molten material. Poorly positioned gates can lead to defects such as flow lines, air traps, or incomplete filling. Researchers have argued that gate location is one of the most important considerations for minimizing wastage and energy costs and consequently increasing sustainability.[3]</p></li></ul><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/what-are-injection-mold-sprues-runners-and-gates" target="_blank"><em>What are injection mold sprues, runners, and gates?</em></a></strong></p><h2 dir="ltr">Identifying, Diagnosing, and Predicting Defects</h2><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732650534151-mold-and-inserts-large-1920x1080-v2.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="moldflow"><span class="fr-inner">Flow simulation tools like Autodesk Moldflow can prevent defects (image credit:&nbsp;<a href="https://www.autodesk.com/ca-en/products/moldflow/" target="_blank" rel="noopener noreferrer">Autodesk</a>)</span></span></span>Visual Inspection</h3><p dir="ltr">Visual inspection is a fundamental step in identifying defects in molded parts. By systematically examining parts after production, manufacturers can detect and address quality issues early.</p><ul><li dir="ltr"><p dir="ltr"><strong>Examine Surface Quality</strong>: Look for visible imperfections such as sink marks, burn marks, or flash. These defects often indicate problems with material flow, temperature, or mold clamping.</p></li><li dir="ltr"><p dir="ltr"><strong>Check for Dimensional Accuracy</strong>: Measure critical dimensions to detect warping, short shots, or shrinkage. Variances in size can compromise the fit and functionality of the part.</p></li><li dir="ltr"><p dir="ltr"><strong>Inspect Weld and Flow Lines</strong>: Observe areas where material flows meet or change direction. Flow lines may appear as streaks or discolorations, while weld lines can signal weakened structural points.</p></li><li dir="ltr"><p dir="ltr"><strong>Assess Overall Consistency</strong>: Compare parts from the same production run to identify variations. Inconsistent quality across parts can highlight issues with process parameters or mold design.</p></li></ul><h3 dir="ltr">Advanced Diagnostic Tools</h3><p dir="ltr">Advanced diagnostic tools play a crucial role in identifying and analyzing defects in injection molding processes (or predicting them in advance). These technologies provide deeper insights into the root causes of defects, enabling manufacturers to make informed adjustments and improve quality.</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>Tool</strong></p></td><td><p dir="ltr"><strong>Description</strong></p></td><td><p dir="ltr"><strong>Benefits</strong></p></td><td><p dir="ltr"><strong>Limitations</strong></p></td></tr><tr><td><p dir="ltr"><strong>Thermal Imaging</strong></p></td><td><p dir="ltr">Detects temperature variations across the molded part and within the mold during the injection process. Identifies areas prone to uneven cooling (e.g., warping, sink marks).</p></td><td><p dir="ltr">Non-invasive&nbsp;</p><p dir="ltr">Real-time analysis&nbsp;</p><p dir="ltr">Easy identification of thermal inconsistencies</p></td><td><p dir="ltr">Limited detection of internal defects&nbsp;</p><p dir="ltr">Cannot identify material-related issues</p></td></tr><tr><td><p dir="ltr"><strong>X-ray Inspection</strong></p></td><td><p dir="ltr">Examines the internal structure of molded parts, detecting voids, inclusions, or incomplete filling not visible externally.</p></td><td><p dir="ltr">High precision&nbsp;</p><p dir="ltr">Assesses material integrity</p></td><td><p dir="ltr">High cost&nbsp;</p><p dir="ltr">Requires specialized equipment and expertise</p></td></tr><tr><td><p dir="ltr"><strong>Flow Simulation Software</strong></p></td><td><p dir="ltr">Models the flow of molten material within the mold, predicting issues like air traps, weld lines, or improper filling. Optimizes mold design and process parameters.</p></td><td><p dir="ltr">Prevents defects proactively&nbsp;</p><p dir="ltr">Reduces costly trial-and-error processes</p></td><td><p dir="ltr">Requires accurate input data&nbsp;</p><p dir="ltr">Demands significant computational resources</p></td></tr></tbody></table></div><h1 dir="ltr">Material Quality Assurance Checklist</h1><p dir="ltr">Prevention of injection molding defects largely comes down to skilled part design and machine operation. However, choosing the right materials and ensuring their proper handling can also help to prevent injection molding defects. Material properties such as viscosity, thermal stability, and moisture absorption can significantly impact the quality of molded parts.</p><p dir="ltr">Some best practices when obtaining and handling materials for injection molding include:</p><ul style="list-style-type: circle;"><li dir="ltr"><p dir="ltr">Verify material certification and supplier quality standards.</p></li><li dir="ltr"><p dir="ltr">Inspect raw materials for signs of contamination, discoloration, or damage.</p></li><li dir="ltr"><p dir="ltr">Test moisture content before processing and ensure it meets the manufacturer’s specifications.</p></li><li dir="ltr"><p dir="ltr">Conduct small-scale trial runs to confirm material performance under intended processing conditions. Adhering to these practices helps ensure material integrity and minimizes the likelihood of defects during injection molding.</p></li></ul><h1 dir="ltr">Conclusion</h1><p dir="ltr">Effectively managing injection molding defects requires an understanding of their causes and the proactive implementation of preventive measures. Manufacturers can enhance product quality by selecting the appropriate materials, optimizing injection molding processes, and designing molds thoughtfully. These efforts not only minimize production costs but also ensure the reliability and consistency of molded parts.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/3d-printing-vs-injection-molding" target="_blank"><em>3D printing vs injection molding: process, materials, applications</em></a></strong></p><h1 dir="ltr">Frequently Asked Questions (FAQs)</h1><p dir="ltr"><strong>Q: What are the most common injection molding defects?</strong></p><p dir="ltr">A: Common defects in injection molded parts include sink marks, warping, short shots, flash, burn marks, and flow lines. Each arises from different factors such as material properties, processing conditions, or mold design.</p><p dir="ltr"><strong>Q: How does material selection impact defect prevention?</strong></p><p dir="ltr">A: Material properties such as moisture absorption, thermal stability, and viscosity significantly affect defect risks. Selecting materials suited to the application and process conditions is essential for defect prevention.</p><p dir="ltr"><strong>Q: What role does process monitoring play in reducing defects?</strong></p><p dir="ltr">A: Process monitoring helps detect anomalies in real time, ensuring consistent quality. Tracking parameters such as temperature, pressure, and cooling rates allows for early adjustments to avoid defects.</p><p dir="ltr"><strong>Q: Can flow simulation software help prevent defects?</strong></p><p dir="ltr">A: Yes, flow simulation software models the material's behavior within the mold, predicting potential issues like air traps, weld lines, or incomplete filling. This helps optimize mold design and processing parameters.&nbsp;</p><p dir="ltr"><strong>Q: Why is mold design critical to defect prevention?</strong></p><p dir="ltr">A: Mold design determines how material flows, cools, and solidifies. Features like gate placement, wall thickness, and rib design directly impact defect risks and product quality.</p><h1 dir="ltr">References</h1><p dir="ltr">[1] Chen YM, Liu JJ. <a href="https://www.sciencedirect.com/science/article/pii/S0736584599000058" target="_blank">Cost-effective design for injection molding</a>. Robotics and computer-integrated manufacturing. 1999 Feb 1;15(1):1-21.</p><p dir="ltr">[2] Gruber DP, Berger G, Pacher G, Friesenbichler W.<a href="https://www.sciencedirect.com/science/article/abs/pii/S0142941811000717" target="_blank">&nbsp;Novel approach to the measurement of the visual perceptibility of sink marks on injection molding parts</a>. Polymer testing. 2011 Sep 1;30(6):651-6.</p><p dir="ltr">[2] Huszar M, Belblidia F, Davies HM, Arnold C, Bould D, Sienz .<a href="https://www.sciencedirect.com/science/article/pii/S2214993715000093" target="_blank">&nbsp;Sustainable injection moulding: The impact of materials selection and gate location on part warpage and injection pressure</a>. Sustainable Materials and Technologies. 2015 Sep 1;5:1-8.</p>

Injection molding problems like sink marks and flash can be prevented by addressing their most common causes. This article serves as a basic troubleshooting guide.

Injection Molding Defects: Causes, Identification, and Prevention

Joined by Adam Tipper, Managing Director and Co-owner at Next Gen Makers, our host Alex Edwards seeks to explore the experiences faced by apprentices and the best practices companies can deliver to retain young talent and rebuild the engineering workforce.

Manufacturing Apprenticeships: How can we rebuild the workforce?

<p dir="ltr" id="isPasted">Manufacturers operate in a rapidly evolving environment with a unique set of challenges. Global competition drives them to reduce costs while meeting rising quality expectations. There's also a race to achieve faster time-to-market to attract and retain clients. Meanwhile, government and industry bodies around the globe have been enforcing stringent sustainability mandates. To meet these targets, manufacturers work towards reducing greenhouse emissions and adopt circular economy practices.</p><p dir="ltr">On top of this, the pace of technological advancement presents another challenge. Staying competitive requires manufacturers to adopt new technologies, which often comes with high upfront costs and can disrupt established workflows. As teams adjust to new workflow, productivity can temporarily dip, which creates strain.</p><p dir="ltr">To overcome these challenges, manufacturers need data-driven strategies to boost accuracy, productivity, and adaptability. Intergrating digital solutions is the way forward as it helps make informed decisions to streamline processes and stay competitive in an every-changing industry.</p><h3 dir="ltr">The Rise of Smart Manufacturing: A Transformation Underway</h3><p dir="ltr">The fourth industrial revolution, or Industry 4.0, is helping manufacturers integrate digital technologies such as automation, AI, cloud computing, and IoT to create smart factories where machinery, sensors, and software are connected. With real-time data collection and intelligent analytics, companies can detect inefficiencies and make informed decisions to optimize processes.</p><p dir="ltr">As a leader in this space, Hexagon offers integrated manufacturing intelligence that spans from design to the final product. By providing tools for design, simulation, and quality management, Hexagon enables manufacturers to adopt processes that drive precision, sustainability, and adaptability.</p><table style="width: 100%;"><tbody><tr><td style="width: 100%; vertical-align: top;"><h2 dir="ltr" id="isPasted">Hexagon Live in Eindhoven: Insights, Innovation, and Networking</h2><p dir="ltr" id="isPasted">On November 27th and 28th Hexagon presents participants the chance to engage first-hand with their manufacturing solutions at Hexagon Live. The event also provides an opportunity to build connections with like-minded professionals, opening doors for future collaborations and growth opportunities.By interacting with thought leaders, visitors can gain valuable knowledge that can help them tackle challenges in their businesses.</p><ul id="isPasted"><li dir="ltr" style="font-weight: bold;"><p dir="ltr"><strong>27 November – Strategic Insights – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></strong></p></li><li dir="ltr" style="font-weight: bold;"><p dir="ltr"><strong>28 November – Technology Deep-Dive – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></strong></p></li></ul></td></tr></tbody></table><h2 dir="ltr">The Need for Advanced Digital Manufacturing Technologies</h2><h3 dir="ltr">Addressing Industry Challenges</h3><p dir="ltr">Manufacturers face a range of challenges that impact every stage of the production cycle. One of the most pressing is supply chain instability, caused by factors such as natural disasters, trade restrictions, and pandemics. These disruptions can delay production in today's globally distributed supply chains.</p><p dir="ltr">Energy and resource efficiency have become critical priorities due to fluctuating energy prices fueled by current geopolitical tensions. High energy costs increase production expenses, trimming already slim margins.</p><p dir="ltr">Equipment downtime poses another key efficiency roadblock. Not only does it require costly repairs but also ends up wasting valuable man-hours. The rising demand for customized products adds to these challenges. Manufacturers are now required to frequently perform time-consuming reconfiguration tasks to accommodate a wider variety of designs.</p><h3 dir="ltr">Solving Challenges with Digital Innovation</h3><p dir="ltr">Digital solutions are addressing core challenges in energy efficiency, downtime reduction, and product customization. While implementing these technologies requires an initial investment, they provide long-term benefits.</p><p dir="ltr">To manage high energy costs, manufacturers are adopting IoT-based energy monitoring and automation systems. These systems utilize sensors and smart controls to optimize energy consumption in real time. For instance, occupancy sensors can detect activity in different areas, adjusting lighting and HVAC systems to minimize energy waste.</p><p dir="ltr">Predictive maintenance has proven effective in minimizing unplanned equipment downtime. The system leverages historical data analysis, real-time machine health monitoring, and machine learning. When an anomaly or potential failure pattern is identified, the system alerts engineers to perform maintenance before a breakdown occurs.</p><p dir="ltr">In response to increasing demand for customized products, manufacturers are turning to digital twins. By creating virtual replicas of production systems, engineers can simulate and test custom designs before production begins, accelerating the design-to-manufacturing cycle. Additionally, companies are deploying flexible manufacturing systems (FMS), which feature modular workstations that can be retooled quickly. This flexibility allows manufacturers to easily switch between different product designs without requiring extensive modifications to the factory setup.</p><h2 dir="ltr">Driving the Manufacturing Intelligence Transformation</h2><p dir="ltr">Hexagon’s intelligence solutions integrate into the manufacturing ecosystem by seamlessly connecting tools, technologies, and data throughout entire production cycles. At the heart of this integration is the use of advanced tools such as digital twins, automation systems, and simulations. This integration allows data collection from each stage of the process allowing teams to monitor progress more effectively.</p><p dir="ltr">Metrology tools help companies ensure that components and products meet exact specifications, maintaining precision throughout production. This minimizes extensive rework and material waste caused by incorrect tolerances. Hexagon enhances this process by providing in-process measurement systems that monitor and measure parts directly on the production line.</p><p dir="ltr">Hexagon's innovative solutions enable real-time collaboration between design and production teams. Through digital simulation, manufacturers can optimize designs before production begins. The ability to check components digitally reduces development time, minimizes material waste, and enhances safety in industries like automotive and electronics.</p><p dir="ltr">The company combines automation technologies with its cutting-edge software to optimize manufacturing workflows. By integrating real-time data, it enhances process efficiency and improves operational outcomes.</p><p dir="ltr">Its predictive maintenance solutions identify potential issues so that engineers can address problems before they cause costly breakdowns. Such practices ensure smooth operations and extend the lifespan of equipment. Hexagon’s IoT-enabled energy monitoring tools further support sustainability efforts. These tools help companies pinpoint inefficiencies, reduce waste, and optimize resource usage.</p><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5Njg0NzkxLUhleGFnb25NSVJRMjAxOFBvZDgwMHg0MjhEZXNpZ25FbmdpbmVlcmluZ0ljb24oMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Through digital simulation, manufacturers can optimize designs before production begins. Source:&nbsp;<a href="https://hexagon.com/company/divisions/manufacturing-intelligence/what-we-do/design-engineering" target="_blank" rel="noopener noreferrer">Hexagon</a>.</span></span></span></h3><h3 dir="ltr">Support and Success</h3><p dir="ltr">Hexagon supports some of the world’s leading organizations in various industries. For example, the iconic Red Bull Racing Formula 1 team relies on Hexagon’s metrology equipment and scanners to ensure the precision needed to build their cutting-edge car.</p><p dir="ltr">Volkswagen Group’s ŠKODA AUTO also uses Hexagon’s automated measurement systems across its manufacturing facilities to enhance production accuracy and capacity.</p><p dir="ltr">Additionally, CERN, the organization dedicated to uncovering the mysteries of the universe, trusts Hexagon’s solutions to monitor its entire technical infrastructure, ensuring seamless operations for groundbreaking research.</p><p dir="ltr">For more success stories, <a href="https://hexagon.com/resources/customer-success-stories">click here</a>.</p><h2 dir="ltr">What to Expect at Hexagon Live in Eindhoven: Insights, Innovation, and Networking</h2><h3 dir="ltr">Gain Exclusive Knowledge from Manufacturing Experts &amp; Network with Industry Innovators</h3><p dir="ltr">On November 27th and 28th Hexagon presents participants the chance to engage first-hand with their manufacturing solutions at Hexagon Live. The event also provides an opportunity to build connections with like-minded professionals, opening doors for future collaborations and growth opportunities.By interacting with thought leaders, visitors can gain valuable knowledge that can help them tackle challenges in their businesses.</p><h3 dir="ltr">Content Tailored to Your Needs: Innovation and Problem-Solving</h3><p dir="ltr">The event offers a range of sessions designed to tackle real-world challenges within the manufacturing sector.</p><p dir="ltr">Hear from companies that have successfully navigated manufacturing challenges with the help of digital innovations. These case studies highlight what's possible and serve as a framework for your strategic planning.</p><h3 dir="ltr">Hands-On Exploration of Digital Reality Solutions</h3><p dir="ltr">The event offers a chance to experience how Hexagon's digital reality tools improve operational efficiency. Visitors get an understanding of how to leverage real-time data, machine learning, and automated workflows to optimize every stage of their operations, from design to delivery.</p><h2 dir="ltr">Explore the Manufacturing of Tomorrow at The Experience Center</h2><p dir="ltr">Hexagon's new Experience Centre in Eindhoven brings the future of manufacturing to life, offering visitors a chance to see how cutting-edge technologies are reshaping the industry. Being one of the first of its kind in Europe, the center promises an immersive experience where you can explore&nbsp;emerging trends, solutions, and new products first-hand.&nbsp;From reimagining production lines to real-time energy monitoring, the center showcases how facilities are evolving to meet the demands of next-generation aircraft and electric vehicles.</p><blockquote><p dir="ltr">“It’s about creating a memorable “wow” factor, leaving visitors inspired by a company offering robust solutions to today’s challenges and a visionary partnership for the future. Experience Centres have the potential to be game-changers.”</p></blockquote><p dir="ltr"><em>Marcel Brand, Senior Director Global Events &amp; Experience Centres<br>Hexagon, Manufacturing Intelligence division</em></p><p dir="ltr">In addition to theory, attendees can get hands-on with the PRESTO system and discover how automation is transforming quality control by improving precision and drastically reducing inspection times.</p><p dir="ltr">Explore the HxGN Machine Trainer, a digital twin simulator used by industry leaders like Safran to train CAM programmers and machine tool operators quickly and safely. Visitors can also experience CMM machines and 3D scanners up close, gaining insights into the latest technologies driving innovation in aerospace, automotive, and electronics manufacturing.</p><h2 dir="ltr">Hexagon Live Day 1: 27 November – Strategic Insights</h2><h2 dir="ltr"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" class="link"></a></h2><h3 dir="ltr" id="isPasted">Practical Innovation Workshops</h3><p dir="ltr">The workshops at the event are designed to address challenges in managing complex semiconductor supply chains. Experts will help attendees understand how to streamline operations to manage global disruptions and enhance supply chain resilience to ensure material availability.</p><p dir="ltr">Visitors can discover how to utilize data and automation to optimize processes in the energy industry. From increasing efficiency to reducing waste, these strategies can improve operations at every level.</p><p dir="ltr">The event touches also upon the latest technologies in energy production and distribution, with a focus on how AI and machine learning are helping in energy forecasting and demand management. You'll learn practical approaches for integrating renewable energy sources into existing infrastructure.</p><p dir="ltr" id="isPasted"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" class="button-main-action">Register Now</a></p><h3 dir="ltr">Insightful panel discussions</h3><p dir="ltr">The company will also host panel discussions featuring industry leaders and experts who will share their perspectives on industry advancements.</p><p dir="ltr">These discussions will explore how technologies digital twins and simulation are accelerating design and product development cycles in both aerospace and automotive manufacturing.</p><h3 dir="ltr">An F1 Engineering Marvel Up Close&nbsp;</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5ODc0ODg0LU9yYWNsZS1SZWQtQnVsbC1SYWNpbmctY2FzZXN0dWR5LWJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The Hexagon Live event will also feature a keynote session from the Oracle Red Bull giving insight into how they leverage Hexagon's technology for success. Source:&nbsp;<a href="https://hexagon.com/resources/resource-library/hexagon-measurement-keeps-productivity-track" target="_blank" rel="noopener noreferrer">Hexagon</a>.</span></span></span></p><p dir="ltr">Who better to offer insights on staying ahead of the competition than Oracle Red Bull Racing? This legendary team has secured 6 Constructors' Championships and 7 Drivers' Championships.</p><p dir="ltr">Competing against the best in the world leaves Red Bull Racing with no margin for error. Don’t miss Red Bull’s keynote to learn how Hexagon helps the team achieve unparalleled accuracy, efficiency, and speed in a sport where just one-tenth of a second can make all the difference.</p><h2 dir="ltr">Hexagon Live Day 2: 28 November – Technology Deep-Dive</h2><h3 dir="ltr">In-Depth Exploration of Technical Breakthroughs</h3><p dir="ltr">On the second day of the event, attendees will get to discover the latest metrology solutions, including in-process measurement that integrates metrology directly into the production phase. The session will also cover the impact of these innovations on quality control processes.</p><p dir="ltr">Next, visitors can explore finite element analysis (FEA) simulation techniques, which utilize digital models to simulate how objects behave under forces to predict real-world results. It will be followed by a deep dive into advanced design, feasibility, and cost optimization for sheet metal components.</p><p dir="ltr"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" id="isPasted" class="button-main-action">Register Now</a></p><h3 dir="ltr">Gain Innovative Perspectives</h3><p dir="ltr">The event will highlight how non-contact reality capture offers real-world analysis with precise 3D representations of environments. Attendees will learn how this technology enables engineers, builders, and forensic teams to ensure no critical details are overlooked. With edge computing, they can validate data accuracy directly on-site, streamlining the process and improving outcomes.</p><h2 dir="ltr">Ready to Be a Part of the Future? Register Now for Hexagon Live!</h2><p dir="ltr">Hexagon Live offers a unique opportunity to explore the latest in manufacturing innovation and gain valuable insights to stay ahead in this ever-changing industry.</p><p dir="ltr">Discover advanced solutions like automation and digital twins, designed to boost efficiency and improve quality. Attend discussion panels and workshops to connect with leading professionals and gather expert knowledge.</p><p dir="ltr">Best of all, general admission is completely free. What are you waiting for? Use the following links to reserve your spot today!</p><ul><li dir="ltr"><p dir="ltr">27 November – Strategic Insights – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></p></li><li dir="ltr"><p dir="ltr">28 November – Technology Deep-Dive – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></p></li></ul><p dir="ltr"><strong>Unable to attend? Wevolver will be livestreaming the event on our&nbsp;</strong><a href="https://www.linkedin.com/company/wevolver/"><strong>Linkedin</strong></a><strong>&nbsp;and </strong><a href="https://x.com/WevolverApp?ref_src=twsrc%5Egoogle%7Ctwcamp%5Eserp%7Ctwgr%5Eauthor" target="_blank" rel="noopener noreferrer"><strong>Twitter</strong></a><strong> page on November 27th.&nbsp;</strong><a href="https://www.linkedin.com/company/wevolver/mycompany/#:~:text=Message-,Following,-Home" target="_blank" rel="noopener noreferrer"><strong>Follow us</strong></a><strong>&nbsp;to get a notification on the day so you don't miss a moment!</strong></p>

Learn how manufacturers are leveraging IoT, AI, and automation to tackle global competition, meet sustainability goals, and enhance customization at Hexagon Live on November 27th-28th.

Step into the Center of Future Manufacturing: Experience Intelligent Manufacturing Solutions at Hexagon Live

<p>From November 12 to 15, Munich became the epicenter of the global electronics industry as <strong>Electronica 2024</strong> brought together 3,480 exhibitors and nearly 80,000 visitors from across the world. Renowned as the industry’s leading trade fair, this year’s event was more international than ever, offering a glimpse into how digital technologies are shaping the path to a carbon-neutral future. Spanning 18 exhibition halls, the event highlighted groundbreaking advancements in <strong>artificial intelligence (AI)</strong>, <strong>sustainability</strong>, and the <strong>future of mobility</strong>, alongside the critical need to foster young talent in electronics.</p><h2>Key Topics Shaping the Electronics Landscape</h2><h3><strong>Sustainability: Electronics Driving the Green Revolution</strong></h3><p>At the heart of this year’s event was the drive to achieve carbon neutrality, with many exhibitors showcasing how electronics play a crucial role in environmental sustainability. From energy-efficient semiconductor solutions to IoT technologies that enable smarter energy management, it was clear that the industry is stepping up to address climate challenges.</p><p>Sustainability discussions centered on:</p><ul><li><strong>Smart Grids and Renewable Energy:</strong> Innovations in optimizing energy systems for greater efficiency.</li><li><strong>Circular Economy:</strong> Efforts to design electronics for recyclability and longevity.</li><li><strong>Green Electronics Manufacturing:</strong> Reducing the environmental footprint of production processes.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732193109394-electronica-infineon.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Smart and sustainable mobility was one of the main topics at this year's Electronica.</span></span></span></p><h3><strong>Artificial Intelligence: Powering the Industry</strong></h3><p>AI continued to dominate conversations, underscoring its influence across sectors. At Electronica 2024, AI’s transformative power was evident in:</p><ul><li><strong>Smart Manufacturing:</strong> Machine learning-driven solutions to optimize production lines and reduce waste.</li><li><strong>AI-powered Sensors:</strong> New sensor technologies with AI integration for predictive analytics in industrial and healthcare applications.</li><li><strong>Autonomous Mobility:</strong> The role of AI in enhancing vehicle safety and energy efficiency.</li></ul><h3><strong>Future of Mobility: Shifting Gears with Electronics</strong></h3><p>The push toward sustainable transportation took center stage, with electronics enabling electric vehicles (EVs), autonomous systems, and advanced battery technologies. Key themes included:</p><ul><li><strong>Electrification:</strong> Efficient power management and battery advancements for EVs.</li><li><strong>Connectivity:</strong> V2X (vehicle-to-everything) communication for smarter traffic ecosystems.</li><li><strong>Safety Systems:</strong> Innovations in sensor fusion and AI-enhanced driver-assistance technologies.</li></ul><h3><strong>Fostering Talent: Investing in the Future</strong></h3><p>With the global electronics industry facing a talent shortage, Electronica 2024 placed special emphasis on nurturing the next generation of engineers and innovators. Events, workshops, and mentorship programs were tailored to inspire students and young professionals to take up roles in this rapidly evolving field.</p><h2>Exhibitor Highlights: Innovations to Watch</h2><h3><strong>Infineon Technologies: AI and Sustainability at the Core</strong></h3><p><a href="https://www.infineon.com/cms/en/product/promopages/electronica/" target="_blank" rel="noopener noreferrer">Infineon</a> stole the spotlight with its dual focus on <strong>sustainability and digitalization</strong>. Showcasing AI-enabled semiconductor solutions, the company emphasized its commitment to green energy and smart mobility. Their technologies are pivotal in advancing applications such as solar energy systems, electric drives, and secure IoT solutions.</p><h3><strong>Altium: Transforming Electronics Design</strong></h3><p><a href="https://www.messe.tv/en/2024/electronica/altium-life-cycle-electronics-development" target="_blank" rel="noopener noreferrer">Altium</a>, a multinational software company specializing in electronic design automation, unveiled a trifecta of solutions—<strong>Altium</strong> <strong>Discover</strong>, <strong id="isPasted">Altium&nbsp;</strong><strong>Develop</strong>, and <strong id="isPasted">Altium</strong> <strong>Lifecycle</strong>—aimed at streamlining the electronics design process. From conceptualization to product lifecycle management, these tools empower engineers to innovate faster and with greater efficiency.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732192928529-novelties_altium_booth_electronica_2024_fair_munich-large.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Altium presented their three new solutions for solutions for the entire electronics development life cycle: Discover, Develop and Lifecycle. Source:&nbsp;<a href="https://www.messe.tv/en/2024/electronica/altium-life-cycle-electronics-development" target="_blank" rel="noopener noreferrer">Altium</a></span></span></span></p><h3><strong>Nordic Semiconductor: The New Standard in Bluetooth LE</strong></h3><p>Nordic Semiconductor introduced the <a href="https://www.nordicsemi.com/Nordic-news/2023/10/Nordic-announces-nRF54L-Series-expanding-industrys-most-efficient-Bluetooth-LE-portfolio" target="_blank" rel="noopener noreferrer"><strong>nRF54L Series</strong>,</a> expanding the world’s most energy-efficient Bluetooth Low Energy (LE) portfolio. With a focus on ultra-low power consumption, this series is ideal for applications like wearables, medical devices, and IoT solutions, pushing the boundaries of connectivity.</p><h3><strong>Analog Devices: Agile Manufacturing Robotics</strong></h3><p><a href="https://www.analog.com/en/lp/001/electronica.html" target="_blank" rel="noopener noreferrer">Analog Devices</a> showcased robotics innovations for agile manufacturing, demonstrating how precision sensors and edge computing can revolutionize production lines. Their solutions highlighted the growing importance of flexibility and efficiency in Industry 4.0 environments.</p><h3><strong>Ignion: IoT Innovation</strong></h3><p>Ignion focused on smart antenna solutions designed to improve IoT device performance, showcasing their new <a href="https://ignion.io/landing-page/discover-omnia-mxtend/" target="_blank" rel="noopener noreferrer">OMNIA mXTEND™</a>, a one-of-a-kind three-port Virtual Antenna® component designed to simplify RF connectivity for IoT applications.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732194027984-ignion-omnia-mxtend-antenna.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Ignion unveiled their new OMNIA mXTEND™ Virtual Antenna.&nbsp;</span></span></span></p><h2>From Carbon Goals to Connectivity: Electronica’s Blueprint for the Future</h2><p>Electronica 2024 left attendees with a clear message: the future of electronics is deeply intertwined with global efforts to create a sustainable, connected, and intelligent world. Innovations showcased at the event demonstrated the industry’s resilience and ability to address pressing challenges, from climate change to supply chain disruptions.</p><p>As we look ahead, several trends stand out:</p><ol><li><strong>AI as the Catalyst:</strong> Expect deeper integration of AI across all electronics applications, driving efficiency and unlocking new capabilities.</li><li><strong>Sustainability as a Mandate:</strong> Green manufacturing and circular design will become non-negotiable for businesses aiming to stay competitive.</li><li><strong>Talent Development:</strong> The need for a robust talent pipeline will see continued investment in education and mentorship.</li></ol><p>For engineers, technologists, and industry stakeholders, Electronica 2024 served as both a showcase of current advancements and a roadmap for the exciting developments yet to come. As the industry evolves, platforms like Electronica will remain indispensable for fostering collaboration, innovation, and progress.</p>

Over 80,000 visitors and 3,400 exhibitors attended this year's Electronica in Munich. Image source: Electronica.

From AI-powered manufacturing to sustainable mobility solutions, Electronica 2024 revealed how electronics are paving the way to a carbon-neutral world. This year’s record-breaking event featured game-changing technologies and fostered collaboration across the global industry.

Electronica 2024: Key Insights and Innovations Driving the Electronics Industry Forward

<p dir="ltr" id="isPasted"><a href="https://protect.checkpoint.com/v2/___https://www.mdpi.com/2071-1050/15/23/16206___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OjJjZmQ6MmJmOGFlZWYwNjYyNjI0OWU4ZTc0YTg5MTJjYjQ0ZjdhN2NiYjIzYzIwMTZmNTVhNGExMGY1MzhmY2IxMDFlZTpwOlQ6Tg">The aerospace industry is a highly regulated and precision-driven industry</a>, where operational excellence is not simply a goal, but rather a top priority. Aerospace manufacturers are under constant pressure to meet the highest quality standards while at the same time optimizing production efficiency and managing complex supply chains. One of the key challenges in this sector is the management of non-conformances (NCs), which can lead to costly delays, safety risks, and decreased customer satisfaction.</p><p dir="ltr">Non-conformance refers to any deviation from specified design, material, or process requirements during manufacturing. In aerospace, even minor deviations can have far-reaching consequences due to the critical nature of components and systems. The most common sources of non-conformance include:</p><ul><li dir="ltr"><p dir="ltr"><strong>Material Defects</strong>: Impurities or inconsistencies in materials that compromise structural integrity.</p></li><li dir="ltr"><p dir="ltr"><strong>Design Discrepancies:</strong> Errors or misinterpretations in design specifications.</p></li><li dir="ltr"><p dir="ltr"><strong>Process Failures:</strong> Incorrect manufacturing processes or assembly techniques.</p></li><li dir="ltr"><p dir="ltr"><strong>Human Error:</strong> Mistakes during production or quality control.</p></li></ul><p dir="ltr">These issues can cause delays, increase costs, and compromise safety. These are the reasons why reducing non-conformance is essential for maintaining operational excellence. Nowadays, aerospace companies can implement novel and robust production support systems based on <a href="https://protect.checkpoint.com/v2/___https://www.ijraset.com/research-paper/digitization-of-non-conformance-workflows-and-processes-in-aerospace-product___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OmRjNmE6NDc3NjZlNjhlZWNjYmYxNzg2MTVhNjczYzgxNzFmMDc0MWZjZDhmYTE3MzliNzJjODYyODcwNzQ5NmQ5NmU4OTpwOlQ6Tg">digital thread technologies</a> in order to significantly reduce non-conformance rates, streamline operations, and achieve higher levels of performance.</p><h2 dir="ltr"><strong>Leading the Way in Digital Thread and Production Support</strong></h2><p dir="ltr" id="isPasted">One of best ways to explore how aerospace manufacturers can leverage digital thread technologies to address these challenges is through a practical approach based on real life case studies. <a href="https://protect.checkpoint.com/v2/___https://www.quest-global.com/___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OmM2MWU6ZjRjZDNkY2QwNjQ2M2ZkNDJhNzlhNzJlZTg5YWMzYTNlMTRiMmFhOGJlOGFhYmMwODJjYTE4MmI5MDgzYTMyODpwOlQ6Tg">Quest Global</a>, a global leader in aerospace production engineering and manufacturing solutions, employs some of the most prominent strategies for reducing non-conformance in the scope of real-life case studies.&nbsp;</p><p dir="ltr">These solutions rely on a communication framework that integrates data across the entire lifecycle of a product. This approach ensures real-time tracking of parts and processes, which enables manufacturers to quickly identify and resolve non-conformances before they escalate into larger problems.</p><p dir="ltr">Quest Global’s approach combines production support with digital thread technologies to optimize flow line operations. The company deploys dedicated cross-functional teams to manage the overall operations and flowlines . In this way, Quest Global ensures that all aspects of production are effectively managed. Thanks to the digital thread approach, the company provides enhanced real-time visibility into key performance indicators (KPIs) while at the same time enabling faster decision-making and improved traceability across the supply chain.</p><h2 dir="ltr"><strong>Real-World Applications: Improving Non-Conformance through Production Support and Flow-Line Efficiency</strong></h2><p dir="ltr">Quest Global has recently implemented a novel production support and flow line efficiency solution for a leading aerospace manufacturer. The manufacturer was struggling with high non-conformance rates due to inconsistent production processes and a lack of real-time data visibility. These issues led to delays in production schedules and increased significantly the costs associated with rework and scrap. Moreover, the aerospace company needed on-the-ground support to manage both internal and external supply chains. This required close collaboration with suppliers and internal teams to ensure smooth operations and timely delivery of components. Also, the customer needed to consult with engineering specialists within their organization to address complex technical issues as they arose.</p><h3 dir="ltr"><strong>Solution Overview</strong></h3><p dir="ltr">To address these challenges, Quest Global deployed a dedicated multi-disciplinary team responsible for managing the entire flow line. This included creating data visualization dashboards, which allowed real-time tracking of key performance indicators (KPIs). The solution enabled the identification of bottlenecks and conducted root cause analysis, which led to significant reductions to non-conformance rates and to tangible improvements to the overall production efficiency.&nbsp;</p><h3 dir="ltr"><strong>Production Support and Flow Line Efficiency</strong></h3><p dir="ltr">The solution consists of a production support and a flow line efficiency part. The production support system provided real-time insights into production processes. This helped the manufacturer to gain better control over their operations towards quicker identification of non-conformances and more informed decision-making.</p><p dir="ltr">The flow line efficiency part optimized the customer’s flow lines by introducing data visualization tools. This allowed for better workflow management, reduced bottlenecks, and smoother production processes.&nbsp;</p><p dir="ltr">Based on the deployment and use of digital threads, the flow line efficiency solution managed to improve data accuracy and to minimize manual errors. This reduced non-conformances and enabled more consistent quality control across the production line. A digital control tower was also established to provide real-time monitoring of production lines. This allowed for immediate corrective actions when deviations were detected, which made the production process more agile and responsive.&nbsp;</p><p dir="ltr">Overall, the digitally enabled flow line efficiency solution led to faster production cycles, reduced waste, enhanced quality control measures, and overall operational improvements. Specifically, the Quest Global’s intervention led to tangible improvements of various KPIs:</p><ul><li dir="ltr"><p dir="ltr">Non-conformance rates&nbsp;were reduced by approximately<strong>&nbsp;30% on key products.</strong></p></li><li dir="ltr"><p dir="ltr">Work-in-progress (WIP) was <strong>reduced by 25%,</strong> while backlogs reduced by 65%.</p></li><li dir="ltr"><p dir="ltr">Total Resolution time (TRT) for NC origination improved dramatically, being processed <strong>within one day.</strong></p></li></ul><p dir="ltr">The solution also enabled ongoing awareness of non-conformance Priorities and Root Cause Analysis (RCA), which was important towards identifying patterns and preventing future issues. Based on RCA, Quest Global enabled trend analysis, which helped pinpoint recurring issues and make informed strategic decisions. This improved forecasting and enabled a proactive approach that allowed the team to predict potential NCs and &nbsp;address them before they escalate.</p><p dir="ltr">Moreover, based on the use of data visualization tools &nbsp;the solution enabled the systematic identification and resolution of bottlenecks in the production process. The elimination of bottlenecks led to more efficient operation of the production line, which is characterized by reduced delays and an overall improved process flow.</p><p dir="ltr">Also, the transition from manual whiteboard tracking to a digital system provided real-time visibility into KPIs. Specifically, this enabled stakeholders to monitor progress at a glance, which led to faster decision-making and more efficient operations across the production line.</p><h3 dir="ltr"><strong>Lessons Learnt: Strategies for Reducing Non-Conformance</strong></h3><p dir="ltr">The successful deployment of the digital thread approach highlights several key strategies that aerospace manufacturers can adopt to reduce non-conformance:</p><ul><li dir="ltr"><p dir="ltr"><strong>Root Cause Analysis (RCA)</strong>: RCA boost the identification of the underlying factors that contribute to non-conformances. In this direction, techniques such as <a href="https://protect.checkpoint.com/v2/___https://www.techtarget.com/whatis/definition/fishbone-diagram___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OmZjMGM6MDI2ZDU1Yjk2YjFkNWFiYzc2ODExMWQ0YjRlN2MxMDMxNjc2NjY3NDZiYzdlMjAzYmZhZTgwMDUyMWFiZWM0OTpwOlQ6Tg">fishbone diagrams</a> can be used to investigate issues thoroughly and to prevent recurrence.</p></li><li dir="ltr"><p dir="ltr"><strong>Continuous Improvement Initiatives</strong>: Regular Kaizen workshops focused on process optimization can lead to significant improvements in flow line efficiency. In the scope of the above-described case study, bottlenecks were methodically identified and eliminated through continuous monitoring.</p></li><li dir="ltr"><p dir="ltr"><strong>Supply Chain Collaboration:</strong> The effective management of both internal and external supply chains is critical for reducing delays and ensuring that quality standards are met. Quest Global's on-the-ground support for suppliers helped streamline operations across multiple stakeholders.</p></li><li dir="ltr"><p dir="ltr"><strong>Digital Transformation – Digital Thread Approach:</strong> The adoption of digital thread technology enables real-time monitoring of production processes and facilitates predictive analytics. This improves operational efficiency and reduces the likelihood of defects.</p></li></ul><h3 dir="ltr"><strong>The reduction of non-conformances leads to tangible benefits, including:</strong></h3><ul><li dir="ltr"><strong>Increased Throughput</strong>: With fewer defects and less rework required, production lines can operate more efficiently and achieve faster turnaround times.</li><li dir="ltr"><strong>Cost Savings:</strong> The reduction of scrap rates and of the delays associated with non-conformances leads to significant cost reductions.</li><li dir="ltr"><p dir="ltr"><strong>Improved Quality:&nbsp;</strong>The early identification of quality issues can lead to products meet the highest quality standards, which is one of the top priorities of the aerospace industry.</p></li></ul><h2 dir="ltr">Non-conformance reduction with digital and agile methods</h2><p dir="ltr">In the next few years emerging technologies such as artificial intelligence (AI), predictive analytics, and advanced digital threads will play an increasingly key role in reducing non-conformances. These technologies will enable manufacturers to predict and potentially remedy potential issues before they occur. This will further enhance safety standards, while improving operational agility. Also, the rise of <a href="https://protect.checkpoint.com/v2/___https://www.tudelft.nl/en/stories/articles/a-digital-product-passport-for-a-circular-economy___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OjdjY2E6ZGJiM2YyNGEyOTFlYzJjMDM1NWY1YTMwMzdlMDU5YTAxZDE3ZDQwMDI1ODc2ZjhmOTkzMjYxODg0MzExODY4OTpwOlQ6Tg">digital product passport</a> technologies will enhance the ability of digital thread solution to provide enhanced real-time visibility on materials, products, and production processes. This enhanced visibility will further enhance the accuracy of aerospace manufacturers’ decisions.</p><p dir="ltr">Quest Global is at the forefront of this transformation. It is already integrating AI-driven predictive analytics into advanced digital thread solutions, in ways that deliver tangible benefits to aerospace enterprises. Quest Global is committed to integrating the most recent Gen AI and digital thread advancements towards reducing downtimes, improve product quality, and drive further efficiency gains.</p><h2 dir="ltr">Towards a digital-first approach in aerospace manufacturing</h2><p dir="ltr">In conclusion, reducing non-conformance is critical for achieving operational excellence in aerospace manufacturing. Quest Global’s combination of production support, flow line optimization, and digital thread technologies provides a practical solution for addressing these challenges. The implementation of real-time data visibility tools has led to significant improvements in workflow efficiency, reduced bottlenecks, enhanced quality control measures, and lower non-conformance rates.</p><p dir="ltr" id="isPasted">Most aerospace manufacturers are on this journey to &nbsp;adopt such digital-first approaches to improve their overall productivity and profitability, while at the same time meeting stringent regulatory requirements</p><h2>References</h2><p>1. &nbsp;Ubacht J. A digital product passport for a circular economy. TU Delft Stories. 2023 [cited 2024 Nov 10]. Available from: https://www.tudelft.nl/en/stories/articles/a-digital-product-passport-for-a-circular-economy</p><p>2. Gopi S, Joshua DR, Valluri VS. Digitization of non-conformance workflows and processes in aerospace product lifecycle management. Int J Res Appl Sci Eng Technol. 2022.</p><p>3. Pop GI, Titu AM, Pop AB. Enhancing aerospace industry efficiency and sustainability: process integration and quality management in the context of Industry 4.0. Sustainability. 2023;15:16206. doi:10.3390/su152316206.</p>

The aerospace industry faces non-conformances like material defects and process errors, causing delays and safety risks. Digital thread technologies help streamline operations, reduce non-conformances, and ensure adherence to strict quality and safety standards.

Achieving Operational Excellence in Aerospace Manufacturing: Reducing Non-Conformance with Production Support and Digital Threads

<p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://fast.wistia.net/embed/iframe/wzpbp2p82h" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><p>Our <em>Insight</em> video series will help you master digital manufacturing.</p><p>Every Friday we’ll post a new video – each one giving you a deeper <em>Insight</em> into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.</p><p>So join us and don’t miss out.</p><p id="isPasted"><strong>Transcript</strong></p><p>Hi, it’s Friday, which means it’s time for another Insight video.</p><p>Today I’m going to talk you about the super allow Inconel 718 and how 3D printing technology has really opened up how you can use this material.</p><p>But first of all, why is it known as a superalloy? Well quite simply it can cope in extreme environments where other metals would struggle or even not cope at all. Inconel can be permanently used in applications of over 600<sup id="isPasted">o</sup>C retaining its high strength and toughness plus corrosion resistance. It is also very light. In these environments, aluminium and steel would succumb to creep and copper would simply melt away.</p><p id="isPasted">And it is equally good in extreme low temperatures and is used in cryogenic environments where it helps prevent parts from becoming brittle, while again retaining its toughness.</p><p>This nickel and chromium mix is truly the Superman of the metal alloy world.</p><p>You won’t be surprised to learn that it is used extensively in aerospace applications where it can account for up to 50% of the weight of a turbojet engine. It is the main component for discs, blades and casings of the high-pressure section of the compressor and discs, plus some of the blades of the turbine engine.</p><p>In fact, without access to superalloys like Inconel, aerospace would probably not have advanced to the extent that it has today.</p><p id="isPasted">And it’s not just the aerospace industry where this superalloy stars, it is a common material for extreme environments in heavy industry as well.</p><p>First produced in the 1940’s if you fast forward to today, we have materials that evolved from those early superalloys. Today Inconel 718 is the world’s predominant superalloy. Its strength is derived from its ability to create a thick stable passivating oxide layer at temperatures as high as 704<sup>0</sup>C protecting the material from attack and retaining its good tensile, fatigue, creep and rupture strength.</p><p>What an amazing material.</p><p>Unfortunately, it is so amazing that there is not much that can touch it – so it’s extremely hard to machine requiring expensive tooling that reach very high temperatures on the edge of the machining insert. That and Inconel’s abrasive nature leads to high wear rates, chipping, notching and the cutting edge breaking on the tool.</p><p>Other traditional manufacturing methods when applied to Inconel 718 often end up sacrificing the very properties that you want in order to obtain the desired shapes.</p><p>Now, thanks to advances in 3D printing using direct metal laser sintering, or DMLS, there is no need to compromise. It also means that using this additive manufacturing technology, which builds a series of very fine layers on top of each other using a laser to melt the metal powder to the next layer, you can design even the most complex and intricate of designs – perhaps to save weight for example.</p><p id="isPasted">The process preserves Inconel 718’s mechanical properties and with its directional solidification it can help exceed the mechanical properties of the material’s cast and wrought counterparts.</p><p>And the other thing of course is that DMLS is an additive process. Inconel 718 is not cheap, you don’t get all of those amazing properties for nothing! Using DMLS will significantly cut down on your waste of this precious material. This layer wise building of components with near final contours produces only about 5% waste. In the aerospace industry they would say that this improves its “buy to fly” ratio.</p><p>Like anything of course Inconel does have some limits, just like superman and kryptonite.</p><p id="isPasted">In this case however we are talking about its geometric limits when using DMLS to produce parts. Let’s quickly run through them now.</p><p>First there is a minimal wall thickness of 1.00 millimetre and a minimum feature size of 1 mm, which is actually pretty small when you think about it.</p><p>If you need embossed details, then these must be at least 0.5mm high and wide and 0.8mm for text and images.</p><p>For engraved details you will be looking at a minimum of 0.5 mm depth and 0.6 mm width increasing to a minimum of 1.00mm width for text and images.</p><p>Also, because the part is formed in a chamber and needs support structures, there is a maximum part size. For us at Protolabs that is 245 by 245 by 300mm.</p><p>Now these restrictions will vary from supplier to supplier, so the best thing to do as always is to talk to them, find out what is possible and weigh up your options.</p><p>So, to pinch a cliché, when the going gets tough for your part, consider turning to Inconel 718. It is the superalloy of choice for many applications and now that it can be produced using 3D printing you can design almost anything you want.</p><p>Right that’s about it for this week. Have a great weekend and I’ll see you again next Friday.</p>

Your masterclass in product design and development.

3D Printing Inconel

<p id="isPasted">Sintering is the process of applying heat and/or pressure to fuse bits of metal, ceramic, and other materials into a solid mass. It’s nothing new. Nature has been fusing sedimentary minerals into slate and quartzite for eons, and humans began using similar methods to make bricks and porcelain millennia ago. Today, sintering is used to produce everything from gears and connecting rods to sprockets and bearings. It’s also used to <a href="https://www.protolabs.com/en-gb/services/3d-printing/" title="3D Printing" target="_blank">3D print</a> parts.</p><p><a href="https://www.protolabs.com/en-gb/services/3d-printing/selective-laser-sintering/#Design_Guidelines:_Selective_Laser_Sintering" title="Selective Laser Sintering" data-anchor="#Design_Guidelines:_Selective_Laser_Sintering" target="_blank">Selective laser sintering (SLS)</a> is a close cousin to <a href="https://www.protolabs.com/en-gb/services/3d-printing/direct-metal-laser-sintering/" title="Direct Metal Laser Sintering" target="_blank">direct metal laser sintering (DMLS)</a>, but builds parts made of plastic rather than metal. SLS uses a computer-controlled CO2 laser versus an ND: YAG fibre laser for DMLS, but both “draw” slices of a CAD model in a bed of material, fusing micron-sized particles of material one layer at a&nbsp;time.</p><p>SLS needs none of the support structures typical with DMLS, however, and unlike <a href="https://www.protolabs.com/en-gb/services/3d-printing/stereolithography/" title="Stereolithography" target="_blank">stereolithography (SL)</a>—the third laser-based additive manufacturing (AM) process available at Protolabs—SLS creates fully functional parts using engineering-grade nylon. This makes it an excellent way to prototype <a href="https://www.protolabs.com/en-gb/services/injection-moulding/" title="Injection Moulding" target="_blank">injection-moulded</a> products, and can even be used as a low-volume alternative to moulding in some cases.</p><h3>Rooted in Nylon</h3><p>As with any additive process, it’s important to understand the many design considerations applicable to SLS. One of these is the material. Despite their wide-ranging uses, all SLS parts are currently limited to nylon materials—the same thermoplastics used in fasteners, flak jackets, frying pans, and thousands of other everyday items. Protolabs offers six different materials (five different polyamides and one TPU):</p><ul><li><strong>PA 12 Smooth White/ Vapour Smooth White&nbsp;</strong>is an economical material choice for functional prototypes and end-use parts. It offers high impact and temperature resistance, is very durable, and remains stable under a range of environmental conditions. The nylon material exhibits a white finish with a slightly rougher surface texture compared to other nylons.</li><li><strong>PA 12 Glass Filled Smooth White</strong> is a polyamide powder loaded with glass spheres that add stiffness and dimensional stability. The material possesses higher thermal resistance than unfilled polyamides and exhibits excellent long-term wear resistance. Due to the glass additive, it has decreased impact and tensile strengths compared to other nylons.</li><li><strong>PAx Smooth Natural/ Vapour Smooth Natural</strong> is a versatile polyamide which is characterised by excellent toughness and flexibility in any direction, including the z plane. The material possesses great long term stability and durability and can be used to produce both prototyping as well as end-use parts.<br>The material is very versatile, so applications range from living hinges and snap fits to fixtures, enclosures as well as orthotics.</li><li><strong>PA 12 Carbon Filled Smooth Black</strong> is an anthracite grey nylon characterised by extreme stiffness and high-temperature resistance, coupled with electric conductivity properties and lightweight. It can be used for both functional prototypes and end-use parts. The carbon-fibre filler provides different mechanical properties based on the considered three-axis direction. This material exhibits a good surface quality and smoother finish compared to other SLS nylons.</li><li><strong>PA 12 Flex Flex Pure Black</strong> PA 12 Flex Black is a black / anthracite nylon characterised by excellent flexibility and impact resistance. PA 12 Flex Black combines positives properties of PA12 and PP. Strength and stiffness is similar to PA 12. The elongation is comparable to that of unfilled PP. Its high durability makes it an excellent choice not only for prototyping, but also for end-use parts.</li><li><strong>TPU-88A Pure Black</strong> is an anthracite grey nylon characterized by extreme stiffness and high-temperature resistance, coupled with electric conductivity properties and lightweight. It can be used for both functional prototypes and end-use parts. The carbon-fibre filler provides different mechanical properties based on the considered three-axis direction. This material exhibits a good surface quality and smoother finish compared to other SLS nylons.</li></ul><h3>Managing the Build</h3><p>These nylon materials cover many different applications.&nbsp;Most of the SLS material consumed at Protolabs is Nylon 12, however many customers are selecting bstiffer materials (the carbon-and glass-filled variants) or more flexible ones (TPU) based on their unique part requirements.&nbsp;There’s far more to effective part design than material selection, however, and controlling the in-build curl and post-build warping common with AM is paramount to good part quality.</p><p>Much of this control falls to Protolabs. To keep parts straight and true, our technicians will often tip parts slightly in the build chamber. If you’re designing a case for a handheld video game, for example, a compound incline of 10 to 15 degrees in the X and Y axes during the build is probably all that’s needed to keep the walls square and the box lid fitting smoothly. It’s important to point out that some “stair stepping” may occur as a result of this technique, so it’s important to identify cosmetic surfaces when submitting your design to Protolabs for quoting and&nbsp;analysis.</p><p>For especially challenging parts, ribs can be used to strengthen large, flat surfaces—if your handheld game design requires a thin lid, a honeycomb or checkerboard pattern on the inside surface will not only strengthen the lid, but also reduce material cost and potential&nbsp;warping.</p><p><img alt="Example of radiused corners" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731598145938-1731598145937.png" class="fr-fic fr-dii" style="width: 322px;"></p><p skip="true"><em>Radiused corners, shown here, can be added to reduce stress.</em></p><h5>It’s Never Too Early to Improve Mouldability</h5><p>Many of the rules applied in injection moulding also apply to SLS, making it a solid choice for parts that will eventually be moulded. The use of hole bosses and support struts, and avoiding thick cross-sections are good practices for either manufacturing process. Additional design considerations include:</p><ul><li>Adding corner radii where walls meet to reduce stress</li><li>Uniform wall thickness—between 1.5mm and 3.8mm is recommended to reduce in-build curl and potential for warping</li><li>Integrating ribs to reduce warping</li></ul><p>Where injection-moulded parts can contain overmoulded metal bushings or threaded inserts, SLS parts achieve comparable functionality via heat-stake inserts—in our handheld game example, threaded inserts can be heat-staked as a secondary process at each corner of the housing for strong assembly&nbsp;purposes.</p><h3>Look and Feel</h3><p>The surface finish produced by SLS is a bit rougher than other AM technologies—anywhere from 100-250 RMS—but it still works reasonably well for most functional prototypes. Protolabs also bead blasts the majority of customers’ parts to remove loose powder and create a smooth matte finish. Very fine text is another consideration—since the minimum feature size with SLS is 1mm, very small fonts tend to get jammed with powder, making letters and numbers less legible. Moving to inset text provides better results, but is still limited to features no smaller than approximately 0.5mm. Lastly, SLS is slightly less accurate than competing laser sintering processes—where DMLS has expected tolerances of ±0.01mm plus an additional 0.001 mm/mm on metal parts, ±0.25mm plus ±0.0015mm is typically achievable with SLS. On well-designed&nbsp;parts.</p><p>The upside here is that SLS has a build frame of 700mm by 380mm by 580mm, far larger than its metal-making sidekick. And because there are no support structures involved, the entire powder bed can be utilized, making it easy to nest multiple parts into a single build. This makes SLS a solid alternative to machined plastic, a logical stepping-stone to injection moulding, and an excellent way to produce functional nylon parts in higher volumes than is usually associated with AM.</p>

SLS builds precise plastic parts for prototyping and low-volume production.

3D Printing Functional Parts with Selective Laser Sintering

<p dir="ltr" id="isPasted">Precision, efficiency, and adaptability have always been essential in aerospace manufacturing. Today, simulations, digital twin technology, and real-time monitoring are not only helping companies meet these goals but also bringing them closer to carbon neutrality.</p><p dir="ltr">To drive these innovations, companies require insights into every aspect of the manufacturing process. This is where Hexagon steps in, offering end-to-end workflow solutions to tackle key challenges across design, production, and quality control, with sustainability at the forefront.</p><h2 dir="ltr">Current Challenges and Opportunities in Aerospace Manufacturing</h2><p dir="ltr">Aerospace manufacturers face the challenge of creating complex parts while adhering to strict regulations. Additionally, they aim to reduce waste as part of their sustainability goals. To meet these demands, the industry requires advanced, integrated solutions to streamline production.</p><h3 dir="ltr">Design and engineering</h3><p dir="ltr">In aerospace design, simulations allow engineers to test for safety and performance without the repeated need for prototypes. This not only reduces costs but also makes the development process significantly less wasteful.&nbsp;</p><p dir="ltr">However, running complex simulations requires powerful computing infrastructure. Without the right infrastructure and expertise, many design teams still rely on the more costly approach of prototype testing. This often leads to delays and added expenses in the development cycle.</p><h3 dir="ltr">Production</h3><p dir="ltr">One of the most prominent challenges is long setup times. Aerospace manufacturing involves intricate parts with each production run often requiring recalibrations and adjustments. Machine breakdowns is another well-known issue that can disrupt production.</p><p dir="ltr">Additionally, maintaining consistent quality across multiple production sites is also a hurdle. Due to strict safety standards in aerospace, even minor deviations lead to additional quality checks, which can further slow down production. The industry also faces a shortage of skilled labor.</p><h3 dir="ltr">Quality control</h3><p dir="ltr">Coordinate Measuring Machines (CMM) are crucial for checking the accuracy of aerospace components.&nbsp;However, this process can be time-consuming, especially considering that parts need to be brought to these machines and may require multiple passes. The lack of real-time insights adds to this issue. Without immediate access to measurement data, it becomes challenging for engineers and technicians to detect and address deviations in production early on.</p><h2 dir="ltr">Manufacturing Made Intelligent&nbsp;</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731924823927-Hexagon_MI_OPTIV_M_Multisensor_CMMs_Family_1_Product_Photo_1680x885px.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Hexagon's Multisensor CMMs Family use tactile probing and the high-speed measuring point capture of non-contact measurement on a single system and within a single measurement run for more efficient measurement of complex parts.</span></span></span></p><p dir="ltr">Hexagon is a global leader in digital reality solutions, offering integrated manufacturing intelligence that spans from design to final product. The company’s goal is to make advanced technology accessible on the shop floor to ensure consistent quality throughout the process. Hexagon has supported top brands and organizations, including Formula 1’s Red Bull Racing, the cutting-edge research of CERN, and automotive giant Volkswagen. Its core offerings are as follows:</p><h3 dir="ltr">Complete integration</h3><p dir="ltr">Hexagon provides comprehensive integration across the entire aerospace production cycle, spanning design, manufacturing, and quality control. This seamless integration allows data to move freely across each stage and system, creating transparency that enables stakeholders to monitor progress at every step. With actionable insights coming from each phase, aerospace teams can make the right decisions that improve overall efficiency and product quality.</p><h3 dir="ltr">Simulation and optimization</h3><p dir="ltr">Hexagon’s Computational Fluid Dynamics (CFD) solutions help aerospace engineers simulate and analyze the aerodynamic forces acting on aircraft components. This allows companies to fine-tune designs without the need for physical prototypes at each iteration. Furthermore, Hexagon's data-driven approach enables teams to pinpoint bottlenecks and improve process efficiency, which leads to more sustainable production.</p><h3 dir="ltr">Real-time monitoring</h3><p dir="ltr">Hexagon’s real-time monitoring solutions bring machine and production data directly to engineers and operators through easy-to-read dashboards.&nbsp;This real-time accessibility enables better communication and collaboration between teams, while continuous monitoring enables predictive maintenance, reducing downtime by identifying potential issues before they escalate.</p><h2 dir="ltr">Ensuring Smart Design, Intelligent Production and Integrated Quality Assurance</h2><h3 dir="ltr">Smart Design for Aerospace Engineering</h3><p dir="ltr">Hexagon offers a cloud-based simulation tool Nexus Compute. Supporting various technologies including scFLOW, it enables engineers to test their designs for aerodynamic stress including hypersonic conditions. The cloud-based nature of the tool ensures that stakeholders from different teams can collaborate seamlessly. Hexagon's solutions also come with Integrated Computational Materials Engineering (ICME) for virtual material testing.</p><h3 dir="ltr">Intelligent Production for First-Time-Right Manufacturing</h3><p dir="ltr">Hexagon’s real-time monitoring solutions provide manufacturers with continuous insights into workflow efficiency, enabling engineers to catch potential issues before they lead to costly delays.</p><p dir="ltr">With digital twin technology, Hexagon takes monitoring to another level by creating virtual replicas of physical equipment.&nbsp;It gives manufacturers a real-time view of machinery performance and its wear patterns paving the way for predictive maintenance.</p><h3 dir="ltr">Integrated Quality Assurance</h3><p dir="ltr">Hexagon offers in-process measurement, a system that measures and monitors parts or components during production. By integrating measurement tools directly into the production stage, manufacturers can detect and address defects early in the cycle, significantly reducing waste.</p><p dir="ltr">Hexagon’s centralized data and documentation platform also ensures that information is easily accessible across teams. This facilitates traceability and better decision-making across the shop floor. Additionally, this approach streamlines processes for regulatory compliance and supports consistent quality across operations.</p><h2 dir="ltr">Real-World Application: Aeroplane Wing Nose Rib Case Study</h2><p dir="ltr">The aeroplane wing nose rib is a critical structural element that withstands intense aerodynamic forces while maintaining minimal weight. Getting it right with traditional methods is a time-consuming affair. However, with its end-to-end workflow solutions, Hexagon helped the client optimize every stage of the production cycle. Let’s find out how its advanced manufacturing intelligence helped streamline operations, reduce costs, and minimize waste to support sustainability.</p><h3 dir="ltr">Design Optimization</h3><p dir="ltr">Using Hexagon’s CFD and system dynamics, the team tested their designs in high-speed flow simulations. Through tools such as scFLOW, engineers were able to simulate high-speed flow conditions, including extreme phenomena like shockwaves. This virtual testing accurately gauged load behaviors and aerodynamic stresses, allowing engineers to evaluate multiple configurations and zero in on the one that meets stringent performance requirements before moving on to the prototyping phase.</p><h3 dir="ltr">Manufacturing Preparation and Verification</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxNTc1NTY3MjU4LWhleGFnb24tbm9zZS1yaWItLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr">In preparation for manufacturing, the client used Hexagon's digital twin technology to ensure precise alignment between design specifications and production processes. Through CAD modeling and direct "Send To CAM" interoperability, engineers ensured compatibility between design and manufacturability. Digital twins allowed for accurate simulation of material and process interactions, ensuring that each step adhered to high-quality standards with minimal operator intervention.</p><h3 dir="ltr">Shop-Floor Operations and Quality Inspection</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxNTc1NjA5MjQyLWhleGFnb24td2luZy1ub3NlLXJpYi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr">With in-machine measurement solutions and portable machines ready for the shop floor, the team was able to collect measurement data without delays. Hexagon's first-time-right machining approach minimized revisions and significantly reduced material waste. Hexagon’s in-machine inspection capabilities enabled real-time measurement of components, ensuring adherence to design tolerances. The integration of CMM allowed the client to capture high-precision measurements for geometric and free-form features. Portable machines equipped with various high-speed sensors enabled continuous quality assurance, minimizing waste and accelerating the process.</p><h3 dir="ltr">Reporting and Analytics</h3><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxNTc1NjUwOTc4LWhleGFnb24tdXNlci1zdG9yeS1xdWFsaXR5LWluc3BlY3Rpb24uanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">The team had easy access to real-time sensor data through Hexagon’s reporting tools. By centralizing all relevant documentation in the cloud, these tools made it easy for engineers and management to review process metrics and identify areas for improvement in both design and manufacturing. The digital records supported regulatory compliance with aerospace industry standards, which effectively reduced time spent on audits.</p><h2 dir="ltr">Key Benefits of Manufacturing Intelligence:</h2><ul><li dir="ltr"><p dir="ltr">With its digital twins, simulation, and optimized workflows, Hexagon can help aerospace manufacturers accelerate product development. In the past, its clients have achieved up to a 30% reduction in time from concept to production.</p></li><li dir="ltr"><p dir="ltr">With Hexagon’s virtual testing tools, the need for physical prototypes is minimized. This can mean up to a 50% reduction in cost for aerospace companies compared to traditional methods.</p></li><li dir="ltr"><p dir="ltr">The company’s manufacturing intelligence solutions can improve “first-time-right” production rates. This reduces the need for rework saving time and resources.</p></li><li dir="ltr"><p dir="ltr">Through real-time monitoring and predictive maintenance, Hexagon maximizes machine uptime and productivity.</p></li><li dir="ltr"><p dir="ltr">A focus on quality control means Hexagon’s solutions help manufacturers comply with industry standards more reliably while also supporting sustainability by reducing waste.</p></li><li dir="ltr"><p dir="ltr">Digital documentation offers complete traceability across the product lifecycle. This ensures compliance with regulatory requirements and industry standards with more confidence.</p></li></ul><p dir="ltr">The aerospace industry faces complex challenges in various production stages. For instance, access to advanced simulation tools is often limited. On the production floor, long setup times are common, and maintaining consistent quality across facilities is a struggle. Precision measurements CMMs is crucial but can often become bottlenecks in the workflow.</p><h2 dir="ltr">Step into the Manufacturing of Tomorrow at Hexagon LIVE</h2><p dir="ltr">Hexagon’s manufacturing intelligence suite addresses these challenges with its end-to-end solutions. Their cloud-based simulation tools enable engineers to run essential design tests faster and more collaboratively. By providing real-time monitoring throughout production, Hexagon helps manufacturers achieve consistent quality and reduce waste. Additionally, Hexagon speeds up the traditionally slow CMM measurement process by integrating measurement tools directly into the production stage.</p><p dir="ltr">Curious about how Hexagon's manufacturing intelligence can transform your organization? Join the Hexagon LIVE event in Eindhoven on <strong>November 27</strong> to explore their digital solutions firsthand.</p><p dir="ltr">Don’t miss this opportunity to connect with industry experts, explore the latest innovations, and get your questions answered by Hexagon specialists.</p><p>Secure your spot today!</p><p><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven?creative=713450062%20759&keyword=hexagon%20live%20eindhoven&matchtype=e&network=g&de%20vice=c&gad_source=1&gclid=Cj0KCQjw99e4BhDiARIsAISE7P-jq9--%20x4A0TeKGXvQPXSR46iJ28I8bV7tNL3-yyfjZcLlvv_LBpE4aAsuEEALw_wcB" target="_blank" rel="noopener noreferrer" class="button-main-action">Read more and register</a></p>

Explore how advanced solutions in manufacturing intelligence are transforming aerospace manufacturing by addressing key challenges in design, production, and quality control while promoting sustainability. 

Harnessing Manufacturing Intelligence to Enhance Operational Excellence in Aerospace

<p dir="ltr" id="isPasted">For years, traditional analog methods, like rotary screen printing, have been useful for certain applications but are now struggling to meet the growing demand for more precision, customized designs, and minimal material waste. This challenge is compounded by their inherent need for screens or stencils, multiple steps, and limited ability to accommodate custom or multi-material designs. In contrast, inkjet printing has been gaining particular attention for its ability to handle multiple materials with high precision, offering a more flexible, efficient, and sustainable alternative.</p><p dir="ltr">Inkjet printing has become a valuable method in industries such as packaging, ceramics, and textiles due to its ability to deposit ultra-fine droplets with high precision. This precision is instrumental when working with functional materials like conductive inks or UV-curable resins. However, conventional inkjet systems have been limited by the viscosity of the materials they could handle, restricting the types of substances that could be printed, especially in more advanced applications.</p><p dir="ltr">This is where Quantica has made a pioneering contribution. By breaking through the viscosity ceiling that has long confined inkjet printing, Quantica’s innovative NovoJet™ printhead technology allows for jetting highly viscous materials far beyond what was previously achievable. This advancement has opened new possibilities for multi-material, industrial printing, allowing manufacturers to not only print components but also jet materials that Improve functionality. For example, adhesives can be jetted to seal parts together, or coatings can be applied to protect and shield components.&nbsp;</p><p dir="ltr">Quantica’s digital, contact-free system combines materials with different properties, such as conductivity, UV resistance, and mechanical strength, all in a single, precise process. As these capabilities continue to mature, Quantica’s solutions are poised to drive impactful changes across industries like electronics and automotive, where precision and material efficiency are key drivers of innovation.</p><h2 dir="ltr">Core Technology</h2><h3 dir="ltr">The NovoJet™ Printhead Technology</h3><p dir="ltr">At the heart of Quantica’s revolution in additive manufacturing is its cutting-edge NovoJet™ printhead technology, which enables scalable, automated, high-precision, multi-material printing. Unlike conventional inkjet heads limited to very low viscosity, the NovoJet™ printhead can jet high-viscosity materials, pushing the boundaries of what can be achieved in 2D printing.</p><p dir="ltr">The NovoJet™ printhead stands out for its precise control over depositing thick, high-performance materials in ultra-fine droplets, achieving precision beyond traditional manufacturing methods. This capability allows manufacturers to produce intricate, multi-material components with varied properties in a single, seamless process—without extra tools or stages. For industries like electronics, automotive, and energy, where functionality and material-specific properties are critical, NovoJet™ offers transformative advantages. With its ability to handle certified materials like conductive inks, UV-resistant coatings, and heat-resistant adhesives exactly where needed, the NovoJet™ printhead supports efficient, sustainable production, minimizing waste while enhancing product functionality.</p><h3 dir="ltr">Revolutionizing 2D Printing with High-Viscosity Materials</h3><p dir="ltr">High-viscosity materials—such as coatings, adhesives, and conductive pastes—are vital for creating products that require durability, precision, and functionality. These materials are essential for industries such as automotive manufacturing, where components must endure demanding conditions, and energy production, where the reliability of fuel cells and other components is crucial.</p><p dir="ltr">By enabling the use of high-viscosity materials, Quantica’s NovoJet™ printhead technology provides precise control over material placement, enhancing the durability and performance of printed components. In industries like electronics, where the demand for smaller, more efficient devices is growing, the ability to print flexible, highly conductive circuits can dramatically improve product performance while reducing waste through jetting. This innovation allows manufacturers to create more robust and sustainable devices.</p><h2 dir="ltr">Application Development Process: From Concept to Production</h2><p dir="ltr">Quantica’s application development process is built on close collaboration with its clients, guiding them from initial material qualification to full-scale production. This structured approach ensures that every manufacturing step is optimized for precision and efficiency. It begins with material qualification, where Quantica assesses whether a client’s material can be jetted effectively with their technology. Once a material is qualified, jetting trials are carried out to fine-tune the process, ensuring the material behaves as expected during jetting.</p><p dir="ltr">The next step is printing trials, where prototypes are produced to verify that the material’s performance meets industry standards. Once these trials are successful, Quantica works with the client to develop an industrial application that integrates seamlessly into their existing workflows through inline, near-line, or robotic-arm systems. For example, Quantica is helping a label printing company convert its traditional screen printing and roll-to-roll processes to a fully digital, inkjet-based solution, significantly reducing material waste and enhancing production flexibility.</p><p dir="ltr">This development process enables Quantica to offer tailored solutions for companies across multiple industries. To expand these services, Quantica partners with major inkjet research institutions like Fraunhofer IPA and iPrint.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxMzI1ODI5NDA2LXF1YW50aWNhLWRpdmVyc2UtYXBwbGljYXRpb25zLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Quantica’s application development process is built on close collaboration with its clients, guiding them from initial material qualification to full-scale production. Source: Quantica.</span></span></span></p><h3 dir="ltr" id="isPasted">Applications Across Industries</h3><p dir="ltr">Quantica’s NovoJet™ printhead technology is not limited to a single application or industry. Its ability to handle high-viscosity materials and deliver multi-material printing capabilities makes it highly versatile across various sectors.</p><h3 dir="ltr">Fuel Cell Production</h3><p dir="ltr">One area where Quantica is driving change is fuel cell production, where efficiency and sustainability are crucial. Traditional methods like dispensing and rotary screen printing often lead to significant material waste and low yield, particularly with costly materials like platinum inks.</p><p dir="ltr">One particularly promising application for Quantica's technology is adhesive deposition in hydrogen fuel cell manufacturing, where precise sealing and separation between components are essential. A reliable sealant directs gas flow accurately, influencing the fuel cell's performance and lifespan.</p><p dir="ltr">Quantica recently evaluated their NovoJet™ technology with a high-viscosity industrial adhesive, measuring 13,000 mPas at room temperature. By applying heat and leveraging shear-thinning effects, they reduced the adhesive’s viscosity to a range compatible with jetting technology. The adhesive was then printed onto multiple fuel cell substrates, including the gas diffusion layer, membrane, catalyst-coated membrane, and carbon composite plate. This adaptation of a standard adhesive to an inkjet system showcased the potential for contact-free, precise, and efficient adhesive application, highlighting a clear improvement over traditional methods.</p><p dir="ltr">Adhesive deposition marks just the beginning of Quantica's innovations in fuel cell manufacturing. Their next target is digitally printing the platinum catalyst layer within the membrane electrode assembly (MEA)—a step that could offer manufacturers greater control over material application, improve precision, and significantly reduce material waste. Given the high value of platinum, this approach enhances production efficiency and contributes to a more sustainable manufacturing process.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxMzI1ODg3OTU5LXF1YW50aWNhLWRpdmVyc2U9YXBwbGljYXRpb25zLTEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: A Quantica print sample of the adhesive printed on a substrate used in hydrogen fuel cell production. Source: Quantica.</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxMzI1ODk0MjcwLXF1YW50aWNhLWRpdmVyc2UtYXBwbGljYXRpb25zLTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: An Open Source Stack (OSS) Fuel Cell, primarily developed at TU Chemnitz that helps visualize a fuel cell stack, including the catalyst layer. Source: Quantica.</span></span></span></p><h2 dir="ltr" id="isPasted">Vision for the Future</h2><p dir="ltr">Quantica is well-positioned to shape and lead the future of additive manufacturing. With a focus on sustainability, precision, and cost-efficiency, the company’s innovations are driving the next wave of manufacturing technology. This is particularly highlighted in its focus on industrial 2D/2.5D applications. As demand for better materials and more efficient and sustainable manufacturing methods grows, Quantica’s unique ability to work with high-viscosity materials in new ways will continue to set it apart.</p><p dir="ltr">Its long-term vision is clear: to lead the industry in digital, contact-free inkjet printing that transforms how products are designed and produced. By focusing on solutions that minimize waste, reduce costs, and offer greater flexibility, Quantica is not just responding to current market needs but actively shaping the future of global manufacturing.</p><p><br></p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Quantica is at the forefront of a transformation in additive manufacturing, delivering solutions that combine precision, efficiency, and sustainability. With their NovoJet™ printhead technology, Quantica is enabling manufacturers to overcome the limitations of traditional methods and create more functional, cost-effective, and environmentally sustainable products.</p><p dir="ltr">As it continues to expand its reach through partnerships, innovation, and investment, its technology will play a key role in redefining the future of electronics, automotive, energy, and beyond. For manufacturers looking to embrace the future of multi-material and high-viscosity printing, Quantica’s offerings represent a leap forward in what’s possible.</p><p dir="ltr">Explore how Quantica’s NovoJet™ technology can enhance your manufacturing processes by <a href="https://www.q3d.io/contact" target="_blank" rel="noopener noreferrer" id="isPasted">booking a call with Quantica today</a>. Learn more about their cutting-edge solutions and how to integrate them into your workflow for better precision, efficiency, and sustainability.</p>

NovoJet Open System Used for Application Development. Source: Quantica.

What if the secret to transforming manufacturing lies in how we print? The answer may lie in a single layer, as the ability to precisely jet valuable materials layer by layer offers a new level of manufacturing freedom. 

The Diverse Applications of Cutting-Edge InkJet Printing

<p dir="ltr" id="isPasted">What if machines could intelligently and automatically adapt to the needs of industrial workers and integrate themselves in the human interaction loop, rather than expecting the worker to become trained about their intricacies?&nbsp;</p><p dir="ltr">What if digitally enabled industrial production systems could prioritize sustainability and social performance in addition to maximizing production efficiency and optimizing production costs? &nbsp;</p><p dir="ltr">This could unlock a new era for industrial production that delivers business and societal benefits at the same time. Imagine a world where digital manufacturing systems will be fundamentally designed to be human-centric and sustainable. This is not the distant future: It is the dawn of Industry 5.0, the next evolutionary step after Industry 4.0 and Cyber Physical Production Systems, where industrial production innovations meet empathy in order to craft a new wave of smarter, cost-effective, sustainable and human centric solutions to the benefit of both consumers and industrial organizations.&nbsp;</p><h2 dir="ltr">Introducing Industry 5.0</h2><p dir="ltr">Industry 5.0 focuses on sustainability and the collaboration between humans and smart systems towards shaping an industrial future that's not only productive but also inclusive and environmentally conscious. Similar to Industry 4.0, Industry 5.0 relies on the deployment of cyber physical systems and their integration with advanced digital technologies. As such it is a continuation of Industry 4.0 towards a more responsible, sustainable and humanized use of manufacturing. The main characteristics of Industry 5.0 production systems are:</p><ul><li dir="ltr"><p dir="ltr">Human-Centric Design: Industry 5.0 places the well-being, creativity, and capabilities of human workers at the heart of technological innovation.</p></li><li dir="ltr"><p dir="ltr">Customization in Production: In the scope of Industry 5.0, the vision of mass customization is realized based on highly personalized products and services that meet the unique demands of consumers.</p></li><li dir="ltr"><p dir="ltr">Sustainable Practices: Industry 5.0 is about manufacturing processes that minimize environmental impact, reduce waste, and promote the recycling of resources.</p></li><li dir="ltr"><p dir="ltr">Cobots (Collaborative Robots): Industry 5.0 relies on co-bots i.e., robots designed to interact and work alongside human colleagues, as opposed to replacing them, which is the case with fully autonomous industrial robots.</p></li><li dir="ltr"><p dir="ltr">Flexibility and Resilience: The production systems of the Industry 5.0 era must adapt swiftly to market changes based on agility that combines the best of machine precision and human intelligence.</p></li></ul><p dir="ltr">Overall, Industry 5.0 extends the digital transformation initiated by Industry 4.0 based on a layer of advanced personalization and environmental stewardship. It is a paradigm shift that recognizes not only the value of efficiency but also the humans’ role in complementing technology with creativity, contextual understanding, and moral judgment.</p><p dir="ltr">To stay ahead in this transformation modern industrial organizations must embrace cutting-edge electronic components and semiconductor products. The latter are among the main building blocks that drive innovation, including for example sensors enabling precision in cobots to chips processing vast amounts of data towards smarter decisions for sustainable products and practices. The components and semiconductors used to support Industry 5.0 advancements are gradually becoming more sophisticated as high-quality and sustainable technologies are required. For instance, semiconductor innovation is driving the efficiency of energy use in production processes, which contributes to the Industry 5.0 sustainability ambition. Moreover, electronics that push the boundaries of what's possible in automation and machine intelligence are foundational for companies that develop advanced personalization and customization services.</p><h2 dir="ltr">Technology Enablers and Integration Challenges </h2><p dir="ltr">Industry 4.0 has been built upon cyber-physical production systems that are powered by Artificial Intelligence (AI), IoT, and advanced robotics. For over a decade, such systems have boosted the automation and optimization of manufacturing processes. For instance, AI systems are instrumental in support predictive maintenance and production scheduling optimization use cases. At the same time, IoT and advanced robots facilitate the convergence of Information Technology (IT) and Operational Technology (OT), which enables digitally controlled applications like digital twins.&nbsp;</p><p dir="ltr">Industry 5.0 builds on the above-listed technologies, yet it also elevates their role to support human centricity and sustainability. As a prominent example, Industry 5.0 leverages "Trusted AI" and "Explainable AI" (XAI) technologies, which integrate ethical principles (e.g., fairness, transparency) into AI systems. Trusted AI and XAI technologies enable AI systems to make decisions that are comprehensible and justifiable to human workers. As another example, state of the art IoT infrastructures evolve in Industry 5.0 to support user-centric digital networks. This enables real-time IoT communications are not only device-centric but also augmented for direct human interaction in ways that enhance machine-to-human collaboration. Moreover, conventional robotics are nowadays integrated with sensory and cognitive technologies to enable cobots and Human-Robot Collaboration (HRC). Cobots work side-by-side with humans towards merging human intuition and empathy with robotics automation capabilities.</p><p dir="ltr">Moreover, Industry 5.0 embraces new technological advancements such as the Digital Product Passport (DPP). A DPP resembles a secure decentralized digital twins’ infrastructure which can track a product's lifecycle journey. It provides detailed data on the origin, components, materials, and assembly process of products, towards boosting supply chain integrity and ecological consciousness.</p><p dir="ltr">Considering these technologies, the implementation and integration of state of the art Industry 5.0 is much more challenging than the integration of systems of earlier generations. The integration challenge lies in the need to blend heterogeneous technologies, while considering the workers’ profile and sustainability parameters. For example, digital twin implementations must be worker centric based on the consideration of workers’ digital profiles. This enables human-centred digital twins that are typically difficult to design and integrate. As another example, the integration of a DPP infrastructure is typically complex as it federates heterogeneous data sources and services from different actors of the manufacturing chain. &nbsp;Overall, the integration of diverse systems in ways that balance automated efficiency and the creative value that human workers provide is one of the main challenges of Industry 5.0.</p><h2 dir="ltr">Industry 5.0 Use Cases</h2><p dir="ltr">Industry 5.0 enables a wide range of use cases that were hardly possible few years ago, including:</p><ul><li dir="ltr"><p dir="ltr">Enhanced Customization and Personalization of Products: Industry 5.0 leverages AI-driven analytics and flexible manufacturing systems to provide a superior degree of product customization, which would traditionally be cost-prohibitive and logistically complex. To this end, machine learning algorithms are used to analyse consumer profiles and preferences towards tailored products at an individual level. Moreover, 3D printing technologies can be integrated with AI to enable just-in-time manufacturing of customized parts in ways that reduce waste and optimize resource use.</p></li><li dir="ltr"><p dir="ltr">Sustainable Manufacturing Use Cases: Industry 5.0 enables the implementation of sustainable manufacturing practices. For instance, DPPs enable transparent tracking of the ecological footprints of products, which is a key for adherence to environmental standards. Furthermore, AI can optimize energy use and automate waste management based on predictive scheduling of machinery maintenance that minimizes downtime and resource depletion. Likewise, AI-enhanced logistics enable eco-friendly supply chain management through optimization of routes and reduction of carbon emissions.</p></li><li dir="ltr"><p dir="ltr">Improved Quality and Innovation through Human Insight and Machine Precision: Industry 5.0 fosters the interplay of human experience and robotic accuracy. For example, in quality control, AI algorithms for rapid and precise anomaly detection are combined with human oversight that can provide a better understanding of varied quality issues that may not be immediately apparent to AI. This symbiosis enhances the product innovation cycle and quality assurance processes, leading in higher production standards and innovative product features.</p></li><li dir="ltr"><p dir="ltr">Anticipating and Meeting the Changing Needs and Expectations of Consumers: Predictive analytics and real-time data processing enable anticipatory models that forecast consumer trends and market demands. AI systems can integrate these insights with dynamic production planning tools to adapt manufacturing processes in near real time. This is a key to fast responsiveness to market fluctuations and consumer demands.</p></li><li dir="ltr"><p dir="ltr">Human-Robot Collaboration: There are several Industry 5.0 applications based on cobots. As a prominent example, in automotive assembly, cobots perform heavy lifting and precision tasks, which reduces ergonomic risk to human workers. At the same time, humans provide critical quality assurance and fine adjustments, which optimizes the assembly process.</p></li></ul><h2 dir="ltr">Best Practices for Industry 5.0 Adoption and Deployment<br><br></h2><p dir="ltr">Industrial organizations wishing to adopt, deploy, and fully leverage Industry 5.0 had better consider the following best practices:</p><ul><li dir="ltr"><p dir="ltr">Integration of Human-Centric Technology Solutions towards a smooth transition: Integrating human-centric technology asks for a structured framework that begins with an identification of the specific needs and capabilities of the human workforce which can be enhanced through technology. Accordingly, there is a need for a comprehensive technological audit that documents the digital maturity of the industrial organization and identifies gaps where human-centric technology can be beneficial. This is a key for designing interfaces and applications that prioritize ease of use, accessibility, sustainability and ergonomic principles. The next step involves the implementation of pilot projects to validate the effectiveness and acceptance of proposed solutions. The latter must be refined iteratively based on stakeholders’ feedback. This requires continuous dialogue between technology designers and end-users to foster innovation and inclusivity.</p></li><li dir="ltr"><p dir="ltr">Strengthening the Human Factor through upskilling and reskilling: Industry 5.0 is hardly possible without a strategic commitment to develop the workforce's skillset to thrive alongside advanced technologies. This involves assessing the skill gaps that may emerge as a consequence of new technology adoption, as well as crafting tailored training programs. It is also essential to promote a culture of lifelong learning and adaptability, which ensures that employees adopt new technologies as an opportunity for growth.</p></li><li dir="ltr"><p dir="ltr">Measuring Economic Performance and Sustainability: Industry 5.0 organizations must adopt a dual-lens approach to performance measurement that encompasses both economic viability and sustainability metrics. This includes incorporating sustainability objectives into the core strategic planning and performance evaluation frameworks. Moreover, it entails the use of advanced data analytics to monitor and optimize resource utilization, energy consumption, and waste generation. Note also that sustainability and economic performance reporting must be transparently to stakeholders in order to foster trust and reinforce commitment to ethical practices.</p></li><li dir="ltr"><p dir="ltr">Human Centricity by Design: Designing systems and processes with a human-centric approach ensures that technological advancements do not detract from the welfare and productivity of the workforce. This entails embedding ergonomic design principles across technological interfaces and work environments to enhance safety and comfort, while prioritizing the development of technologies that augment human abilities and creativity. A good practice is also to engage workers in the design and innovation process towards ensuring that their insights shape the development of technologies and work practices.</p></li><li dir="ltr"><p dir="ltr">Sustainable by Design Production: A 'Sustainable Production by Design' philosophy integrates sustainability considerations into every stage of the product lifecycle, from conception to disposal. Relevant strategies include: (i) Selecting materials and product configurations that lead to eco-friendly products; (ii) Leveraging digital twin technology for optimizing product designs with minimal material waste and energy usage; (iii) Adopting circular economy principles, such as designing for disassembly and recyclability that minimize the environmental footprint; (iv) Employing lifecycle assessment tools to evaluate and mitigate the environmental impact of products and operations.</p></li><li dir="ltr"><p dir="ltr">Keeping up with Future Trends like AI Advancements and Sustainable Technologies: Staying abreast of technological advancements is crucial for maintaining competitiveness and sustainability in Industry 5.0. This requires: (i) Investing in research and development (R&amp;D) and establishing partnerships with academic and industry leaders to tap into emerging technologies; (ii) Adopting a proactive approach to technology scouting to anticipate technological breakthroughs and their implications; (iii) Cultivating a culture of innovation that encourages experimentation and the exploration of novel applications of Industry 5.0 concepts.</p></li></ul><h2 dir="ltr">Conclusion</h2><p dir="ltr">Overall, Industry 5.0 introduces a transformative convergence of advanced digital technologies with human-centric design and sustainability principles. This convergence recalibrates the industrial fabric towards personalization, circularity, and enhanced collaboration. It also asks for the strategic integration of AI, IoT, and cyber-physical systems in ways that augment human expertise and innovation. Industry leaders must embrace these principles towards the dual objective of optimizing economic growth and environmental performance.&nbsp;</p>

Industry 5.0 envisions a future where machines adapt to workers’ needs, integrating seamlessly into human workflows. In this new era, digital manufacturing systems will focus on sustainability and social impact alongside efficiency and cost-effectiveness. 

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