Toshiba Hydro Power (Hangzhou) Co., Ltd (THPC), a joint-venture between Japan’s Toshiba and China’s Power Construction Corporation, is now seeking new technology “3D scanning” to ensure high quality of its manufactured hydropower equipment and provides cutting-edge products to customers worldwide.The company, long been involved in hydropower industry, is committed to developing new technologies and offering advanced products, specially in the design, development and manufacturing of hydropower equipment.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720601913-1.jpg" style="width: 100%px;" class="fr-fic fr-dib">Hydropower is a renewable and clean source of energy that can offer various advantages to the society and the environment. It can reduce dependence on fossil fuels and enhance energy security. Therefore, improving the quality of hydropower equipment can help to maximize the benefits of this renewable energy source.The hydropower industry is undergoing rapid growth, and the large-scale equipment used in this industry requires huge investments and high maintenance costs. It is important for hydropower equipment manufacturers to enhance product reliability from the design to the manufacturing to reduce costs and improve efficiency.&nbsp;Mr. Sato from the leading company Toshiba Hydro Power (Hangzhou) Co., Ltd shared with us how they collaborated with Scantech to leverage 3D scanning to enhance inspection.&nbsp; <h2 id="isPasted">Hydropower Equipment Manufacturer&nbsp;Seek to&nbsp;Improve Its&nbsp;Parts</h2>Hydropower equipment consists of large and complex components that are affected by various factors during production and operation. These factors include vibration, humidity, temperature, acid and alkali corrosion, etc. High-quality components can ensure the performance and lifespan of the equipment, as well as the efficient and stable operation of the hydropower unit. This way, the hydropower equipment manufacturers can optimize their benefits.&nbsp;The manufacturer in this story is seeking to develop more advanced equipment to achieve higher capacity, speed and efficiency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720639107-2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">How a 3D Scanner Helps to Inspect Hydropower Equipment</h2>Traditional measurement methods have some shortcomings such as low efficiency, high personnel requirements, and being time-consuming. Moreover, these methods cannot generate intuitive reports or provide complete measurement data for further analysis. The lack of data means that these methods cannot provide comprehensive guidance for subsequent maintenance and repair. It is because operators and engineers cannot predict or evaluate the operating conditions of the equipment without complete measurement data.&nbsp;High-tech 3D scanning offers more diverse solutions for hydropower equipment manufacturers from product design, production to even maintenance. By using TrackScan-Sharp, the advanced optical 3D laser scanner from Scantech, operators can conduct NDT testings of equipment to ensure the quality of equipment. High quality helps to extend the service life of hydropower systems, reduce losses and improve the efficiency.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720656882-3.jpg" style="width: 100%px;" class="fr-fic fr-dib">Mr. Sato expressed his thoughts on using TrackScan-Sharp, “The TrackScan-Sharp can obtain 3D data of parts quickly with optical tracking, and no targets are needed. I am impressed by its 6-m tracking distance. It is really good when compared to common optical tracking systems. As its working volume is large, operators do not need to move the tracker frequently to scan the whole part.&nbsp;It is lightweight and portable, which can be set up easily on the site. The working conditions in a factory is usually harsh. TrackScan-Sharp’s footprint is small, and it is highly adaptive to harsh environmental conditions. It can be used on site to fulfill tasks.&nbsp;TrackScan-Sharp can meet our needs for quality control and help us deliver high-quality products faster to our customers.”&nbsp;&nbsp;<h2>Advantages&nbsp;of Optical 3D Scanning System&nbsp;</h2>Free&nbsp;and wide-range measurements&nbsp;The optical tracking system features a 25-MP industrial camera and a 49-m³ tracking volume, delivering high-resolution and wide-range measurements. It can capture data from long distances in a wide range without the need to move the tracker frequently. This makes it ideal for measuring large parts such as: large hydraulic turbine blades, runner of pumped storage unit, generator wire rods, and more.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720689806-4.jpg" style="width: 100%px;" class="fr-fic fr-dib">High-precision measurements for various scenarios&nbsp;The system combines advanced hardware and robust algorithm to deliver high-precision measurements for various tracking ranges: 0.049-mm volumetric accuracy for 10.4 m³ small-range tracking, 0.067-mm volumetric accuracy for 28.6m³ medium-range tracking, and 0.089-mm volumetric accuracy for 49.0m³ large-range tracking. It can easily capture the fine details of various medium and large components of hydropower equipment.&nbsp;Advanced and efficient 3D scanning&nbsp;TrackScan-Sharp can scan the entire part without requiring any targets, saving time for sticking and removing them. It also allows scanning multiple part simultaneously, enhancing the measurement efficiency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720704567-5.jpg" style="width: 100%px;" class="fr-fic fr-dib">Real-time&nbsp;inspection&nbsp;reportsTrackScan-Sharp features powerful 3D software that can capture, analyze and store data in real time. It can scan the components of hydropower equipment and process the point clouds to generate color maps. It can also store the 3D data in the database for further archiving. TrackScan-Sharp offers precise assessment of the part conditions to deliver high-quality products.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1740720750676-6.jpg" style="width: 100%px;" class="fr-fic fr-dib">SCANTECH’s 3D scanners and 3D solutions are widely applied in the field of energy engineering, such as inspection of hydraulic turbine guide vane, turbine casting, oil and gas pipeline, wind power flange, etc. It helps many large-scale energy enterprises to achieve digital transformation and upgrading.

This video shows how Toshiba Hydro Power (Hangzhou) Co., Ltd, a leading hydropower equipment manufacturer, improves inspection workflows with SCANTECH’s optical 3D measurement system TrackScan-Sharp. Learn more.

SCANTECH 3D Scanner Helps Toshiba Hydro Power to Inspect

<h2 data-start="287" data-end="352" id="isPasted">Understand the Future of Component Traceability with Our Latest Whitepaper</h2>We are pleased to have partnered with Rochester Electronics to launch the white paper:&nbsp;Beyond Date Codes: The Importance of Traceability in Semiconductor Reliability and Supply Chain Resilience.The semiconductor industry drives advancements across critical sectors such as aerospace, medical devices, automotive, and industrial automation. But despite semiconductors' transformative impact, the industry's logistics pose significant challenges, particularly in maintaining the continuity and reliability of supply chains. Traditional methods, notably the "two-year date code," have increasingly failed to meet the modern demands for traceability and quality assurance.Over the last five years, global supply chain pressures, "just-in-time" manufacturing, and supply issues seen during the COVID-19 pandemic have further underscored the limitations of current practices. This period led to a pivotal rethinking of traceability standards as industries found themselves relying on older semiconductor components, challenging the rigid enforcement of date codes without compromising component quality. This whitepaper delves into the evolving landscape of semiconductor traceability, examining the shift in standards and practices that promise enhanced supply chain resilience. It highlights how Rochester Electronics is at the forefront of these changes, ensuring component quality, authenticity, and reliability.<h2 data-start="545" data-end="569" id="isPasted">Whitepaper highlights:</h2><ul data-start="571" data-end="1455"><li data-start="571" data-end="733">The Evolution of Traceability Standards: Understand how past practices shape current expectations and the shift towards more robust traceability mechanisms.</li><li data-start="734" data-end="887">Debunking Myths: Challenge the outdated two-year date code standard and learn about the empirical evidence supporting extended storage reliability.</li><li data-start="888" data-end="1077">Modern Traceability Techniques: Explore cutting-edge methods like 3D barcoding, RFID tagging, and IoT tracking systems that enhance component traceability and supply chain resilience.</li><li data-start="1078" data-end="1258">Impact of Traceability on Industry Sectors: Gain insights into how improved traceability affects sectors like aerospace, medical devices, automotive, and industrial controls.</li><li data-start="1259" data-end="1455">Rochester Electronics' Vision and Practices: Learn from a leader in traceability about best practices in component storage, certification, and maintaining compliance with industry standards.</li></ul>Download the whitepaper below to stay up to date on this critical topic.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQwNDczNjM4MDQwLXJvY2hlc3RlciBtb2NrIHVwMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><iframe width="540" height="375" src="https://c8056756.sibforms.com/serve/MUIFAL_uGBhxJhP25H6Vwi8zVZC4Gcnj7qX6AyfIkSY9ebg5trMGZsG1EuV0wK-G4b12imjo4ykfFHgVym6m_2j3yrwk1ploh7cME5kC3qwdAGI10gTPQkqJPW-9jAad0x0T9DYihyCAxZpxHQTYrE0FDgo-_xUkoyVhlM_ozP_zxWr_PxsC8ImpBGa_wzmSGPDOzJfci3ZsuJmd" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block;margin-left: auto;margin-right: auto;max-width: 100%;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;</iframe><hr><h2>Whitepaper Foreword</h2>The semiconductor industry has long been at the forefront of the world’s greatest technological innovations. Fields as diverse as aerospace, medical devices, automotive, and industrial automation have all been profoundly impacted by advances in semiconductor technology. But, while the semiconductors themselves have been impactful, industry logistics have been a notable challenge.These fields, often demanding component lifecycles extending 25 years or more, depend heavily on supply chain continuity and reliability. At the highest level, reliability lies in tracing a component's origins and ensuring integrity throughout its lifecycle. However, reliance on traditional metrics like the "two-year date code" has proven increasingly insufficient in addressing the traceability and quality demands of modern supply chains.Today, the pressures of globalized supply chains and “just-in-time” manufacturing exacerbate challenges associated with date codes. A two-year date code, when enforced rigidly, can lead to unnecessary obsolescence, reduced inventory flexibility, and increased costs for both component suppliers and end users. The semiconductor shortages during the COVID-19 pandemic highlighted the fragility of these practices. During this period, many industries disregarded the two-year standard and utilized older components without reporting quality issues. This experience has since prompted the industry to reevaluate and modernize traceability practices in light of current technological capabilities.This whitepaper explores the topic of component traceability in the context of the evolving semiconductor landscape. It examines the history and evolution of traceability standards, debunks the myths surrounding date codes, and provides insights into the power of traceability in unlocking supply chain resilience. Finally, it discusses how Rochester Electronics, with its decades of experience as an authorized distributor and traceability leader, is helping the industry embrace these changes while ensuring quality, authenticity, and long-term reliability.<h3 dir="ltr" id="isPasted">You can learn more about component traceability by diving into our related article series.&nbsp;</h3><table style="width: 100%;"><tbody><tr><td style="width: 50.0000%;">Evolving Standards in Semiconductor Traceability&nbsp;</td><td style="width: 50.0000%;">Launching soon</td></tr><tr><td style="width: 50.0000%;">Long-Term Storage and Dispelling Myths About Date Codes</td><td style="width: 50.0000%;">Launching soon</td></tr><tr><td style="width: 50.0000%;">Traceability for Supply Chain Resilience</td><td style="width: 50.0000%;">Launching soon</td></tr><tr><td style="width: 50.0000%;">Component Storage, Certification, and Maintaining Traceability</td><td style="width: 50.0000%;">Launching soon</td></tr><tr><td style="width: 50.0000%;">Industry Impact of Extended Date Codes</td><td style="width: 50.0000%;">Launching soon</td></tr><tr><td style="width: 50.0000%;">The Future of Semiconductor Traceability</td><td style="width: 50.0000%;">Launching soon</td></tr></tbody></table>

The Importance of Traceability in Semiconductor Reliability and Supply Chain Resilience

Beyond Date Codes

For any company in the business of industrial manufacturing and custom part procurement, protecting intellectual property (IP) is non-negotiable. The nature of the businesses requires routinely sharing proprietary designs and engineering data with suppliers, which inherently exposes them to risks such as data leaks, misuse, or inadequate safeguards.&nbsp;Fortunately, FACTUREE offers a novel approach to procurement that mitigates these risks and keeps your IP secure. By leveraging anonymization, AI-driven supplier selection, and internationally recognized security standards, FACTUREE helps unlock a more secure and efficient procurement process.<h2 dir="ltr">The Risks of Sharing Intellectual Property in Procurement</h2>Traditional procurement processes inherently involve the dissemination of sensitive design files and technical specifications to multiple potential suppliers. This method presents three primary risks<ul><li dir="ltr">Exposure of Sensitive Data: The conventional approach requires businesses to send proprietary information to multiple suppliers, often through unsecured communication channels. Once the data leaves the organization’s controlled environment, it becomes susceptible to interception, unauthorized access, or mismanagement.</li><li dir="ltr">Potential Misuse or Leaks: Even with non-disclosure agreements (NDAs) in place, some suppliers may not enforce rigorous internal security protocols. Therefore, there is potential for inadvertent or deliberate leaks of sensitive designs. The risks are even further amplified when dealing with international suppliers that operate under different regulatory frameworks. For example, <a href="https://www.npr.org/2019/01/29/689663720/a-robot-named-tappy-huawei-conspired-to-steal-t-mobile-s-trade-secrets-says-doj">in 2014, T-Mobile US sued Huawei,</a> alleging that Huawei's employees stole technology related to T-Mobile's smartphone testing robot, "Tappy." The lawsuit claimed that Huawei's staff illicitly photographed and copied proprietary information despite having signed confidentiality agreements. Although Huawei acknowledged some misconduct and terminated the employees involved, NDAs alone were not enough to prevent deliberate intellectual property theft.</li><li dir="ltr">Lack of Adequate IP Protection:&nbsp;Many procurement models lack the necessary measures to ensure that proprietary information is adequately safeguarded throughout the entire supply chain. Without centralized security policies, businesses face inconsistent levels of protection depending on individual suppliers' security practices.</li></ul><h2 dir="ltr">FACTUREE’s Comprehensive Data Security Measures</h2>FACTUREE addresses these concerns through a multi-layered security framework designed to protect intellectual property&nbsp;[1].One of the central tenets of FACTUREE’s approach is an advanced anonymization process that prevents manufacturers from tracing the origin of requests. By decoupling customer identities from project specifications, FACTUREE guarantees that suppliers receive only the necessary data required for manufacturing without revealing sensitive business relationships. This means that manufacturers cannot draw any conclusions about the customer placing the order. They do not know for whom a part is being produced, which significantly enhances data security. Enquiring through FACTUREE is, therefore, more secure than reaching out to a manufacturer directly, as it eliminates the risk of exposing business connections or proprietary information.And, in addition to anonymizing customer data, FACTUREE serves as the sole contractual partner throughout the procurement process. This means that both customers and suppliers communicate exclusively with FACTUREE so that all interactions are centralized for decreased risk. Simply put, the manufacturing partners therefore do not know for whom a part is being manufactured, which significantly increases the security of customer data. This level of anonymity and security cannot be attained by an individual approaching manufacturers for quotes.&nbsp;Moreover, FACTUREE enforces stringent NDAs with both its customers and manufacturing partners to establish legally binding commitments to protect shared data. As part of this, FACTUREE’s approach seeks to be more judicious about the sharing of data by minimizing contact with only the most relevant supplier. With fewer stakeholders involved and robust legal protections governing these interactions, &nbsp;FACTUREE’s approach enforces strict confidentiality throughout the procurement process.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzQxMDcyODcwNjg4LXNodXR0ZXJzdG9ja18xOTkxNDkxOTE5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><h3 dir="ltr">AI-Driven Supplier Selection: A Key Differentiator</h3>A real differentiator for FACTUREE’s digital procurement model is its AI-driven supplier selection, which fundamentally transforms the efficiency, security, and precision of the process.Whereas traditional mass-inquiry methods involve sending requests to a broad supplier base, FACTUREE employs AI-driven analytics to identify the most suitable manufacturing partners for each project. FACTUREE’s AI evaluates over 600,000 data points per manufacturer, looking at metrics such as pricing, material compatibility, geometry, and finishing requirements to identify the best possible manufacturing partners for each request for proposal (RFP). This result is that only suppliers who meet the highest quality and cost-efficiency standards are considered.Beyond just narrowing down suppliers, FACTUREE’s AI proactively optimizes for security and confidentiality. Instead of exposing sensitive design data to a broad network, FACTUREE’s AI carefully selects a small, vetted subset of manufacturers—typically no more than three—who best fit the specific technical and commercial requirements. By minimizing the number of stakeholders while maximizing their quality and reliability, FACTUREE significantly reduces the risk of intellectual property leaks and ensures compliance with data security protocols.Ultimately, FACTUREE’s AI-driven methodology reshapes procurement by eliminating the uncertainties of traditional approaches. It ensures that every supplier selected is among the best of the best and aligns perfectly with the project’s requirements while maintaining a highly secure and cost-effective procurement environment.<h3 dir="ltr">Building Trust through International Standards</h3>To further inspire customer confidence, FACTUREE is working toward adherence to internationally recognized information protection standards. For example, the company is currently undergoing the certification process for ISO 27001, which is widely acknowledged as the global benchmark for information security management systems. Specifically, ISO 27001 compliance will ensure that FACTUREE implements systematic protocols to protect intellectual property, covering aspects such as encryption, access control, and risk assessment [2]. &nbsp;<h2 dir="ltr">Advantages of FACTUREE’s Digital Procurement Model</h2>Beyond its leading security measures, FACTUREE’s digital procurement model delivers substantial operational benefits for business sourcing custom-manufactured parts. By integrating AI-powered analytics, secure data handling, and streamlined supplier selection, FACTUREE allows businesses to optimize their procurement strategies while mitigating risks associated with IP exposure.&nbsp;However, digitalization does not replace personalized service. That’s why FACTUREE assigns each customer a dedicated contact person who ensures smooth project execution with expert support at every stage.Benefits of FACTUREE’s model include<ul><li dir="ltr">Faster Procurement Cycles: Digital procurement eliminates inefficiencies associated with traditional sourcing methods by unlocking rapid supplier identification and order fulfillment. The accelerated process reduces lead times and speeds up overall project timelines.</li><li dir="ltr">Reduced Complexity: FACTUREE also serves as a single contractual partner and point of contact to eliminate inefficiencies in traditional sourcing. Customers benefit from reduced complexity, as FACTUREE handles everything from quote requests and order processing to delivery, assembly, and surface treatment. Unlike fully automated platforms, FACTUREE guarantees that specialists oversee each order to meet customers’ technical requirements.</li><li dir="ltr">Cost Efficiency: By centralizing procurement activities through a secure digital platform, FACTUREE reduces operational costs related to supplier management, negotiation, and compliance monitoring. The AI-driven selection process further enhances cost savings by confirming competitive pricing and high-quality supplier matches.</li><li dir="ltr">Resilience Against Supply Chain Risks: FACTUREE’s controlled approach to supplier selection minimizes disruptions by only engaging with vetted and reliable partners. Customers can achieve noticeable gains in supply chain resilience and reduce the likelihood of delays or security breaches stemming from unvetted suppliers. Even if one supplier fails, the extensive network of other suppliers ensures continued operation and makes failure virtually impossible in practice. &nbsp;</li></ul><h2 dir="ltr">Conclusion</h2>In a business world where intellectual property protection is non-negotiable for maintaining competitive advantage, businesses must adopt smarter procurement strategies that prioritize data security. <a href="https://www.facturee.de/en/">FACTUREE’s digital procurement model&nbsp;</a>provides a robust, efficient, and secure alternative to traditional sourcing methods by leveraging anonymization, AI-driven supplier selection, and ISO 27001 certification.By utilizing FACTUREE’s cutting-edge approach, companies can confidently engage in custom part procurement without compromising sensitive designs. As the digital procurement landscape continues to evolve, businesses that prioritize security, efficiency, and strategic supplier management will be best positioned for enduring success.<h1 dir="ltr">References</h1><ol><li dir="ltr"><a href="https://www.facturee.de/en/how-facturee-ensures-data-protection-in-digital-procurement/">https://www.facturee.de/en/how-facturee-ensures-data-protection-in-digital-procurement/</a></li><li dir="ltr"><a href="https://www.iso.org/standard/27001">https://www.iso.org/standard/27001</a></li><li dir="ltr"><a href="https://www.facturee.de/en/agenda/" target="_blank" data-saferedirecturl="https://www.google.com/url?q=https://www.facturee.de/en/agenda/&source=gmail&ust=1741254608729000&usg=AOvVaw3l2MheK7YHEdtXgH3hHWBN" id="isPasted">https://www.facturee.de/en/agenda/</a> </li></ol>

FACTUREE’s novel approach to procurement helps safeguard intellectual property.


Protecting Intellectual Property: How Smart Digital Procurement Keeps Your Data Secure

STEP files are a widely used 3D model format in engineering and manufacturing, designed for seamless data exchange between different CAD software. As an ISO standard (ISO 10303-21), they provide a reliable way to store and share complex 3D models with high precision. Unlike mesh-based formats, STEP files retain full parametric and geometric data, making them essential for industries that require accuracy and interoperability.This article explores the technical architecture of STEP files, explaining how they structure and store 3D model data. Understanding their internal composition helps engineers and designers maximize their effectiveness in CAD systems, CNC machining, and simulation workflows. Additionally, we will examine the various applications where STEP files play a critical role, from product design to reverse engineering.Finally, we will compare STEP files to other popular 3D formats like STL, OBJ, and 3MF, highlighting their advantages in precision, modifiability, and long-term storage. While alternative formats serve specific purposes, STEP files remain the gold standard for professional-grade 3D modeling due to their comprehensive data retention and cross-platform compatibility.<h2 dir="ltr">What Is a STEP File?</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1738673434912-computer-aided-design-software.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="step">STEP files enable the sharing of complex 3D modelsThe Standard for the Exchange of Product Model Data (STEP) file format, defined under the ISO 10303 standard, is a comprehensive data exchange protocol designed to facilitate interoperability between various CAD, CAM, and CAE systems.[1] Developed to address the limitations of proprietary file formats, STEP (or STP) enables the seamless sharing of complex 3D models, product structures, and metadata across different engineering platforms.STEP files play a critical role in modern engineering workflows by providing a neutral, standardized format that ensures data integrity and consistency. Industries such as aerospace, automotive, and manufacturing rely on STEP for efficient collaboration, long-term data preservation, and interoperability between software tools.[2] Unlike other CAD file exchange formats, such as IGES and STL, STEP supports a rich set of data types, including parametric geometry, assembly structures, and product lifecycle information.<h2 dir="ltr">Technical Architecture of STEP Files</h2>A STEP file is a structured text-based file that stores 3D model data in a way that different CAD software can understand. It follows the ISO 10303 standard and is typically formatted as plain text with a series of commands that describe the geometry, relationships, and properties of a 3D object. STEP file names have the file extension&nbsp;.step&nbsp;or&nbsp;.stp.A STEP file consists of several sections, but the most important is the&nbsp;DATA&nbsp;section, which contains the actual description of the 3D object. This section represents the model as a collection of geometric shapes, such as points, lines, curves, and surfaces. These shapes are defined mathematically and are connected to form solid parts. The file uses a structured format called EXPRESS, which assigns unique numerical identifiers to each element in the model. For example, a simple cube might be defined by listing its corner points, the edges that connect them, and the surfaces that form its faces.Each element in the DATA section follows a standardized syntax. For instance, a line in the file might look like this:<pre dir="ltr">#10 = CARTESIAN_POINT('', (10.0, 20.0, 30.0));</pre>This means that a point is defined at coordinates (10, 20, 30). More complex shapes, like cylinders or curved surfaces, are built by combining multiple geometric definitions. By structuring data this way, a STEP file ensures that a 3D model can be recreated precisely in any compatible CAD software. Unlike STL files, which only store simple triangle meshes, STEP files retain full mathematical descriptions, allowing engineers to modify and analyze designs with high accuracy.<h2 dir="ltr">Uses for STEP Files</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1738673447009-cnc_milling_machine.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="cnc">CNC machines make use of STEP files for toolpath generationSTEP files are widely used in engineering, manufacturing, and product design for 3D model exchange. Their neutral format makes them compatible across CAD (Computer-Aided Design) software, facilitating collaboration between teams using different platforms.<ul><li dir="ltr">Product Design &amp; Development: STEP files allow seamless sharing of 3D models between designers, engineers, and manufacturers. This interoperability ensures accurate communication, reducing errors in prototyping and production. &nbsp;</li><li dir="ltr">Manufacturing: CNC (Computer Numerical Control) machines and CAM (Computer-Aided Manufacturing) software frequently use STEP files to generate tool paths for milling, cutting, and machining metal or plastic parts. &nbsp;</li><li dir="ltr">Simulation &amp; Analysis: Engineers use STEP files in FEA (Finite Element Analysis) and CFD (Computational Fluid Dynamics) simulations to test mechanical properties, thermal performance, and fluid dynamics before manufacturing. &nbsp;</li><li dir="ltr">Reverse Engineering: Scanned 3D data can be converted into STEP files to recreate CAD models for modifications, documentation, or reproducing discontinued parts. &nbsp;</li><li dir="ltr">Collaboration &amp; Archiving: STEP files serve as a long-term storage format for 3D models, ensuring compatibility across software updates and preserving designs for future reference. &nbsp;</li></ul>Because of their precision and compatibility, STEP files remain a critical tool in modern engineering, manufacturing, and product lifecycle management.Recommended reading: <a href="https://www.wevolver.com/article/what-is-cnc-turning" target="_blank">What is CNC Turning? Process, Advantages, Applications</a><h2 dir="ltr">Types of Software That Use STEP Files</h2>STEP files are widely used across various software applications in engineering, manufacturing, and design. CAD (Computer-Aided Design) software like SolidWorks, AutoCAD, CATIA, Siemens NX, and PTC Creo utilize STEP files for precise 3D modeling and design collaboration. These programs allow engineers to modify and analyze STEP models with high accuracy. &nbsp;CAM (Computer-Aided Manufacturing) software, such as Mastercam and Fusion 360, also supports STEP files to generate toolpaths for CNC machining. This ensures that 3D models can be efficiently converted into machine instructions for manufacturing. &nbsp;Additionally, simulation software like ANSYS and Abaqus uses STEP files for Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD), enabling engineers to test mechanical properties and fluid behavior before production. &nbsp;Lastly, 3D printing and visualization software, including Cura and Autodesk Meshmixer, can import STEP files, though they often require conversion to STL or other mesh formats for slicing and printing.<h2 dir="ltr">STEP Versus Other Formats</h2><div dir="ltr" align="left"><table><tbody><tr><td>Format</td><td>Used Since</td><td>Advantages</td><td>Disadvantages</td></tr><tr><td>STEP</td><td>1994</td><td>Retains full parametric and geometric data, high precision, widely used in CAD and manufacturing, excellent interoperability</td><td>Large file size, complex structure, not optimized for visualization or basic 3D printing</td></tr><tr><td>STL</td><td>1988</td><td>Simple and widely supported, lightweight, ideal for 3D printing</td><td>Only stores mesh data, lacks color, textures, and metadata, not easily editable</td></tr><tr><td>OBJ</td><td>1990</td><td>Supports color and texture mapping, good for visualization and animation, widely used in graphics</td><td>Large file size, lacks parametric data, not ideal for engineering applications</td></tr><tr><td>3MF</td><td>2015</td><td>Supports color, textures, and metadata, more efficient than STL, optimized for advanced 3D printing</td><td>Less widely adopted than STL and STEP, limited support in some CAD programs</td></tr></tbody></table></div>STEP files, STL, OBJ, and 3MF are commonly used 3D model formats, each with distinct advantages and limitations depending on the application.&nbsp;STEP files are widely used in engineering and manufacturing due to their ability to store precise geometric and parametric data. Unlike mesh-based file types, STEP files retain solid modeling information, making them ideal for 3D design and CAD applications, CNC machining, and high-precision engineering. Their primary disadvantage is their larger file size and complexity, which can make them harder to process in software primarily designed for visualization or 3D printing. &nbsp;STL (Stereolithography) files are the most common format in 3D printing. They represent 3D surfaces as a mesh of triangles, making them lightweight and widely compatible with slicing software. However, STL files lack color, texture, and metadata, and they do not support parametric features, making modifications difficult. Their reliance on approximated surfaces can also introduce precision errors in highly detailed models. &nbsp;OBJ files offer improvements over STL by supporting color and texture mapping, making them more suitable for visual applications such as game design and CGI. However, like STL, they are still mesh-based and lack parametric data, which limits their use in precision engineering and manufacturing. OBJ files also tend to be larger than STL due to their ability to store more detailed surface information, making them less efficient for simple geometric designs. &nbsp;3MF (3D Manufacturing Format) was developed as a modern alternative to STL, addressing many of its shortcomings. It supports color, textures, and metadata while maintaining a more efficient file structure.[3] This makes it particularly useful for multi-material and professional 3D printing applications. However, 3MF is not as universally supported as STL and STEP, limiting its adoption in some industries.Recommended reading: <a href="https://www.wevolver.com/article/3d-printer-file-formats-stl-obj-3mf" target="_blank">Understanding 3D Printer File Formats (STL, OBJ, 3MF, and more)</a><h2 dir="ltr">Conclusion</h2>STEP files are essential in engineering and manufacturing, offering precise 3D model data that retains full parametric and geometric information. Unlike STL and OBJ, which are mesh-based, STEP files provide accuracy and interoperability, making them ideal for CAD modeling and CNC machining. &nbsp;The structured DATA section of a STEP file ensures that 3D objects are defined mathematically, preserving their integrity across different software platforms. This allows for seamless modifications and high-fidelity data exchange, reducing errors in the design and production process. &nbsp;While other formats serve specific purposes, STEP files stand out for their versatility and precision. As industries demand better data exchange and reliability, STEP files remain the preferred choice for accuracy and long-term compatibility in digital modeling.<h2 dir="ltr">Frequently Asked Questions</h2>How can compatibility issues be resolved between different CAD systems?Compatibility issues often arise due to differences in how CAD systems interpret STEP data. Using standardized application protocols (e.g., AP203, AP214, AP242) and performing validation checks can help ensure smooth data transfer between platforms.What are the best strategies for optimizing STEP file performance?Performance optimization strategies include entity deduplication, binary encoding, and model simplification. Additionally, using compression techniques such as Gzip can reduce file sizes while preserving data integrity.Are there security concerns when working with STEP files?Security considerations include protecting intellectual property and ensuring that STEP files do not contain malicious code. Implementing encryption and access controls can help safeguard sensitive design data.What tools are available for troubleshooting STEP file errors?Several tools can assist in troubleshooting STEP file errors, including STEP File Analyzer, Open CASCADE utilities, and CAD software validators. These tools help identify syntax errors, missing references, and inconsistencies in geometric representations.<h2 dir="ltr">References</h2>[1] Venkiteswaran A, Hejazi SM, Biswas D, Shah JJ, Davidson JK. <a href="https://asmedigitalcollection.asme.org/IDETC-CIE/proceedings-abstract/IDETC-CIE2016/50114/254972" target="_blank">Semantic interoperability of GD&amp;T data through ISO 10303 STEP AP242</a>. InInternational Design Engineering Technical Conferences and Computers and Information in Engineering Conference 2016 Aug 21 (Vol. 50114, p. V02BT03A018). American Society of Mechanical Engineers.[2] Planning S. <a href="https://www.nist.gov/el/economic-impact-studies" target="_blank">Economic Impact Assessment of the International Standard for the Exchange of Product Model Data (STEP) in Transportation Equipment Industries</a>. Economic Analysis. 2002 Dec.[3] Kumar A, Kumar P, Mittal RK, Singh H. <a href="https://www.sciencedirect.com/science/article/abs/pii/B9780323918343000065" target="_blank">Printing file formats for additive manufacturing technologies</a>. Advances in Additive Manufacturing. 2023 Jan 1:87-102.

This article serves as an exploration of the Standard for Exchange of Product Model Data (STEP) file format, examining its implementation in modern CAD systems.

The STEP File Format: A Technical Guide

Accurately forecasting procurement costs is essential for maintaining efficiency and competitiveness in manufacturing. Historically, cost estimation methods like “Should Costing” have been widely adopted across industries to predict the expenses associated with production. However, in today’s more dynamic market where custom parts are becoming increasingly important, the limitations of “Should Costing” are being exposed. This article explores why “Should Costing” falls short and how <a href="https://www.facturee.de/">FACTUREE’s AI-driven costing approach&nbsp;</a>offers a powerful new alternative. &nbsp; &nbsp;<table style="width: 100%;"><tbody><tr><td style="width: 6.7401%;">ℹ️</td><td style="width: 93.1396%;">Did you know that should costing has its roots in the U.S. Department of Defense? It was developed to help procurement officers determine fair and reasonable pricing for military equipment and services. Today, this practice has been adopted by various industries to optimize costs and enhance supplier negotiations.</td></tr></tbody></table><h2 dir="ltr" id="isPasted">Understanding “Should Costing”</h2>“Should Costing” is a cost analysis methodology aimed at determining the “ideal” cost of manufacturing a product [1]. Specifically, it evaluates costs based on theoretical calculations of material expenses, labor requirements, and production overhead. The method assumes that by understanding these factors, procurement teams can negotiate better prices with suppliers or identify cost-saving opportunities.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM3NzMzMzgxMjg1LTI1MDEyM19XZXZvbHZlciAxLTAyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The 'Should Costing' methodology. While “Should Costing” provides a structured framework for estimating costs, it relies heavily on assumptions, including static labor costs, standard material prices, and predictable production capabilities. For off-the-shelf components, where parameters are consistent, “Should Costing” can be moderately effective. However, custom parts—which are designed for specific applications and often involve unique geometries, materials, and processes—render this methodology unreliable.<h3 dir="ltr" id="isPasted">Challenges in Applying “Should Costing” to Custom Parts</h3>Custom parts introduce a level of complexity that “Should Costing” cannot effectively address. This complexity arises from factors such as:<ol><li dir="ltr">Unique Design Requirements: Custom parts often feature non-standard geometries and design specifications that deviate from typical manufacturing norms. These features may require specialized tools, additional production steps, or unique materials. </li><li dir="ltr">Material Variability: Raw material costs can fluctuate significantly based on market conditions, supplier availability, and required specifications (e.g., purity, strength, or thermal properties). “Should Costing” struggles to account for such variability. </li><li dir="ltr">Process Complexity: Manufacturing custom parts may involve niche techniques like advanced CNC machining, additive manufacturing, or surface treatments. These processes introduce costs that are difficult to predict using “Should Costing” assumptions. </li><li dir="ltr">Supplier Capabilities: Supplier-specific factors such as equipment capabilities, production schedules, and compliance with industry standards play a significant role in determining costs. “Should Costing” often overlooks these nuances.</li></ol>Ultimately, by relying on idealized cost projections, “Should Costing” can lead to inaccurate estimates. This can cause procurement teams to negotiate based on unrealistic expectations or select suppliers ill-suited to meet the actual production requirements. The consequences include higher-than-expected product costs, delays in delivery, and compromised product quality.<h2 dir="ltr" id="isPasted">FACTUREE’s Approach: Best Costing (Powered by AI)</h2>Recognizing the shortcomings of traditional costing models, FACTUREE developed a “Best Costing” approach—a predictive, data-driven methodology designed to address the unique challenges of custom part procurement. At the heart of this model lies artificial intelligence (AI) and a robust database of supplier information to enable precise and market-aligned cost forecasts.FACTUREE’s AI analyzes a wide range of parameters, including part geometry, material properties, supplier production capacities, logistics and delivery timelines, and compliance and auditing requirements. To this end, the model leverages over 600,000 data points per supplier, covering factors like pricing trends, manufacturing capabilities, and historical performance.&nbsp;With such comprehensive data analysis, FACTUREE’s approach ensures that predictions are grounded in actual market dynamics rather than speculative assumptions. And, with an accuracy rate exceeding 90 percent, FACTUREE’s AI can tackle even the most complex interactions between design, materials, and manufacturing processes.&nbsp;Importantly, custom part designs are processed anonymously to safeguard intellectual property and minimize the need to share sensitive information with multiple suppliers. A key benefit of the data-driven approach is that it not only streamlines the selection process but also enhances security by limiting the number of potential manufacturing partners that need to be contacted, thereby minimizing exposure and risk<h3 dir="ltr">Advantages of the “Best Costing” Approach</h3>The benefits of FACTUREE’s “Best Costing” approach extend beyond accurate pricing. Major advantages include<ul><li dir="ltr">Cost Savings: On average, FACTUREE can generate savings of 37% in procurement and overhead costs.</li><li dir="ltr">Optimized Supplier Selection: By matching parts to suppliers with the right capabilities, the approach enables efficient and cost-effective production.</li><li dir="ltr">Reduced Time-to-Market: Automated processes and precise cost forecasts streamline decision-making to accelerate the procurement cycle.</li><li dir="ltr">Supply Chain Resilience: The model’s data-driven insights enable manufacturers to respond flexibly to market changes and mitigate supply chain risks.</li></ul><a href="https://www.facturee.de/en/inquiry/" class="button-main-action">Get started with Facturee here.</a><h2 dir="ltr" id="isPasted">Digitalization in Procurement</h2>FACTUREE integrates its methodology into a centralized digital procurement platform, which digitizes and automates key processes like supplier selection, manufacturing coordination, and post-production services. The platform simplifies procurement by handling all aspects of supplier engagement, from initial consultations to final delivery, effectively eliminating the need for buyers to manage multiple vendors.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM3NzMzODg3MDQ0LXNodXR0ZXJzdG9ja18xNzI4NTY3MDczLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">As a result of the platform, customers achieve real-time visibility into production timelines and enhanced process transparency, attributes directly facilitated by a designated liaison who is explicitly available to each customer for technical support and queries.&nbsp;The platform also accommodates a breadth of manufacturing methods, including CNC machining, sheet metal processing, 3D printing, casting, and surface finishing, making it versatile enough for diverse custom part requirements. <a href="https://www.facturee.de/en/services/">Read about the full list of services here</a>.&nbsp;FACTUREE’s procurement model provides substantial advantages in managing supply chains efficiently. Through predictive analytics, manufacturers can swiftly adapt to changes in demand or material availability. The platform mitigates reliance on individual vendors via its extensive supplier network, thus maintaining production continuity. Centralized data and communication tools streamline coordination between stakeholders, enhancing operational efficiency. Importantly, FACTUREE acts as the sole intermediary: customers and manufacturers communicate only with FACTUREE, not each other. They manage the entire process, significantly reducing stress and complexity for their clients. As the exclusive contractual partner, they coordinate all aspects, including quality control. When a customer registers FACTUREE in their system, they gain access to a network of over 2000 potential partners, simplifying their procurement process through a single point of contact<h2 dir="ltr" id="isPasted">The Future of Procurement</h2>Traditional costing methods like “Should Costing” are ill-suited to the complexities of custom part procurement. Their reliance on static assumptions and theoretical calculations exposes manufacturers to financial and operational risks. FACTUREE’s AI-driven approach provides a robust alternative that leverages real-world data to deliver accurate pricing, cost savings, and streamlined operations.By adopting FACTUREE’s novel solutions, manufacturers can navigate the challenges of modern procurement with confidence to achieve greater efficiency and resilience. &nbsp;With <a href="https://www.facturee.de/en/">FACTUREE</a>, the future of procurement is not just smarter—it’s simpler, safer, and significantly more effective.<h2 dir="ltr">References</h2>[1] <a href="https://www.facturee.de/en/facturee-shows-should-costing-in-procurement-is-not-cost-effective/#:~:text=With%20%22Should%20Costing%2C%22%20the,frequently%20complex%20and%20individually%20produced">https://www.facturee.de/en/facturee-shows-should-costing-in-procurement-is-not-cost-effective/</a>[2]&nbsp;<a href="https://www.facturee.de/en/agenda/" target="_blank" data-saferedirecturl="https://www.google.com/url?q=https://www.facturee.de/en/agenda/&source=gmail&ust=1741255027168000&usg=AOvVaw1VfJCzK9KpRMEoiLdGwOfv" id="isPasted">https://www.facturee.de/en/agenda/</a>&nbsp;

FACTUREE's innovative costing methods result in an average reduction of procurement expenses by 37%. Learn more about how to streamline your custom manufacturing processes with their solutions.

'Should Costing' and Why It Doesn't Work for Custom Parts

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;<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;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;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;<h3 id="isPasted">Comparing Plastics for Medical Parts&nbsp;</h3>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;<h5 id="isPasted">PC&nbsp;</h5>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;<h5 id="isPasted">UHMW-PE&nbsp;</h5>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;<h5 id="isPasted">PEI&nbsp;</h5>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;<h5 id="isPasted">PSU&nbsp;</h5>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;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519080624-1734519080624.png" class="fr-fic fr-dib" style="width: 806px;">This medical component from IDEXX Laboratories, Inc. is part of an instrument that veterinarians use to test blood and urine.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519116565-1734519116565.png" style="width: 808px;" class="fr-fic fr-dib">Moluded part manufactured with medical-grade liquid silicone rubber.<h5 id="isPasted">PEEK&nbsp;</h5>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;<h5 id="isPasted">Silicone&nbsp;</h5>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;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1734519177098-1734519177098.png" class="fr-fic fr-dib">An operator removes a silicone part from the LSR press. Due to the elasticity of silicone parts, manual removal is necessary.<h3 id="isPasted">More Options to Consider&nbsp;</h3>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;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;

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

Plastics for Medical Devices and Applications

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) ?

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.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.<h2>Requirements for a new measuring system and implementation</h2>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.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.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).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.<h2>Truck add-on parts: Teamwork between Creaform Go!SCAN SPARK, engineering department and workshop</h2><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">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.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.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><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">Area with additional mounting bracket for toolboxes to be scannedAlthough 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.<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">3D scan of the truck chassis with additional elements mounted by Sutter in the VXmodel softwareWith 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.<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">Reverse engineering in SolidworksWhere 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.<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">CAD view of the scanned areas with traced toolbox holders and purchased part (hydraulic tank)<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">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<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">Finished body<h2 id="isPasted">How the Go!SCAN SPARK with VXmodel has improved processes and practices at Sutter AG</h2>Apart from the main requirement of accuracy already mentioned before, there have been several improvements at a practical level:<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>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.All these factors have led to considerable improvements in internal processes and shared practices in the execution of projects.<h2>Future areas of application</h2>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.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’.”<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">Blue triangle. At the top corner is says “Quality,” at the bottom left corner “Time,” at the bottom right corner “Cost.”

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

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.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;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!<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;">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</iframe><h2 dir="ltr" id="isPasted">A Decade of Collaboration: How Hexagon’s technologies underpin Red Bull Racing’s success</h2>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.<h2 dir="ltr">Inauguration of Hexagon’s New Experience Center</h2>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.<h2 dir="ltr">A R-evolutionizing Approach to Rainforest Conservation</h2><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 Green Cubes, 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;

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

These include the increasing use of intelligent automation, plus the capacity of artificial intelligence (AI) and machine learning (ML) to analyse and predict machine behaviour while dictating its operations. We’re more familiar now with predictive maintenance, augmented reality, digital twinning (DT) and 3D printing, so our predictions at Rowse for 2025 manufacturing trends continue to build on these developments.&nbsp;The global pandemic instigated a radical transformation in the way we work, with more dispersed work sites joined together by more agile, internet-connected devices. The resultant growth of sensory data and immersive experiences has produced&nbsp;<a title="Metaverse" href="https://www.sciencedirect.com/science/article/pii/S2405959524000237" target="_blank" rel="nofollow noopener">the industrial metaverse</a> – a phrase that’s become a buzzword in modern manufacturing. It embraces connectivity across all aspects of production, with many integrated, interactive and collaborative features that allow 24/7 interaction around the world.&nbsp;The metaverse offers a new range of benefits, such as optimised production processes, improved planning and faster decision-making, plus streamlined supply chain management and energy usage. Technology platforms and cloud computing allow global design teams to collaborate in real time, creating and troubleshooting digital twins and virtual 3D models. These can be linked to factory floor devices, sensor networks and robotics that enable the whole production process to be constantly monitored.We predict that the following manufacturing trends are also likely to influence the industrial landscape in 2025:<h2 dir="ltr">Dispersed Manufacturing</h2>The pandemic caused the manufacturing industry to evaluate alternative production models so that disruptions to business would be minimised. One approach to this is decentralised or dispersed manufacturing, which helps companies to increase their agility and resilience. By embracing dispersed local models, business owners can develop a new manufacturing concept that can react quickly and respond coherently to market changes. Several manufacturers are establishing self-contained micro-factories, which can be set up, moved and re-formatted with very little disruption. These can be situated anywhere in the world so that goods can be produced in the environment that’s closest to their primary markets.<h2 dir="ltr">On-Demand Manufacturing</h2>Micro-factories go hand-in-hand with <a title="On-Demand" href="https://www.rowse.co.uk/blog/post/what-is-on-demand-manufacturing" target="_blank">on-demand manufacturing</a>, where goods are only produced when they’re needed. Saving space, time and energy, these smaller, more agile facilities can leverage predictive analytics and market demand sensing to become more responsive and less wasteful. AI can assess changes in demand patterns through data analysis, while individual customer needs can be met without fuss or unnecessary tooling.&nbsp;<a title="3D Printing" href="https://www.rowse.co.uk/blog/post/3d-printing-vs-traditional-manufacturing" target="_blank">3D printing</a> also contributes to the ability of manufacturers to respond to one-off or small product runs, working from CAD models or existing objects. Along with intelligent automation and analytics, new opportunities will be available for customisation in manufacturing, so consumers may even be able to go directly to pop-up factories to purchase on-demand bespoke products.&nbsp;<h2 dir="ltr">Foresight Factories</h2>The manufacturing sector is an industry leader when it comes to intelligent automation. Many facilities already use predictive maintenance to identify and solve potential production problems. AI and ML can predict what impact any action might have before it actually takes place. By 2025, the advance of digital transformation will increase this level of foresight in smart factories and may see them developing sentience so that they respond intuitively to fluctuations in supply and demand.&nbsp;Some research suggests that the average level of factory automation will rise over the next decade by at least 10%. It will soon be having an impact on every aspect of industrial activity, as connectivity expands to embrace the whole manufacturing value chain. We’ve seen DTs being leveraged by the military, the rail industry and&nbsp;<a title="Shipyards" href="https://www.rowse.co.uk/blog/post/what-is-a-digital-shipyard" target="_blank">shipyards</a>, where virtual replicas are used to simulate large-scale production and design situations.&nbsp;<h2 dir="ltr">Purposeful Production</h2>By 2025, most manufacturers will be able to establish a real-time understanding of their operations. Big data analytics will be used to make facilities more cost- and energy-efficient and companies can leverage this information to decrease their environmental impact. Based on the analysis of centralised data management systems, manufacturers can plan for more purposeful production and aim for a more sustainable future. They can combine, for example, product lifecycle management software with manufacturing operations management to pursue lean manufacturing. &nbsp;Along with the IIoT, AI and robotics, the techniques of&nbsp;<a title="Just-In-Time" href="https://www.rowse.co.uk/blog/post/what-is-just-in-time-manufacturing" target="_blank">Just-in-Time manufacturing</a> can lead to a harmonious, streamlined and fully automated operation that should achieve zero-emission status.<h2 dir="ltr">Metaverse Monitoring</h2>From 2025, the metaverse will begin to redefine the way everything functions, including industry. Within manufacturing itself, metaverse-based tools will enhance the abilities and safety of workers by providing virtual monitoring, testing and training. For instance, industrial technology companies are developing IIoT and wireless-enabled smart glasses that offer hands-free operation, audio-visual capabilities and voice commands. Workers wearing the device experience immersive, real-time situational awareness, so they can compare their immediate physical environment with a virtual rendition of how these conditions should be. This is useful for remote maintenance and monitoring while offering significant safety enhancement.&nbsp;Industrial metaverse capabilities can also test new manufacturing software. Using simulations in realistic virtual worlds, engineers can test software and physical integrations before real-world implementation. They can also train robot operators and run multiple potential scenarios to evaluate the optimal set-up.<h2 dir="ltr">How It Will Look In 2025</h2>In 2025 we’ll see predictive capabilities being further developed through digital technologies like AI, ML and big data. Manufacturers will need to embrace the metaverse and explore hyper-local concepts with the potential for micro-factories and on-demand manufacturing. Operations must be imbued with purpose, making use of technological advancements to achieve a more sustainable future.As we’ve previously noted, the increase in digitalisation brings with it the threat of disruption to data security, such as loss of data, malware and other malicious intrusions like denial of service attacks. This means that industrial enterprises must also leverage the metaverse for the protection and monitoring of control systems and their associated manufacturing networks. Remote monitoring tools and security management will, therefore, be increasingly important.

Digital transformation in the manufacturing industry is advancing fast to meet the constant demand for new products and processes. The development and adoption of immersive technology have introduced us to a new arena – the metaverse – with all its exciting possibilities. 

2025 Manufacturing Trends

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.<h3 id="isPasted">Designing for Carbon’s 3D Printing Technology</h3>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.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.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.<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">Build platform (1), UV curable resin (2), dead zone (3), oxygen permeable window (4), projector (5).Along these lines, here are important size and design considerations when using Carbon:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733222328102-1733222328102.png" style="width: 692px;" class="fr-fic fr-dib"><h3 id="isPasted">Carbon DLS vs. Stereolithography</h3>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:<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>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:Materials. 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;Holes, slots, channels. 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.Part size. 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.<h3>Applications for Carbon DLP 3D Printing Technology</h3>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.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.

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

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.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.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.<h2 dir="ltr">What Are Injection Molding Defects?</h2><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">Because they are made quickly and affordably, molded parts can exhibit defectsInjection 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]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.<h2 dir="ltr">Common Types of Injection Molding Defects</h2>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:<h3 dir="ltr">Sink Marks</h3>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]<h3 dir="ltr">Warping</h3>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.<h3 dir="ltr">Short Shots</h3>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.<h3 dir="ltr">Flash</h3>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.<h3 dir="ltr">Burn Marks</h3>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.<h3 dir="ltr">Flow Lines</h3>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.<h3 dir="ltr">Delamination</h3>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.<h3 dir="ltr">Jetting</h3>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.<h3 dir="ltr">Voids</h3>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.<h3 dir="ltr">Knit Lines</h3>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.Recommended reading: <a href="https://www.wevolver.com/article/the-pros-and-cons-of-3d-printing-low-run-injection-molds" target="_blank">The pros and cons of 3D printing low-run injection molds</a><h2 dir="ltr">Root Causes of Injection Molding Defects</h2><h3 dir="ltr">Material-Related Causes</h3><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">Some injection molding materials are more defect-prone than othersThe 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.<ul><li dir="ltr">Moisture Content: 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.</li><li dir="ltr">Contamination: 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.</li><li dir="ltr">Material Selection: 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.</li></ul><h3 dir="ltr">Process-Related Causes</h3>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.<ul><li dir="ltr">Temperature: 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.</li><li dir="ltr">Pressure: 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.</li><li dir="ltr">Injection Speed: 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.</li></ul><h3 dir="ltr">Design-Related Causes</h3>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.<ul><li dir="ltr">Wall Thickness: 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.</li><li dir="ltr">Rib Design: 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.</li><li dir="ltr">Gate Location: 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]</li></ul>Recommended reading: <a href="https://www.wevolver.com/article/what-are-injection-mold-sprues-runners-and-gates" target="_blank">What are injection mold sprues, runners, and gates?</a><h2 dir="ltr">Identifying, Diagnosing, and Predicting Defects</h2><h3 dir="ltr"><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">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>)Visual Inspection</h3>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.<ul><li dir="ltr">Examine Surface Quality: Look for visible imperfections such as sink marks, burn marks, or flash. These defects often indicate problems with material flow, temperature, or mold clamping.</li><li dir="ltr">Check for Dimensional Accuracy: Measure critical dimensions to detect warping, short shots, or shrinkage. Variances in size can compromise the fit and functionality of the part.</li><li dir="ltr">Inspect Weld and Flow Lines: 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.</li><li dir="ltr">Assess Overall Consistency: Compare parts from the same production run to identify variations. Inconsistent quality across parts can highlight issues with process parameters or mold design.</li></ul><h3 dir="ltr">Advanced Diagnostic Tools</h3>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.<div dir="ltr" align="left"><table><tbody><tr><td>Tool</td><td>Description</td><td>Benefits</td><td>Limitations</td></tr><tr><td>Thermal Imaging</td><td>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).</td><td>Non-invasive&nbsp;Real-time analysis&nbsp;Easy identification of thermal inconsistencies</td><td>Limited detection of internal defects&nbsp;Cannot identify material-related issues</td></tr><tr><td>X-ray Inspection</td><td>Examines the internal structure of molded parts, detecting voids, inclusions, or incomplete filling not visible externally.</td><td>High precision&nbsp;Assesses material integrity</td><td>High cost&nbsp;Requires specialized equipment and expertise</td></tr><tr><td>Flow Simulation Software</td><td>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.</td><td>Prevents defects proactively&nbsp;Reduces costly trial-and-error processes</td><td>Requires accurate input data&nbsp;Demands significant computational resources</td></tr></tbody></table></div><h1 dir="ltr">Material Quality Assurance Checklist</h1>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.Some best practices when obtaining and handling materials for injection molding include:<ul style="list-style-type: circle;"><li dir="ltr">Verify material certification and supplier quality standards.</li><li dir="ltr">Inspect raw materials for signs of contamination, discoloration, or damage.</li><li dir="ltr">Test moisture content before processing and ensure it meets the manufacturer’s specifications.</li><li 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.</li></ul><h1 dir="ltr">Conclusion</h1>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.Recommended reading: <a href="https://www.wevolver.com/article/3d-printing-vs-injection-molding" target="_blank">3D printing vs injection molding: process, materials, applications</a><h1 dir="ltr">Frequently Asked Questions (FAQs)</h1>Q: What are the most common injection molding defects?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.Q: How does material selection impact defect prevention?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.Q: What role does process monitoring play in reducing defects?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.Q: Can flow simulation software help prevent defects?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;Q: Why is mold design critical to defect prevention?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.<h1 dir="ltr">References</h1>[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.[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.[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.

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?

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.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.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.<h3 dir="ltr">The Rise of Smart Manufacturing: A Transformation Underway</h3>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.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.<table style="width: 100%;"><tbody><tr><td style="width: 100%; vertical-align: top;"><h2 dir="ltr" id="isPasted">Did you miss it? Watch Wevolver's reporting from Hexagon Live in Eindhoven on-demand</h2>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.&nbsp;<a href="https://www.wevolver.com/article/highlights-from-hexagon-live-2024-watch-the-livestream-on-demand" target="_blank" rel="noopener noreferrer" class="button-main-action">Watch the livestream</a></td></tr></tbody></table><h2 dir="ltr">The Need for Advanced Digital Manufacturing Technologies</h2><h3 dir="ltr">Addressing Industry Challenges</h3>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.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.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.<h3 dir="ltr">Solving Challenges with Digital Innovation</h3>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.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.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.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.<h2 dir="ltr">Driving the Manufacturing Intelligence Transformation</h2>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.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.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.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.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.<h3 dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5Njg0NzkxLUhleGFnb25NSVJRMjAxOFBvZDgwMHg0MjhEZXNpZ25FbmdpbmVlcmluZ0ljb24oMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">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>.</h3><h3 dir="ltr">Support and Success</h3>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.Volkswagen Group’s ŠKODA AUTO also uses Hexagon’s automated measurement systems across its manufacturing facilities to enhance production accuracy and capacity.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.For more success stories, <a href="https://hexagon.com/resources/customer-success-stories">click here</a>.<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>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.<h3 dir="ltr">Content Tailored to Your Needs: Innovation and Problem-Solving</h3>The event offers a range of sessions designed to tackle real-world challenges within the manufacturing sector.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.<h3 dir="ltr">Hands-On Exploration of Digital Reality Solutions</h3>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.<h2 dir="ltr">Explore the Manufacturing of Tomorrow at The Experience Center</h2>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.<blockquote>“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.”</blockquote>Marcel Brand, Senior Director Global Events &amp; Experience Centres Hexagon, Manufacturing Intelligence divisionIn 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.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.<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>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.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.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.<h3 dir="ltr">Insightful panel discussions</h3>The company will also host panel discussions featuring industry leaders and experts who will share their perspectives on industry advancements.These discussions will explore how technologies digital twins and simulation are accelerating design and product development cycles in both aerospace and automotive manufacturing.<h3 dir="ltr">An F1 Engineering Marvel Up Close&nbsp;</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5ODc0ODg0LU9yYWNsZS1SZWQtQnVsbC1SYWNpbmctY2FzZXN0dWR5LWJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">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>.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.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.<h2 dir="ltr">Hexagon Live Day 2: 28 November – Technology Deep-Dive</h2><h3 dir="ltr">In-Depth Exploration of Technical Breakthroughs</h3>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.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.<h3 dir="ltr">Gain Innovative Perspectives</h3>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.<h2 dir="ltr">Ready to Be a Part of the Future?</h2>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.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.Best of all, general admission is completely free. What are you waiting for? Use the following links to reserve your spot today!Unable to attend? Wevolver livestreamed the event on our&nbsp;<a href="https://www.linkedin.com/company/wevolver/">Linkedin</a>&nbsp;and&nbsp;<a href="https://x.com/WevolverApp?ref_src=twsrc%5Egoogle%7Ctwcamp%5Eserp%7Ctwgr%5Eauthor" target="_blank" rel="noopener noreferrer">Twitter</a>.&nbsp;<a href="https://www.wevolver.com/article/highlights-from-hexagon-live-2024-watch-the-livestream-on-demand" target="_blank" rel="noopener noreferrer" class="button-main-action">Watch it on-demand now.</a>

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

From November 12 to 15, Munich became the epicenter of the global electronics industry as Electronica 2024 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 artificial intelligence (AI), sustainability, and the future of mobility, alongside the critical need to foster young talent in electronics.<h2>Key Topics Shaping the Electronics Landscape</h2><h3>Sustainability: Electronics Driving the Green Revolution</h3>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.Sustainability discussions centered on:<ul><li>Smart Grids and Renewable Energy: Innovations in optimizing energy systems for greater efficiency.</li><li>Circular Economy: Efforts to design electronics for recyclability and longevity.</li><li>Green Electronics Manufacturing: Reducing the environmental footprint of production processes.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMTkzMTA5Mzk0LWVsZWN0cm9uaWNhLWluZmluZW9uLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Smart and sustainable mobility was one of the main topics at this year's Electronica.<h3>Artificial Intelligence: Powering the Industry</h3>AI continued to dominate conversations, underscoring its influence across sectors. At Electronica 2024, AI’s transformative power was evident in:<ul><li>Smart Manufacturing: Machine learning-driven solutions to optimize production lines and reduce waste.</li><li>AI-powered Sensors: New sensor technologies with AI integration for predictive analytics in industrial and healthcare applications.</li><li>Autonomous Mobility: The role of AI in enhancing vehicle safety and energy efficiency.</li></ul><h3>Future of Mobility: Shifting Gears with Electronics</h3>The push toward sustainable transportation took center stage, with electronics enabling electric vehicles (EVs), autonomous systems, and advanced battery technologies. Key themes included:<ul><li>Electrification: Efficient power management and battery advancements for EVs.</li><li>Connectivity: V2X (vehicle-to-everything) communication for smarter traffic ecosystems.</li><li>Safety Systems: Innovations in sensor fusion and AI-enhanced driver-assistance technologies.</li></ul><h3>Fostering Talent: Investing in the Future</h3>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.<h2>Exhibitor Highlights: Innovations to Watch</h2><h3>Infineon Technologies: AI and Sustainability at the Core</h3><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 sustainability and digitalization. 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.<h3>Altium: Transforming Electronics Design</h3><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—Altium Discover, Altium&nbsp;Develop, and Altium Lifecycle—aimed at streamlining the electronics design process. From conceptualization to product lifecycle management, these tools empower engineers to innovate faster and with greater efficiency.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMTkyOTI4NTI5LW5vdmVsdGllc19hbHRpdW1fYm9vdGhfZWxlY3Ryb25pY2FfMjAyNF9mYWlyX211bmljaC1sYXJnZS53ZWJwIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">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><h3>Nordic Semiconductor: The New Standard in Bluetooth LE</h3>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">nRF54L Series,</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.<h3>Analog Devices: Agile Manufacturing Robotics</h3><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.<h3>Ignion: IoT Innovation</h3>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;<h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMTk0MDI3OTg0LWlnbmlvbi1vbW5pYS1teHRlbmQtYW50ZW5uYS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">Ignion unveiled their new OMNIA mXTEND™ Virtual Antenna.&nbsp;Celus: AI-Powered Tool for Efficient PCB Design</h3><a href="https://www.celus.io/">CELUS</a> demonstrated their AI-powered Design Platform, emphasizing its capability to automate the transformation of functional requirements into comprehensive electronic solutions. The platform assists engineers by selecting optimal components, generating bills of materials, creating schematics, and providing PCB floor plans in native EDA formats. This automation streamlines the design process, reducing reliance on traditional PDF datasheets and application notes, thereby accelerating time-to-market and enhancing development team efficiency.<h2> </h2><h2> </h2><h2> </h2><h2>From Carbon Goals to Connectivity: Electronica’s Blueprint for the Future</h2>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.As we look ahead, several trends stand out:<ol><li>AI as the Catalyst: Expect deeper integration of AI across all electronics applications, driving efficiency and unlocking new capabilities.</li><li>Sustainability as a Mandate: Green manufacturing and circular design will become non-negotiable for businesses aiming to stay competitive.</li><li>Talent Development: The need for a robust talent pipeline will see continued investment in education and mentorship.</li></ol>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.

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.

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