For much of the history of printed circuit boards (PCBs) and electronics, development of new devices has been limited to highly skilled experts and organizations with the necessary resources. This is in large part an issue of cost, but has also come down to technological limitations, which have constrained how people are introduced to electronics design in an educational context. While theoretical lessons and rudimentary breadboards are useful for teaching the very basics of circuitry, students need a solution that gives them real hands-on experience in designing, testing, and validating electronic circuits. Enter the <a href="https://www.voltera.io/products/v-one?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=v-one-hands-on-learning-pcb-design&amp;utm_content=v-one">V-One</a>, a PCB printer developed by <a href="https://www.voltera.io/about">Voltera</a>, a Canadian company that makes rapid prototyping platforms for printed electronics. This desktop tool is an affordable solution for educational institutions looking to give their students a high level of hands-on learning in PCB design. As we’ll explore in greater detail, the V-One has multiple functionalities, a shallow learning curve, and can be used at a range of levels for teaching simple circuitry or developing complex electronics. Ultimately, creating access to PCB design, even from a young age, is imperative to getting students excited about technological creation and empowering the next generation of innovators.<iframe src="https://www.youtube.com/embed/6TXIS79ZTt0?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" style="width:1920px;height:450px">   </iframe><h2>Getting to know the V-One</h2>The V-One offers educators an accessible platform for bringing PCB designs to life—both in terms of cost and learning curve. The sub-$4,500 benchtop printer integrates multiple functions including:<ul><li>Drilling holes into a substrate for through-hole components and double-sided PCBs</li><li>Printing traces from conductive ink based on digital designs </li><li>Depositing solder paste with higher precision than manual application</li><li>Reflow for soldering (as well as heating for curing conductive inks)</li></ul>These functions result in a versatile machine that can make anything from simple circuits, to double-sided PCBs, to flexible electronic prototypes (Voltera also offers a dedicated platform for flexible electronics, <a href="https://www.voltera.io/products/nova">NOVA</a>). Users can also manually place rivets or additional electronic components onto the printed board and use the V-One solder paste deposition and reflow tool to finalize the circuit.Thanks to these capabilities, the V-One has become a popular tool for rapidly prototyping electronics and for teaching PCB design. Today, various educational institutions, from high-schools to Ivy League universities, have adopted the technology and have seen the benefits of teaching circuitry in a hands-on yet still highly efficient way. In short, the V-One allows students to translate their theoretical understanding of electronics to the real world and bring functional prototypes to life. <h2>Accessible interface for learning</h2>Part of what makes the V-One so well suited to the world of education is its user-friendly interface and simplified workflow. At the core of the system’s usability is Voltera’s free software platform, which guides users through the steps of preparing the V-One and initiating its various workflows (Print, Solder, Drill, and Heat). Students working with the V-One can easily set-up the system for their circuit printing projects, answering prompts like what type of PCB is being printed (i.e. a blank board or a development board that has existing conductive traces) and what ink will be used. From there, they can upload their circuit design and initiate calibration, following a series of clear instructions accompanied by demonstration videos. It’s worth mentioning that having students use V-One’s four workflows will give them valuable first-hand knowledge of material properties, subtractive and additive manufacturing processes, and product development. If students have any questions along the way or any troubleshooting is required, Voltera’s software also integrates an in-app chat function.<h2>Case Study: 7-Segment Display Decimal Counter</h2>In South Korea, Voltera reseller ITIZ developed a <a href="https://www.voltera.io/use-cases/white-papers/printing-decimal-counter-circuit-silver-conductive-ink-fr1?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=v-one-hands-on-learning-pcb-design&amp;utm_content=lesson-plan">lesson plan</a> for teaching high school students about the fundamentals of electrical engineering and PCB design. The project has a fairly simple output—a decimal counter that counts from zero up to 99—but is designed to integrate many key PCB development concepts, covering different types of voltage regulation, variable resistors, wave pulse generation, and seven-segment displays.In the educational program, students are tasked with creating three single-sided circuits: a voltage regulator that converts 9V input into 5V output, a wave pulse generator that turns that voltage into pulse signals, and a decimal counter board, which translates the pulses into an LED counter that goes up to 99. Students must go through the process of creating each of these three boards using the V-One, FR1 boards, conductive silver ink, and solder paste. When each individual board is printed, the students must also connect them to create the functional counter device, whose speed can be controlled by the pulse generator.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742892384725-ezgif-28d4cf63ff862f.jpg" style="width:100%px" class="fr-fic fr-dib" />7-Segment display decimal counter“This project highlights the potential of additive PCB prototyping in electronics education,” writes Voltera. “By combining theory and practice, students can explore how digital counting systems function, understand the role of BCD-to-seven-segment conversion, and observe how timing signals interact with display components. Direct ink writing platforms like V-One empower the next generation of engineers to innovate beyond breadboards and rapidly iterate on electronics designs.”<h2>A V-One on Every Desk</h2>As we saw, the V-One gives students a hands-on way to learn the fundamentals of PCB development, but it can also be used for more complex projects as students advance in their education. For instance, students can make their own creative electronic devices using the V-One and 3D printers, such as bluetooth speakers, lighting fixtures, or interactive toys. As their skills further develop, it is possible to design and make even more complex PCBs, like a custom breakout board for a <a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control">remote-controlled robotic hand</a> or <a href="https://www.voltera.io/use-cases/customer-stories/princeton-university">CubeSats to be launched into space to gather data</a>. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742892484412-ezgif-209fdbef39ef8e.jpg" style="width:100%px" class="fr-fic fr-dib" />A project completed using V-One by students in South Korea The key difference between the V-One and more traditional tools for learning circuitry design, like breadboards, is that students can actually test and refine their PCBs. Moreover, this can be done directly in the classroom and often in less than an hour. This enables students to design, print, test, and reiterate PCBs directly without having to depend on external prototyping services. Ultimately, this gives students the opportunity to conduct multiple experiments and projects within a single semester, expanding their skills and knowledge at a more significant rate.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1742892605240-ezgif-289b8803016144.jpg" style="width:100%px" class="fr-fic fr-dib" />A South Korea classroom with a V-One for each student As Shannen Prindle, a student from <a href="https://www.voltera.io/use-cases/customer-stories/princeton-university?utm_campaign=Wevolver&amp;utm_source=wevolver&amp;utm_medium=v-one-hands-on-learning-pcb-design&amp;utm_content=princeton-university">Princeton University</a> who worked on CubeSats using the V-One, said: “If we didn't have something like the Voltera V-One (...) I don't think I would fully understand what goes into a circuit. Being able to see where the electronics go helped me understand what components go where.”<h2>Conclusion</h2><a href="https://news.harvard.edu/gazette/story/2019/09/study-shows-that-students-learn-more-when-taking-part-in-classrooms-that-employ-active-learning-strategies/">Research</a> has shown that hands-on, active learning has clear benefits for understanding concepts and knowledge retention. This is particularly true in fields like electronics engineering that rely on a combination of digital and physical tools to create functional devices. The V-One can thus improve how students learn about electronics and PCBs, offering an accessible platform for bringing circuit designs to physical life. In the end, getting V-One modules into the hands of educators and students will allow for greater access to PCB development and equip the next generation with the skills needed to develop innovative new solutions in the field of electronics.

V-One, a PCB printer developed by Voltera, a Canadian company that makes rapid prototyping platforms for printed electronics.

Learn by Printing: How the V-One Empowers Hands-On Learning in PCB Design

In the dynamic world of manufacturing, small batch injection molding is a game-changer. It's a process that's redefining how we produce plastic parts.This method is all about flexibility and cost-effectiveness. It's ideal for startups and small businesses, reducing the initial investment required for production.But it's not just about cost. Small batch injection molding also offers the ability to test and validate product designs before mass production. This reduces financial risk and allows for quick market entry with new or updated products.Moreover, it aligns with&nbsp;<a href="https://apsx.com/sustainability" target="_blank" rel="noopener noreferrer">sustainable&nbsp;</a>practices. By producing only what is needed, waste is minimized. This is a significant step towards a more sustainable manufacturing sector.<h2>Understanding Small Batch Injection Molding</h2>Small batch injection molding is an innovative approach tailored for producing limited quantities of parts. It is especially useful when production flexibility is needed.Unlike traditional methods, this process is highly adaptable and efficient. It caters to businesses that do not require large production volumes. This makes it suitable for specialized markets and niche products.Another key feature is its time-to-market advantage. Businesses can quickly test and iterate designs, ensuring the product meets customer needs.Ultimately, small batch injection molding supports a more responsive and&nbsp;<a href="https://apsx.com/smart-production" target="_blank" rel="noopener noreferrer">smart production</a> environment.<h3>Definition and Distinction from High-Volume Molding</h3>Small batch injection molding focuses on producing parts in smaller quantities. This contrasts with high-volume injection molding, which targets mass production.The primary distinction lies in flexibility. High-volume methods prioritize quantity, whereas small batch molding emphasizes adaptability.Small batch processes are cost-effective with lower setup costs. High-volume setups require significant investment for extensive production runs.This makes small batch injection molding ideal for testing new products without substantial financial risk.<h3>The Role of Small Batch Molding in Prototyping and Design</h3>Small batch injection molding is invaluable in prototyping. It allows designers to test and refine product designs efficiently.The prototyping phase benefits from small batch runs. Designers can experiment with various materials and designs.This iterative process ensures optimal product performance and functionality. Feedback can be quickly implemented, speeding up development cycles.Moreover, small batch molding bridges the gap between concept and mass production, fostering innovation and accuracy.<h2>Cost-Effectiveness and Financial Benefits</h2>Small batch injection molding offers significant cost advantages. It enables the production of parts with minimal upfront expenses.By using small batches, businesses can reduce the financial burden. They avoid the costs associated with large production runs.This method is particularly appealing to companies watching their spending. It supports a lean approach to manufacturing.Moreover, small batch processes minimize waste. This further enhances their cost efficiency.<h3>Lower Initial Investment for Startups</h3>For startups, managing budget constraints is crucial. Small batch injection molding reduces initial investment requirements.This is due to the lower tooling and setup costs. Unlike traditional methods, there is no need for large production commitments.It allows startups to allocate resources more effectively. Focus can remain on product development and marketing.This agile approach gives startups the flexibility to adapt and grow. It fosters innovation without excessive financial risk.<h3>Reducing Inventory and Storage Costs</h3>Small batch production significantly cuts inventory and storage expenses. Producing only what is needed decreases the need for storage space.This method reduces the overhead associated with holding large volumes of parts. Businesses can manage their supply chain more efficiently.By avoiding overproduction, unnecessary costs related to warehousing diminish. Smaller batches also facilitate a faster response to market changes.Ultimately, these savings contribute to a healthier bottom line. The business can reinvest these funds into growth and innovation.<h2>Enhancing Flexibility and Speed to Market</h2>Small batch injection molding greatly enhances flexibility. It allows for quick adjustments in production. This agility is crucial in today's fast-paced market. Responding swiftly to consumer demands is a competitive advantage.Moreover, businesses benefit from faster market entry. This process supports rapid development cycles and faster product releases. It helps businesses seize new opportunities promptly. Speed is a vital component of staying competitive.Flexibility also means&nbsp;<a href="https://apsx.com/apsx-machines-compact" target="_blank" rel="noopener noreferrer">accommodating varying design changes</a>. This is beneficial for testing new iterations without hefty investment. Adapting to changes in product specifications becomes seamless and efficient.Ultimately, enhancing flexibility leads to better alignment with market trends. Companies can pivot swiftly as conditions change. This aligns manufacturing with strategic objectives.<h3>Quick Turnaround Times and Market Entry</h3>Small batch injection molding facilitates quick production cycles. This enables products to reach the market faster. Businesses can quickly test and launch new items.A faster turnaround time reduces the time-to-market significantly. It keeps companies competitive and responsive. Products can be refined based on early feedback.Accelerated entry into the market can maximize returns. Being first or among the early adopters brings numerous benefits. Timing can influence a product's success drastically.Rapid prototyping and production help mitigate risks. Businesses can assess real-world performance early. This approach supports more informed decision-making.<h3>Customization and Agile Manufacturing Strategies</h3>Small batch production encourages customization. It allows for tailored products to meet specific client needs. Customization is often crucial in niche and specialized markets.Agile manufacturing thrives through small batch approaches. This method fosters the ability to swiftly pivot design and production. Companies can experiment with new features efficiently.By focusing on short runs, manufacturers engage in adaptive practices. This agile approach promotes creative solutions to complex challenges. Flexibility in manufacturing can lead to innovation.Leveraging customization enhances customer satisfaction. Offering personalized products builds stronger client relationships. It sets businesses apart in competitive industries, proving its strategic importance.<h2><a href="https://apsx.com/sustainability" target="_blank" rel="noopener noreferrer">Sustainability&nbsp;</a>and Environmental Impact</h2>Small batch injection molding supports sustainable manufacturing. It reduces material waste with precise production capabilities. This approach minimizes the environmental footprint of manufacturing processes.Additionally, by producing only what's needed, companies can maintain an efficient inventory system. This approach aligns with eco-friendly business goals, cutting down on excess materials.Sustainable practices reflect positively on a brand's image. Consumers increasingly prefer businesses with green credentials. Integrating sustainable technologies can also improve overall cost-effectiveness.Moreover, adopting environmentally conscious manufacturing processes opens new market opportunities. Businesses can target eco-focused consumers with sustainable product offerings.<h3>Reducing Waste with On-Demand Production</h3>On-demand production drastically reduces waste. It ensures products are made only when ordered. This strategy prevents unnecessary stockpiling and material usage.Reducing waste is vital for cost management and sustainability. Through precise small runs, resources are optimized. This efficient utilization lessens overall production impact.Targeted production also promotes strategic resource planning. Businesses can streamline their inventory systems effectively. This leads to lesser storage needs and minimized overheads.Additionally, lowering waste supports broader environmental initiatives. Reduced material waste contributes to a healthier planet. It is integral to responsible manufacturing practices.<h3>Supporting Circular Economy and Green Manufacturing</h3>Circular economy principles are enhanced by small batch production. This approach supports resource efficiency. Companies can recover and reuse materials through closed-loop systems.Green manufacturing prioritizes resource conservation. Small batch injection molding aligns with this priority. It aids in reducing emissions and conserving energy.Incorporating recycled materials into production is more feasible. Small runs facilitate easier experimentation. This promotes the development of sustainable material usage.Adhering to circular economy strategies helps in achieving long-term sustainability goals. Companies investing in these methods lead the industry towards responsible innovation. The benefits extend beyond profitability, benefiting both economy and environment.<h2>Technological Advancements in Small Batch Molding</h2>Technology is a game-changer in small batch injection molding. Recent advancements boost efficiency and precision. They also improve the scalability of the production process.<a href="https://apsx.com/automation-efficiency" target="_blank" rel="noopener noreferrer">Automation</a> plays a critical role here. It streamlines production, reducing manual efforts. This leads to faster cycle times and greater consistency.Additionally, robotics enhances operational accuracy. It handles complex tasks with precision, minimizing human error. This is crucial for maintaining high-quality standards.Industry 4.0 technologies, such as the Internet of Things (IoT), optimize performance. They enable real-time monitoring and data analysis. This allows manufacturers to adapt quickly to changing needs.<h3>Automation, Robotics, and Industry 4.0</h3>Automation seamlessly integrates with small batch production. It reduces labor costs and improves efficiency. This is especially beneficial for low-volume runs.Robotics offers unmatched precision and control. It handles intricate tasks with ease and consistency. This ensures a high level of product quality.Industry 4.0 fuels innovation by connecting machines. It facilitates data-driven decisions and optimizes processes. This integration leads to smarter manufacturing practices.<h3>Material Selection and Mold Design Innovations</h3>Choosing the right material is pivotal. It affects product performance and sustainability. Small batch molding allows experimentation with diverse materials.Innovative mold designs also enhance production. They improve cycle times and reduce waste. This results in a more efficient and cost-effective process.Advanced materials offer unique properties. They cater to specific industry needs, enhancing product functionality. This expands the possibilities of what can be manufactured.Design advancements streamline the production phase. They ensure high-quality outputs and repeatability. This is vital for maintaining consistency in small batch operations.<h2>Case Studies and Real-World Applications</h2>Small batch injection molding is making waves across industries. Its impact is evident in various sectors. From healthcare to electronics, companies are reaping the benefits.In the medical field, rapid prototyping has led to breakthroughs. Custom medical devices are now feasible. This flexibility caters to specific patient needs.Electronics companies leverage this technology for innovation. They quickly adapt designs based on market feedback. This agility keeps them ahead in a competitive landscape.Furthermore, small batch molding aids consumer goods. Limited edition products hit the shelves faster. This resonates well with niche markets seeking exclusivity.<h3>Success Stories in&nbsp;<a href="https://apsx.com/applications" target="_blank" rel="noopener noreferrer">Various Industries</a></h3>Several industries showcase success stories. In aerospace, customization is key. Small batch molding delivers complex components efficiently.In the automotive sector, specialized parts are vital. Manufacturers appreciate the precision and speed. They can adjust designs swiftly to meet demands.Toys industry benefits too. Limited editions capture the market. This adds value and encourages collectible items.The sporting goods sector takes advantage as well. Personalized equipment enhances performance. This sector thrives on tailored innovation.<h3>Impact on Supply Chain and Competitive Advantage</h3>Small batch injection molding reshapes supply chains. It minimizes dependencies and allows local production. This reduces lead time and transportation costs.Firms gain a competitive edge by being agile. Quick adjustments to product lines are possible. This responsiveness meets consumer trends swiftly.Moreover, it optimizes inventory levels. Companies produce on-demand, slashing overproduction. This alignment with market needs enhances profitability.Ultimately, staying adaptable is crucial. Businesses must respond quickly to changes. Small batch molding offers this strategic advantage.<h2>Conclusion: The Strategic Value of Small Batch Injection Molding</h2>Small batch injection molding stands as a transformative force in modern manufacturing. Its versatility and responsiveness provide companies with strategic advantages. This ensures they remain competitive in ever-changing markets.From reducing waste to enhancing customization, the benefits are substantial. Industries are embracing this method to meet varied consumer demands. It's a pivotal tool in adapting to agile manufacturing practices.Adopting small batch processes can yield long-term gains. Companies not only save on costs but also promote sustainability. As markets evolve, this strategy offers firms a path toward innovation and efficiency.

In the dynamic world of manufacturing, small batch injection molding is a game-changer.

Advantages of Small Batch Injection Molding

In this episode, we explore how origami-inspired concrete zigzag structures are being used to make construction greener and more sustainable.

Podcast: Origami-inspired Concrete Construction

This article was discussed in our <a href="https://www.wevolver.com/profile/the.next.byte" rel="noopener noreferrer">Next Byte podcast</a>.&nbsp;<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/11657a36-86db-4481-8a9d-7c941046cce7?dark=false" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The full article will continue below.<hr>Concrete is the most widely used construction material in the world. Made from cement, water, sand and gravel, this relatively cheap mixture can be shaped as needed and withstand high forces in compression. Yet it performs poorly under tensile stress, requiring steel reinforcement, and excessive amounts of material are often used. This fuels climate change, since producing concrete and steel generates significant carbon emissions.Research by ETH Professor Philippe Block’s team has consistently shown that it is possible to achieve structural stability while using less concrete and steel. One of the Block Research Group's (BRG) innovations is <a href="https://ethz.ch/en/news-and-events/eth-news/news/2017/04/modern-construction-using-long-forgotten-techniques.html">vaulted floor elements made of concrete</a>. Through clever geometry, these floors achieve much thinner sections than their conventional counterparts and do not require any embedded steel reinforcement. This technology is now being commercialized through the ETH-spinoff <a href="https://www.vaulted-floors.com/">external pageVAULTED AG.</a><h2>Considering sustainability at the first production step</h2>Vaulted floors need a formwork system – moulds that give the poured concrete its delicate structure. However, these moulds can be bulky and are often made from petroleum-based materials like Styrofoam. Moreover, formwork for non-standard geometry is typically single-use, and its manufacturing process creates substantial waste. “Unfortunately, this cancels out some of the sustainability gains,” explains Lotte Scheder-Bieschin. The doctoral student at the Block’s research group has developed a foldable formwork system that can be reused and requires fewer resources to produce.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM3MDUyNjI0NDk3LWltYWdlLmltYWdlZm9ybWF0LjEyODYuNDE0NDk2MzY5LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">This is what the finished formwork looks like from above. It consists of four individual parts that can be unfolded like a fan. (Photograph: Lotte Scheder-Bieschin / ETH Zurich, BRG)<h2 id="isPasted">Massively reducing concrete and steel use</h2>Unfold Form consists of thin, flexible plywood strips that are connected by textile hinges and can be unfolded like a fan. Four of these compact units can be rapidly assembled within a wooden frame to create a sturdy, zigzag shaped mould onto which concrete can be poured directly.<blockquote>“I was looking for a solution that uses strength through geometry, not just for the final structure but also for the formwork itself.”<cite>Lotte Scheder-Bieschin</cite></blockquote>After the concrete cures, the formwork can be easily detached from underneath, folded away and stored for its next use. While the system used for the prototype weighs just 24 kilogrammes, it is can support up to a tonne of concrete.“I was looking for a solution that would allow me to use strength through geometry, not only to optimise the final structure but also the formwork itself,” says Scheder-Bieschin. “This approach reduces material usage and makes the entire process more environmentally friendly.” The formwork’s distinctive geometric structure allows for reductions of up to 60 percent in concrete and 90 percent in reinforcement steel.“The Unfold Form formwork can be produced and assembled without specialised knowledge or high-tech equipment,” notes Scheder-Bieschin. One of her aims was to create a simple and robust system that could be used worldwide, even with limited resources. Currently, formwork for non-standard concrete shapes typically requires digital fabrication. “This creates barriers for sustainable concrete construction in developing countries, where the need for new buildings is especially high,” she says.The formwork can be produced cheaply. “The only things needed in addition to the materials are a template for the shape and a stapler,” adds Scheder-Bieschin. The materials for the prototype cost only 650 Swiss francs in total.The individual components are light and compact enough to transport easily. Scheder-Bieschin demonstrated the system's simplicity by assembling it herself during her pregnancy. “I wanted to ensure my design was simple enough for anyone to build, regardless of their circumstances,” she says.<h2>Zigzag ridges like seashells</h2>How does this innovative formwork achieve both lightness and stability? During development, Scheder-Bieschin applied her expertise in bending-active structures – a topic she had worked on during her studies. This technique involves bending elastic materials like thin and long splines or plates of wood, where the resulting deformation creates stability and allows for curved, lightweight structures.A key feature of Unfold Form is the zigzag-like arrangement of wooden strips. “This ribbing provides additional stiffness without significantly increasing the overall weight,” explains Scheder-Bieschin. “You can find such articulated structures in nature, like in seashells.”The zigzag pattern strengthens both the formwork and the concrete poured onto it: “The concrete incorporates this design into a structural rib pattern, which assist in load transfer.”<h2 id="isPasted">Strength through curvature</h2>The interaction between the individual strips is crucial for the formwork’s stability, Scheder-Bieschin explains: “When you bend a single strip or plate, it becomes very wobbly when loaded, and it's difficult to control which shape the board will bend into.” However, when you connect two strips along a curved edge, you achieve much higher rigidity. “Under load, the strips deform minimally, and you can control the final shape via the design of these connection curves,” she says. This technique, called curved-crease folding (CCF), has been around for some time and draws its inspiration from the art of origami.Folding in general consistently progresses from larger to smaller sizes, beginning with a flat element that is gradually reduced through the folding process. This makes the folding technique unsuitable for use in construction. “Consider a vaulted concrete floor measuring two by three metres – the starting plate would need to be approximately three by five metres. From a transport perspective, this is of course highly impractical,” Scheder-Bieschin points out.<h2>From paper model to concrete prototype</h2>Scheder-Bieschin was intrigued by the challenge of adapting this simple but ingenious CCF system for architectural purposes. She experimented with paper models at her desk, eventually devising a system that she calls curved-crease unfolding: “At some point, I started gluing the pieces together differently. And that's how I found a system that starts out as a stacked shape that can be fanned out – just like a hand fan. And at the same time, the curved shape is achieved.”The next challenge was to move from a thin sheet of paper to a structural material of a certain thickness. The doctoral student solved this tricky problem with the help of textile hinges.<iframe width="640" height="360" src="https://www.youtube.com/embed/0AXD9qbJiOY?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;</iframe>The creation of the prototype in fast motion (Video: L. Scheder-Bieschin, M. Hellrich, A. Jipa / ETH Zurich, BRG)She then developed a computer method for the simulation. “The initial prototypes already validated my concept,” she recalls. “Using simple 2D prefabrication, I could create folded, compact panels that unfold easily and have the required rigidity to support concrete.”<h2>Real-life test in South Africa</h2>In addition to the final 3-by-1.8-metre prototype, which is located in the Robotic Fabrication Laboratory (RFL) on the Hönggerberg campus, a twin concrete structure also exists in South Africa. It was built using the same formwork. Mark Hellrich, a scientific assistant and contributor to the Unfold Form project, transported the folded formwork to Cape Town using two surfboard bags. Working together with <a href="https://noncrete.com/">external pagenonCrete</a>, a local firm dedicated to sustainable construction and affordable housing solutions, they cast the second prototype.This demonstrated three things at once: The formwork system can be reused without any loss of quality, it is easy to transport, and it works with different types of concrete. NonCrete used its bio-concrete based on shredded invasive vegetation from the area. “This shows that premium-grade concrete isn't necessary for creating sturdy floors with the new formwork,” Scheder-Bieschin notes.She says that the South African partner company was impressed by the results: “The goal is to use this innovative formwork system to construct high-quality, dignified and sustainable housing in South African townships.”<h2>Helping people help themselves</h2>After completing her doctorate in a few months, the researcher will continue developing her technique as a postdoc at ETH Zurich, with plans to bring her product to market. Currently, the 33-year-old is working on the design for a market hall in a Cape Town township using her formwork system. The next step, however, is primarily about helping people help themselves: “We are planning training programs for the locals so they can build the formwork and the buildings on their own.”

Architecture PhD student Lotte Scheder-Bieschin, pictured with daughter Heidi, created this vaulted floor in unreinforced concrete using her innovative formwork system. (Photograph: Andrei Jipa / ETH Zurich, BRG)

An architecture PhD student at ETH Zurich has developed a simple solution for building concrete floors in a more climate-friendly way. Significant amounts of concrete and steel can be saved thanks to a lightweight, robust and reusable formwork design.

Zigzags for greener construction

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of the additive manufacturing space as a cost-efficient, reliable and flexible tool that is changing how people and companies view workflow optimization and production uptimes.One of the key areas where&nbsp;<a href="https://ultimaker.com/">UltiMaker’s 3D printing solutions</a> are being leveraged is in manufacturing components with complex geometries(including lattices or internal channels), small production runs and various tooling, jigs, and fixtures used to improve existing traditional manufacturing workflows. Let’s dive into some of the key benefits that 3D printing provides and go over some application examples:<h2>Reducing material waste</h2>When compared to traditional subtractive manufacturing methods such as milling or CNC routing, which will always result in wasted material as part of the part-shaping process, 3D printers will only use as much material as needed for the part, layer by layer. This is further compounded when taking into consideration complex assemblies that often require The ability to produce parts as needed translates directly into reduced costs associated with maintaining large inventories.<h2>Accelerated prototyping and iterations</h2>UltiMaker allows companies to exponentially increase the speed with which they can prototype, test, and refine designs. This is done without needing to rely on expensive external suppliers, which, as we’ve seen in recent years, are vulnerable to supply chain delays or interruptions.Global brands such as <a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">Heineken have ensured production continuity with 3D printing</a> and decreased lead times (by as much as nine months) and production costs by 3D printing spare parts for their packaging and assembly machinery.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216290885-1733216290885.png" class="fr-fic fr-dib"><h2 id="isPasted">Eliminating tooling costs</h2>Traditional manufacturing methods often require expensive molds, dies, or tooling for each part design and more and more manufacturers are turning to 3D printing technologies to create mold inserts, assembly aids and jigs in order to streamline their production. With a market value estimated at over $73.60 billion the tooling application area is one of the fastest growing: whereas only 37% of manufacturers reported using additive manufacturing for tooling in 2019 that number grew to 57% in 2021.UltiMaker 3D printers allowed companies like <a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa to produce tools and fixtures in-house</a> and within two years see assembly-tooling cost savings increased from 70% to 95% (saving an estimated $375,000 per year).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216309556-3d-printed-wheel-protection-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">In fact, the ability to tune in and dynamically address the needs of operators working on production lines by creating various custom jigs and fixtures allows companies to streamline processes, enhance precision, and reduce the risk of human error. With more and more customer success stories such as Audi Sport’s implementation of UltiMaker’s 3D printing technology to<a href="https://ultimaker.com/learn/audi-sport-3d-printed-tools-jigs-and-fixtures-in-a-day-instead-of-weeks/" id="isPasted">&nbsp;create almost 200 new tools, jigs and fixtures</a> or <a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/">ERIKS’s improvement to their manufacturing process</a>, it’s evident that additive manufacturing is one of the key investments for businesses that want to stay ahead of the curve.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216327298-1733216327298.png" class="fr-fic fr-dib"><h2 id="isPasted">On-demand manufacturing</h2>UltiMaker's accessible ecosystem enables distributed manufacturing for custom or low-volume parts. Businesses print just-in-time components instead of mass-producing and storing potentially unused inventory and with over 200+ materials available on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> we’re already seeing costly metal parts like conveyor infeed worms being replaced.This is especially relevant when taking into consideration situations where certain machine parts can no longer be sourced as 3D printing allows manufacturers to reverse engineer obsolete parts and far extend the lifespan of existing legacy systems. Just ask one of our clients Trivium, who turned to 3D printing replacement parts for their automated packaging lines.If possible insert an image with the infeed worm that Trivium 3D printed or maybe grab a still from the video with the part being used in the production line?<h2>Easy to implement, easy to scale</h2>Leveraging 3D printing in production processes is also incredibly easy especially when compared to traditional manufacturing techniques that require experienced engineers and designers to create and operate the complex tooling involved which often comes with complicated specialized software that not only adds to the cost but technical expertise as well.With UltiMaker the design process is easily accessible through the various CAD softwares available (with some versions having a reduced learning curve) with the chief advantage being the ability to directly translate a CAD design into a 3D printed prototype faster than with any of the traditional methods currently available.Coupled with an unparalleled scaling capability through distributed manufacturing, a single engineer can upload 3D parts in Digital Factory making it available in any of the connected locations for localized production as the operation of the 3D printer itself is extremely simple.<h2>The future of manufacturing</h2>From rapid prototyping to on-demand production, 3D printing is reshaping the way manufacturers innovate, save costs, decrease lead times, maintain production uptimes, and minimize waste. If you’re looking to leverage the unique benefits of 3D printing, the Ultimaker Factor 4 printer combines state-of-the-art features with unmatched reliability, empowering your business to achieve more with less.

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of additive manufacturing as a cost-efficient, reliable, and flexible tool that is changing how companies view workflow optimization and production uptimes.

Benefits of 3D Printing in Manufacturing

Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing.

IMES3D: Expert Support for Industry-Level 3D Printing

<a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a> is a versatile and precise manufacturing process capable of producing components with a wide range of complexity and sizes using various materials. However, it does come with size limitations dictated by various factors. Awareness of these constraints is crucial for optimising designs and ensuring that designs can be manufactured.<h2 data-counter-attr="value0">General Size Limitations of CNC Machining</h2>This section highlights several design tips and considerations that could improve part manufacturability while optimising cost and lead time. It discusses part complexity and CNC manufacturing constraints such as fillets, holes, pockets, threads, and undercuts.<h3 data-counter-attr="value1">Material Blank Size</h3>This refers to the size of the raw material used to create the finished part. Material blanks typically need to be slightly larger than the finished part’s measurements to allow for variations and to cut away rough faces of the raw material.&nbsp;For example, if the final dimensions are to be 50 x 50 x 50 mm, then a suitable material blank would be roughly 53 x 53 x 53 mm. When designing, take this into consideration by adding additional X, Y, and Z dimensions to your part and matching it to the part size limits below.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514482046-blank-size-1.png" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value2" id="isPasted">Limitation for Milled, Lathe and Drilled Parts</h3><table><thead><tr><th>Part/Feature</th><th>CNC Milling</th><th>CNC Turning</th><th>CNC Drilling</th></tr></thead><tbody><tr><td>Maximum size</td><td>The largest CNC milling machines, like the <a href="https://www.k-mm.com/large-machining/" target="_blank" rel="noopener">SNK HF-7VM vertical gantry mill</a>, have a pallet size of 3500 mm by 10000 mm, with X-axis travel of 11000 mm, Y-axis travel of 4700 mm, and Z-axis travel of 2450 mm.</td><td>The largest CNC turning centres, such as the SL 603, can handle parts with diameters up to 930 mm and lengths up to 4000 mm.</td><td>The largest CNC drilling machines, like the <a href="https://www.voortman.net/en/products/v200-plate-drilling-machine" target="_blank" rel="noopener">Voortman V200</a>, can handle plates up to 2400 mm in length, 1000 mm in width, and 60 mm in thickness, with a maximum weight of 600 kg.</td></tr><tr><td>Minimum size</td><td>Typically, the smallest feasible feature size is 0.5 mm. For practical purposes, machining features smaller than 2.5 mm in diameter is considered micro-machining and is generally avoided unless necessary.</td><td>The smallest practical diameter for turned parts is approximately 0.5 mm, with common practice starting from about 1 mm.</td><td>Standard practice for most drilling applications starts at 2.5 mm diameter for ease of production and accuracy. Although, the smallest standard drill bit size used is around 1 mm. For very small features, holes as small as 0.05 mm (50 micrometers) can be drilled, but this falls into the realm of micro-drilling, which requires specialised equipment and techniques.</td></tr><tr><td>Better alternatives for larger parts (than maximum)</td><td>• Injection molding (plastics) • Die casting, metal extrusion (metals)</td><td>• Injection molding (plastics) • Forging, casting (metals)</td><td>–</td></tr><tr><td>Better alternatives for smaller parts (than minimum)</td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics) • Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics) • Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>–</td></tr></tbody></table><h3 data-counter-attr="value3">Feature Size Limitations: Reference Chart</h3>The following chart summarises the design guidelines associated with various features that can be made using CNC. Its purpose is to help designers optimise components for manufacturability.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514529304-diagram-cnc-machining-design-guidelines-1.webp" style="width: 100%px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514573679-chart-cnc-machining-design-guidelines.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value4" id="isPasted">Size Limitations for Post-Processing</h3>The different post processing operations that can be carried out on a part depend on the size of the part. For example, larger parts often do not fit in media-blasting cabinets, therefore such parts cannot be blasted. Another example is that custom racking may be required for parts larger than 3 meters that need to be anodized, electroplated or powder coated.<table><thead><tr><th>Process</th><th>Maximum part size&nbsp;</th><th>Notes</th></tr></thead><tbody><tr><td>CNC Turning</td><td>Diameter up to 500 mm and length up to 4500 mm</td><td>Xometry uses specialized tooling, including standard 2-axis lathes, live tooling systems, multi-spindle machines, and Swiss lathes, to produce parts with milled or intricate features.</td></tr><tr><td>CNC Milling</td><td>Xometry’s partner network can typically mill parts up to X-2000 mm, Y-750 mm, and Z-600 mm.</td><td>If your part exceeds 600 mm in machinable height, it will require specialized tooling and an additional manual review for manufacturability.</td></tr><tr><td>CNC Drilling</td><td>Equipment includes upright, bench, and radial drill presses, enabling Xometry to drill holes up to 7 cm in diameter in simple and complex patterns.</td><td>The complexity of the drilling pattern and material may affect lead times and costs.</td></tr></tbody></table><h3 data-counter-attr="value5">General Manufacturing Standards</h3>Unless otherwise specified, Xometry manufactures CNC-machined components to the following standards:<ul><li>Surface Finish: The as-machined surface finish is Ra 3.2 or better, with CNC machine tool marks possibly leaving a swirl-like pattern.</li><li>Edge Treatment: Sharp edges will be broken and deburred by default. If critical edges need to remain sharp, this should be noted and specified on the CAD drawing.</li><li>Plastic Components: Clear or transparent plastics will have a matte finish or translucent swirl marks on any machined face. Bead blasting will result in a frosted finish on clear plastics.</li><li>Tolerances: Tolerances on foam or similar compressible materials cannot be guaranteed.</li></ul><h3 data-counter-attr="value6">General Tolerances</h3>Unless specifically specified by the designer, Xometry will adhere to the industry standard ISO 2768 and ISO 286 tolerances listed below:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514609862-cnc-machining-tolerances-2048x867.webp" style="width: 100%px;" class="fr-fic fr-dib">General tolerances for CNC machining start at ±0.1 mm. Tighter tolerances, defined as smaller than the general standard, can be achieved with CNC machining, reaching up to ±0.01 mm.&nbsp;Specialized setups and additional operations like reaming and grinding can allow for even tighter tolerances depending on the material and part geometry. Geometric tolerances (GD&amp;T) can be applied to the drawing, but these may increase inspection times due to the necessary tools and time for checking.While tighter tolerances improve a part’s form, fit, and function, they have drawbacks. They can lead to higher scrap rates, additional fixturing, special measurement tools, and longer cycle times from slower cutting speeds. These factors can increase pricing and lead times. Depending on the tolerance and geometry, the part cost can more than double compared to a standard tolerance.<h2 data-counter-attr="value7">General Size Limitations of CNC Machines</h2>The physical dimensions of CNC machines’ work envelopes are the main factor limiting their part size capabilities. This constraint affects all types of CNC machines, including turning, milling, and drilling. Other limiting factors include the machine’s axis travel and the number of axes.<h3 data-counter-attr="value8">CNC Machining Work Envelope</h3>The CNC machining work envelope refers to the 3D space within which the machine operates. Different machines each have their own work envelope, which limits the size of components that can be manufactured using the machine.&nbsp;The physical size of the machine, and more specifically, the X, Y, and Z directions in which the machine can move, dictates the work envelope.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514654906-1732514654906.png" class="fr-fic fr-dib">However, it is important to note that when designing components, the work envelope might be reduced due to tooling size. For example, as shown above, if the cutting bit were longer, the CNC work envelope would be smaller in the Z direction.<h3 data-counter-attr="value9">CNC Axis Travel</h3>CNC axis travel is the range over which the cutting tool or workpiece can move along the X, Y, and Z axes. This has a direct impact on the size of components that can be machined. Below is an example of a 3-axis CNC milling machine. In this case, the rail lengths dictate the distances the machining bit can move in each direction.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514681918-cnc-axis-travel-1536x1536.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value10" id="isPasted">CNC Axis Types</h3>CNC machines typically operate within 3 to 5 axes. Three-axis CNC machines move the cutting tool along the X, Y, and Z axes. Four-axis CNC machines add an additional rotation axis, which increases the complexity of the parts that can be manufactured.&nbsp;Finally, five-axis CNC machines add two additional rotation axes to the X, Y, and Z movements. The number of axes significantly affects the size and complexity of components that can be manufactured.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514699442-3-axis4-axis-5-Axis-CNC-Machining.webp" style="width: 100%px;" class="fr-fic fr-dib">Diagram of 3-axis, 4-axis and 5-axis CNC machines (Source: worthyhardware.com)<h2 data-counter-attr="value11" id="isPasted">CNC Turning Size Limitations</h2>CNC turning involves a rotating workpiece, while a single-point cutting tool removes material. The physical geometry of a CNC lathe dictates the size limitations. CNC turning machines are constrained by their centre distance, swing distances, and how the workpiece is mounted.<h3 data-counter-attr="value12">Distance Between Centres</h3>For a CNC Lathe, the distance between centres refers to the distance between the lathe headstock and tailstock. This limits the total maximum machinable length of the component that can be machined.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514792535-Technical-illustrations-01-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value13" id="isPasted">Swing Over Bed, Cross Slide, and Gap</h3>The terms “Swing Over Bed,” “Swing Over Cross Slide,” and “Swing Over Gap” define different clearance measurements on a lathe. Swing Over Bed indicates the maximum diameter that can be machined over the bed’s longitudinal guideway.&nbsp;“Swing Over Cross Slide” is the diameter allowance over the cross slide, which is smaller than the Swing Over Bed. “Swing Over Gap” indicates a small gap allowing larger diameter parts, such as flanges, to be machined.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514816151-Technical-illustrations-06-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib">These different swing parameters affect the CNC turning diameter limits and the component length. Here’s a more detailed description:<ul><li>Swing Over Bed: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li>Swing Over Cross Slide: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered. &nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm. If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li>Swing Over Bed: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li>Swing Over Cross Slide: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered.&nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm.&nbsp;If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li>Swing Over Gap: The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility. The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility.</li></ul><h3 data-counter-attr="value14">Mounting Method of the Workpiece</h3>In typical CNC lathe operations, the workpiece is secured in the headstock and supported by the tailstock. However, for certain tasks, the workpiece is only mounted in the headstock. In these cases, the material type and thickness determine the allowable length of the workpiece, as excessive length can cause flexing and potential issues.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514839913-Technical-illustrations-04-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 data-counter-attr="value15" id="isPasted">CNC Milling Size Limitations</h2>CNC milling machines use rotating cutting tool to remove material from a workpiece. Milling machine size limitations are dictated by the CNC machining work envelope and tool reach.<h3 data-counter-attr="value16">CNC Machining Work Envelope</h3>The physical size of the milling machine table (X and Y) and the maximum axis (Z) travel limit the size of the workpiece. One should note that the work envelope does not denote the exact maximum size of the workpiece, and the workpiece might be further limited by the tooling.&nbsp;<h3 data-counter-attr="value17">Tool Reach</h3>The length of the cutting tool and the ability to reach different areas without interference places a size limitation on the workpiece. For example, deep features in the part could typically be limited by the tool length rather than the travel of the tool.&nbsp;To further illustrate this, if you were to have a part with narrow grooves, as in the image below, the tool length would be the limiting factor as the tool holder would not be able to move past the top face of the component, should the depth of the grooves surpass the length of the tool.&nbsp;In terms of accuracy, machines produced by Kern Microtechnik can achieve tolerances as tight as ±2 microns (±0.00007 inches).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514866771-cnc-mill-interior-1536x865.webp" style="width: 100%px;" class="fr-fic fr-dib">Deep features in the part can typically be limited by the tool length<h2 data-counter-attr="value18" id="isPasted">CNC Drilling Size Limitations</h2>CNC drilling is used to create holes in a workpiece, and the size limitations are primarily influenced by the machine’s Z-axis travel and the length of the drill bits. Thus, it is important to ensure that the drill bit length and axis travel surpass the thickness/height of the workpiece that needs to be drilled. Another size limit is the bed size of the CNC drilling machine, which dictates the maximum length and width of the workpiece that can be drilled.

This article reviews the CNC machining size limitations, covering major constraints such as the work envelope of CNC mills and the diameter limitations of CNC-turned parts. It highlights CNC capabilities and size constraints at Xometry, available materials, and post-processing considerations.

CNC Machining Size Limitations: Everything You Need to Know

The Challenge: Optimizing Real-Time Quality Testing<a href="https://www.snaptron.com/" target="_blank">Snaptron</a>, a leading manufacturer of tactile dome switches used across industries from aerospace to medical, originally developed the Sapphire Force Testing Machine to ensure rigorous quality control. However, as technology advanced, their Director of Engineering, Kevin Albertsen, recognized the need for an upgrade. Their existing setup, which used stacked PC/104 cards on a single-board computer, was complex and costly, lacking the efficiency needed for real-time data analysis.Snaptron’s goal was clear: streamline the system to reduce expenses and increase processing speed, providing a high-quality solution without a hefty price tag. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5NDQzNjk4LVNhcHBoaXJlX2xvLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" />A Simple, Cost-Effective Solution: The Portenta H7 Lite  <iframe id="635a907b01e7d30008f114c0" width="250" height="440" src="https://wevolver.com/iframe/specs/arduino-portenta-h7?iframe=true" frameborder="0" scrolling="no"></iframe> Snaptron chose the <a href="https://www.arduino.cc/pro/hardware-product-portenta-h7/" target="_blank">Portenta H7 Lite</a> to upgrade the Sapphire machine. The board’s versatility allowed for rapid prototyping and iteration, reducing development time significantly. With seamless data transfer via USB and straightforward integration of digital and analog connections, Snaptron could simplify in-house PCB assembly and low-volume production.Albertsen noted the benefit of Arduino’s extensive library support and open-source resources, which accelerated the prototyping phase, freeing up resources for other projects. The Portenta H7 Lite’s cost-effectiveness also helped Snaptron manage their budget, allowing for further improvements to their system. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5NDYzNjI0LUFCWDAwMDQ1XzA1LnVuYm94LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" />Expanding Market Opportunities with a New Product LineWhat began as an internal solution for quality control quickly revealed market potential. Snaptron discovered that customers also needed a similar force-displacement switch tester, prompting them to develop a commercial product based on the upgraded Sapphire. This new offering has since opened up a fresh revenue stream, showcasing how rapid prototyping can lead to unexpected opportunities. Curious to find out more? Read the <a href="https://www.arduino.cc/pro/case-studies-snaptron" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta H7 Lite provides an efficient and cost-effective solution for quality testing.

Snaptron optimized their quality testing machine, Sapphire, to enable faster data processing and lower costs. Leveraging Arduino’s Portenta H7 Lite, they not only improved in-house quality control but also opened up a new market segment for force-displacement testing solutions. 

Snaptron Streamlines Quality Testing with Efficient Prototyping

<html><head></head><body>&nbsp;The Challenge: Addressing E-Mobility’s Compact Performance Challenge&nbsp;As e-mobility infrastructure expands, the need for advanced charging stations has introduced new technical requirements for size, reliability, and flexibility. When <a href="https://abinsula.com/" target="_blank">Abinsula</a> – an innovative company in the embedded systems and IoT solutions space – was tasked with creating a POC for a smart, wall-mounted EV charger, the company’s priority was to balance high-performance with a compact design that could be customized for future functionality.Abinsula’s experience in embedded systems positioned them well to tackle this project, but they quickly realized that most existing market solutions were either too bulky or limited in flexibility. After evaluating several options, they selected the <a href="https://www.arduino.cc/pro/hardware-product-portenta-x8/" target="_blank" rel="noopener noreferrer">Portenta X8</a> from Arduino’s Pro line and combined it with the <a href="https://www.arduino.cc/pro/hardware-product-portenta-breakout/" target="_blank">Portenta Breakout</a> to create a powerful yet compact solution that could be optimized for rapid development.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5MDQyMDc4LTE3MzE5MzkwNDIwNzgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" id="isPasted" class="fr-fic fr-dii">Developing a Customizable Solution with Portenta X8Using Yocto for software customization, Abinsula was able to adapt the microcontroller to meet specific application needs while maintaining efficiency and scalability. As Paolo Doz, co-founder and CTO of Abinsula, explained, “The primary challenge was optimizing the resources of the microprocessor while planning for future functionality expansions. We were able to offload some functionalities to the Portenta X8’s onboard real-time microcontroller, ensuring the system could support additional smart features as needed, such as remote communication via 4G/Wi-Fi®.”This approach allowed Abinsula to also integrate a full human-machine interface (HMI) and control software within just one month, a major accomplishment in a field where time-to-market can provide a decisive edge.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5MDY0NDgxLUFCWDAwMDQ5XzAyLnVuYm94LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Efficiency, Reliability, and Scalability for Future Innovation &nbsp;<iframe id="635a948941249700089f8799" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/arduino-portenta-x8?iframe=true" frameborder="0" scrolling="no"></iframe>Abinsula’s success in delivering a complete, compact POC highlights the benefits of leveraging high-performance microcontrollers for e-mobility applications. The <a href="https://www.arduino.cc/pro/hardware-product-portenta-x8/" target="_blank">Portenta X8</a>’s design offered Abinsula access to a powerful processing-to-size ratio, enabling the development of a fully operational charger that met the client’s standards for both functionality and flexibility. The project also benefited from Arduino’s Board Support Package (BSP), which allowed Abinsula to focus on application development without having to start from scratch.&nbsp;Curious to find out more?&nbsp;Read the <a href="https://www.arduino.cc/pro/case-studies-abinsula/" target="_blank">full case study on the Arduino website</a>.</body></html>

The Arduino Portenta X8 combines high performance and compact form factor.

The growth of e-mobility demands versatile, reliable charging solutions that meet high standards in compact formats. Using Arduino, Abinsula developed a proof of concept (POC) for a wall-mounted, smart EV charger within a remarkable timeframe.

Abinsula: Rapid Development of a Compact EV Charger

Did you know that injection molding is transforming the medical device industry? This advanced process empowers designers to create high-quality and cost-effective products, ranging from common medical items to highly regulated devices. As products move through various stages of development—from initial prototyping to full-scale production—they must consistently meet stringent compliance, safety, and functionality standards. This ensures that each medical device aligns with critical industry requirements at every step.If you’re considering taking the next step in medical injection molding, this article will guide you through 4 key considerations in medical injection molding, from understanding device classifications and regulations to selecting suitable materials and preparing your design.<h2 dir="ltr">Key Considerations in Medical Injection Molding</h2><h3 dir="ltr">1. Regulatory Compliance: Meeting Corresponding Standards</h3>&nbsp;Food and Drug Administration (FDA) guidelines in the U.S. mandate rigorous tracking and documentation at every production stage to guarantee the traceability of each component. Meanwhile, Medical Device Regulation (MDR) standards in the EU emphasize consistent product safety across the device’s entire lifecycle, pushing manufacturers to follow stringent standards.Medical devices are divided into three classifications, by both FDA and MDR, based on associated risk, each with specific regulatory requirements:Class I Medical Devices: These low-risk devices pose minimal harm to users, often including items like bandages, gloves, and hand-held surgical instruments. Regulatory requirements are relatively basic, focusing mainly on general safety and quality.Class II Medical Devices: Moderate-risk devices, such as syringes, infusion pumps, and diagnostic equipment, require additional regulatory controls. These may involve special labeling, performance standards, and post-market supervision.Class III Medical Devices: High-risk devices, including pacemakers, defibrillators, and implants, require the highest level of regulatory supervision. This includes rigorous premarket approval, extensive testing, and clinical trials to confirm safety and effectiveness.For instance, a diagnostic device used for detecting infectious diseases needs each plastic component to withstand various sterilization processes without degrading or releasing harmful substances. Even minor contamination could compromise the device’s accuracy or pose risks to patients, underscoring the importance of these strict regulatory standards. Ensuring regulatory compliance is essential in medical injection molding, as incorrect categorization or non-compliance can lead to delays, increased costs, and a longer time to market.<h3 dir="ltr">2. Certifications: Guaranteeing Quality and Safety</h3>Certification is a standard, ensuring the products meet or exceed industry requirements. Key certifications in the medical industry include:ISO 13485: This certification ensures a quality management system is in place, maintaining consistency across production batches. For example, if producing IV systems or ventilators, ISO 13485 certification is critical.ISO 10993: For parts that come in direct contact with bodily fluids or tissues, ISO 10993 ensures biocompatibility. This certification is essential when manufacturing parts such as catheter tips or implantable device housings, where material safety directly impacts patient health.ISO 14644: This cleanroom certification is crucial for preventing contamination. A cleanroom-certified facility, for instance, can safely produce surgical device components that require a sterile environment, ensuring they meet hospital and surgical standards.<h3 dir="ltr">3. Material Selection: Biocompatibility and Durability</h3>Choosing materials for medical applications involves considerations beyond standard injection molding. Examples include:<ul><li dir="ltr">Polycarbonate (PC): Due to its strength and transparency, often used for housing devices requiring internal visibility, such as blood analyzers.</li><li dir="ltr">Polyethylene (PE):&nbsp;Known for chemical resistance and flexibility, PE is used in IV bags and tubing, ensuring durability and low moisture absorption.</li><li dir="ltr">Polypropylene (PP): With strong impact resistance and sterilization stability, PP is used in syringes and medical containers, offering long-term reliability.</li><li dir="ltr">Polystyrene (PS):&nbsp;Widely used for disposable labware, PS offers rigidity, transparency, and easy sterilization, making it suitable for laboratory applications.</li><li dir="ltr">Polyether Ether Ketone (PEEK):&nbsp;Widely used in implantable devices due to its strength, stability under sterilization, and biocompatibility.</li><li dir="ltr">Thermoplastic Elastomer (TPE):&nbsp;Its flexibility makes it suitable for soft-touch surgical instrument handles that withstand repeated sterilization.</li></ul>Every material choice has specific trade-offs. For instance, while PE and PP are cost-effective and chemically resistant, they might lack the strength needed for parts exposed to high-stress environments. Therefore, understanding these nuances helps in material selection, optimizing for both performance and cost.<a href="https://www.rpworld.com/en/resources/blog/what-materials-work-best-for-your-medical-device-development.html">&nbsp;Click Here</a> to explore more material choices.<h3 dir="ltr">4. Prototyping to Production: Ensuring a Smooth Transition</h3>Transitioning from prototypes to full-scale production isn’t always straightforward. During prototyping, designs may feature thinner walls or more complex geometries than standard injection molding processes can easily reproduce at scale. For example, a prototype with sharp corners that’s achievable created by the vacuum casting process, but requires design optimization, such as adding radii, and adding draft angle for efficient injection molding without sacrificing quality.When scaling up, an experienced injection molding partner with expertise and capabilities can help optimize these designs for manufacturability without compromising on quality. At RPWORLD, we assist clients in this crucial transition, helping optimize part design, select the most suitable materials, finishing options and more to support efficient and regulatory-compliant production.<h2 dir="ltr">How RPWORLD Injection Molding Accelerates Your Medical Development</h2>At RPWORLD, we integrate material expertise, one-stop manufacturing services, in-depth DFM analysis and ISO-certified process to help bring medical devices to market faster. Our services cover the entire lifecycle—from prototyping to mass production—tailoring to meet the unique needs of each medical device.Our Injection Molding Services Include:<ul><li dir="ltr">20+ years of experience in medical device injection molding, from prototyping to end-use production.</li><li dir="ltr">Mold flow analysis, and in-house tools design and fabrication.</li><li dir="ltr">Design for Manufacturing (DFM) guidance, including design optimization, material selection, finishing selection and more to avoid costly rework and save time up to 80%.</li><li dir="ltr">A wide variety of post-processing options to perfect your parts.</li><li dir="ltr">State-of-the-art quality inspection equipment and stringent quality control including real-time process monitoring to ensure consistency.</li></ul>

Photo by National Cancer Institute on Unsplash

If you’re considering taking the next step in medical injection molding, this article will guide you through 4 key considerations in medical injection molding, from understanding device classifications and regulations to selecting suitable materials and preparing your design.

From Prototype to Production - 4 Critical Considerations for Safe and Compliant Medical Injection Molding

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

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

Sustainability and Small-Batch Production with APSX Machines

From accelerating production timelines to ensuring unmatched quality control, the adoption of APSX machines can redefine operational performance for businesses of all sizes from an inventor/entrepreneur alone to global companies around the world.1. Revolutionizing Manufacturing Efficiency with AutomationAPSX machines are built with automation at their core, reducing manual intervention and optimizing every stage of production. They incorporate CNC capabilities, allowing for precise execution of complex parts and simple injection molding process for making real plastic functional parts instead of fragile 3D printed parts. This translates into shorter production cycles, lower lead times, and a dramatic reduction in product development and production costs.By integrating APSX machinery, businesses can achieve substantial efficiency gains, minimizing downtime due to long lead times and ensuring continuous production. These systems also enable manufacturers to schedule operations 24/7, maximizing output and enhancing the overall production capacity without compromising quality.2. Scalable Solutions Tailored for SMEsFor small and medium enterprises (SMEs), balancing capital investment with production output is critical. APSX machines provide a cost-efficient solution, featuring modular designs that scale with business growth. Unlike traditional machinery, APSX systems have a low total cost of ownership (TCO), owing to their energy-efficient operations, minimal maintenance requirements, and a reduced need for expensive tooling.This scalability ensures that SMEs can start with a smaller setup and expand their manufacturing capabilities as demand increases, without the need for a complete overhaul of their production infrastructure. The flexibility and affordability of APSX solutions make them ideal for companies looking to innovate while maintaining profitability.3. Enhanced Versatility Across Multiple SectorsOne of the standout features of APSX machinery is its adaptability to various manufacturing needs. From automotive components to medical device production, these machines are engineered to handle a broad spectrum of materials, including metals, plastics, and composites. This versatility is supported by advanced programming options and customizable mold designs that allow for seamless transitions between different product specifications.For industries requiring precision and consistency—such as aerospace and electronics manufacturing—APSX machines provide unparalleled control over complex geometries and intricate detailing, ensuring that each output meets stringent industry standards.4. Accelerated Prototyping for Rapid Product DevelopmentIn today’s competitive market, speed-to-market is a critical success factor. APSX machines empower businesses to rapidly prototype new designs using subtractive and additive manufacturing techniques. By leveraging CNC milling or 3D printing capabilities, companies can iterate quickly on product designs, making necessary adjustments in a fraction of the time required by traditional methods.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727718506442-27.09.2024_12.21.09_REC.png" style="width: 100%px;" class="fr-fic fr-dib">This rapid prototyping capability reduces the time between concept and market-ready product, enabling manufacturers to respond swiftly to consumer feedback and changing market trends. Moreover, the ability to produce functional prototypes allows for comprehensive testing, ensuring that final products meet all performance and reliability criteria before mass production.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NzE4MzI0NTY1LUFQU1gtUElNX0hvbWVQYWdlXzEwMDAuSlBHIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">5. Precision Engineering for Superior Product QualityPrecision and repeatability are the hallmarks of APSX machinery. Using state-of-the-art software and premium components, these machines deliver exceptional accuracy, maintaining tight dimensional control even in high-volume production runs. This capability is essential for industries where product uniformity and reliability are non-negotiable, such as medical device manufacturing and precision engineering.APSX machines utilize closed-loop feedback systems, ensuring real-time adjustments that prevent deviations and guarantee that each part produced is identical to the next. This high degree of precision reduces the incidence of defective products, enhances quality assurance, and minimizes material waste, ultimately leading to improved profitability and sustainability.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NzE4MzUwODEwLXN3aXNzLWJhbm5lcl8xLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">6. Sustainability Through Resource EfficiencyEnvironmental responsibility is becoming a priority for manufacturers worldwide. APSX machines contribute to sustainability by incorporating energy-efficient drives and low-waste manufacturing techniques. With programmable precision, these machines optimize material usage, minimizing scrap rates and reducing the overall carbon footprint of the production process.In addition, the adoption of APSX technology aligns with green manufacturing practices by supporting the use of recyclable materials and facilitating the remanufacturing of worn components, extending the lifecycle of products and reducing industrial waste. #injectionmolding #cncmachining #prototyping #sustainability

APSX machines represent a significant breakthrough in modern agile manufacturing, designed to boost efficiency with easy setups, precision for injection molding over 3D printing, and scalability across diverse industrial sectors due to their low initial investment and small sizes. 

Top Benefits of Leveraging APSX Machines for Industrial Optimization

Sensors and actuators are essential elements of industrial systems, instrumental to any application that requires automated control. Sensors measure changes in the environment while actuators control physical changes, with both devices serving as mediator between the physical environment and the electronic system where they are embedded.Raspberry Pi provides general purpose header pins that can be connected to sensors, making the innovative low-cost board a popular and valuable choice for engineering prototypes. However, Pi’s GPIO pins are designed for driving low current devices such as LEDs, so is it possible to connect to the I/O necessary for industrial environments?The type of sensors you’ll need to connect to your Pi will depend on the particular job your prototype is designed to perform. In manufacturing, the most common processes are concerned with monitoring and control:<ul><li>Temperature: Both contact and contactless sensors can be used to measure temperature.</li><li>Photoelectric: Ideal for counting specific objects using light or lasers.</li><li>Button and Switches: Simple human inputs used to control the functioning of a system.</li><li>Dial: Simple human input providing analogue/continuous control of a signal over a range of values.</li><li>Pressure: Useful for detecting blockages, and signalling when a system needs servicing.</li><li>Vibration: Often the first sign of a problem, sensors that detect changes in vibration are great for predictive maintenance.</li><li>RFID: Used to track and/or locate devices, personnel, and/or equipment.</li><li>Inductive: The typical automation sensor, alerting to the presence of metal.</li><li>Power Consumption: Key to understanding energy usage, also a useful signal for predictive maintenance</li></ul>Industrial sensors typically require 12-24V power and signal changes using the same voltage. Raspberry Pi’s GPIO input circuitry can be driven to either 3.3V (high) or 0V (low). This means that whilst a 12V water flow sensor might initially work hooked straight up to a Raspberry Pi, in long- term industrial projects the incompatibility of the currents will almost certainly cause problems.<h2>Does this mean Raspberry Pi can’t be connected to industrial sensors beyond a prototype?</h2>Connecting a sensor to Raspberry Pi directly often means stripping the sensors wiring and soldering the cable to the correct GPIO pin. The 12 or 24V of an industrial sensor will then be driven straight to the Pi with nothing in the way to protect Pi internal circuitry, including the processor. By adding extra circuitry as a buffer between the input pin and the Pi, it’s possible to extend the processor’s source/ sink current capabilities, and prevent excessive power dissipation in the chip.<h2>Breadboards and the Factory Floor</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NjY2MTkzNzgzLXZpc2hudS1tb2hhbmFuLXZ0Zzh0QWRvV1ZRLXVuc3BsYXNoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Photo by Vishnu Mohanan on UnsplashBreadboards are solderless circuit boards that can house the most complex circuits, making them an invaluable option for prototyping. The impermanence afforded by the boards allows you to build and test multiple circuits without the need to constantly solder rewired connections. In this way, breadboards are great for testing new parts, integrated circuits and for troubleshooting.Some circuits will require a considerable amount of space, another feature of breadboards that makes them useful tools in industrial prototyping is the ability to extend the surface size by connecting multiples together.While breadboards can go a long way in adapting Raspberry Pi for industrial applications, certain considerations may be prohibitive to deploying such a prototype directly to a factory environment. The completed set-up is undeniably still a prototype; the connections, whilst providing industrial I/O options, are not optimised for the rigours of the factory floor.&nbsp;<h2>Industrialised Pi</h2>Powered by Raspberry Pi, Brainboxes BB-400 is a smart industrial controller that allows prototypes to be deployed straight into industrial environments.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NjY2NTk4MTgyLWJiLTQwMC1waTMtMTAyNHg2ODEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Rather than adding protection to the GPIO using a breadboard and external circuitry, the built in circuitry of the BB-400 allows 12V and 24V sensors to be directly connected to the IO lines without the need to add additional components to step down the voltages.<h2>Never Lose a Configuration with Removable Terminal Blocks</h2>Using a screwdriver to connect sensors’ wires/cables into the embedded terminal blocks means that the circuitry doesn’t require soldering to create strong and secure connections, allowing multiple reconfigurations. As the terminal blocks can be unplugged, it’s easy to take the module out without affecting any of the pre-wired terminals.As a single misplaced component leg can cause the whole circuit to malfunction or even cease to function at all, another useful feature of the terminal blocks is their numbering. It’s a lot easier to decipher the correct connection when you eliminate the need to count down a row of tiny header pins!The BB-400 has 8 onboard digital I/O and multiple connectivity options: RS232/422/485 Serial port,Bluetooth, Wi-Fi and Dual Ethernet, making it usable straight out of the box without the need for any add-on units. Packaged in an industrial DIN rail enclosure, the BB-400 is the perfect solution for deploying a Raspberry Pi prototype straight onto the factory floor.<a href="https://offer.brainboxes.com/prototyping-on-a-pi" target="_blank" rel="noopener noreferrer">Download the Prototyping with Pi E-book here. </a>

The type of sensors you’ll need to connect to your Pi will depend on the particular job your prototype is designed to perform. In manufacturing, the most common processes are concerned with monitoring and control

Unlock Industrial Prototyping: Your Guide to Connecting Industrial Sensors to Raspberry Pi

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.EV manufacturers need to innovate more quickly than ever to stay competitive in a market that’s expected to grow rapidly. According to<a href="https://www.grandviewresearch.com/industry-analysis/electric-powertrain-market" target="_blank">&nbsp;Grand View Research</a>, the global electric powertrain market was valued at $83.30 billion in 2022 and is projected to grow at a compound annual growth rate (CAGR) of 15.3% through 2030.<h2 dir="ltr">Manufacturing Challenges in EV Motors, Batteries, and ECUs</h2>At the heart of this rapid shift towards electric vehicles are three critical components: EV motors, batteries, and ECUs (Electronic Control Units). These elements form the backbone of every electric vehicle, powering its movement, optimizing energy efficiency, and managing complex operations. However, as the industry grows, so do the manufacturing challenges associated with these components.<h3 dir="ltr">EV Motors</h3>The design of EV motors is crucial for efficiency. Manufacturers now use thinner stamped lamination sheets (between 0.15 mm and 0.3 mm) to reduce power consumption, but producing these sheets requires extreme precision, especially when handling intricate profiles and sharp corners. Additionally, the need for lightweight materials and complex cooling systems to prevent overheating further complicates motor manufacturing. For mold makers, these factors demand high accuracy to ensure performance and keep assembly costs low.<h3 dir="ltr">Batteries</h3>Batteries serve as the heart of every EV, where power storage and management are critical to vehicle performance. Several production challenges arise:<ul><li dir="ltr">Efficient cooling systems are needed to prevent overheating during use.</li><li dir="ltr">Precise use of materials such as silicon carbide and ceramics is required for durability and heat resistance.</li><li dir="ltr">Perfectly sealed shields are essential to prevent leaks and sediments, which can compromise battery efficiency and safety.</li><li dir="ltr">The growing demand for smaller, lighter battery designs calls for highly accurate mold tooling and efficient production methods.</li></ul><h3 dir="ltr">ECUs (Electronic Control Units)</h3>These units manage critical functions such as power distribution and motor control. Producing intricate micro molds for ECUs is a significant challenge, as even small deviations can affect performance and safety. Manufacturers must ensure precision and consistency, particularly in customized production.<h2 dir="ltr">How Rapid Prototyping Solves These Manufacturing Challenges?</h2>Automotive Manufacturers need solutions that increase efficiency, reduce costs, and allow for greater customization. Rapid prototyping has become a key tool to address these challenges.<ul><li dir="ltr" style="font-weight: bold;">Digital Manufacturing and Quality Control</li></ul>Rapid prototyping uses advanced digital manufacturing techniques to ensure precise production of complex components like thinner stamped lamination sheets for EV motors. By leveraging 3D printing and CNC machining, manufacturers can quickly create and test motor designs, optimizing for both efficiency and durability. This process allows for rapid iteration of complex cooling systems to prevent overheating, ensuring that all parts meet the required specifications.<ul><li dir="ltr" style="font-weight: bold;">Low-Volume, High-Customization Production</li></ul>Battery production often requires customized solutions for challenges like efficient cooling and ensuring perfect seals. Rapid prototyping enables manufacturers to produce small batches of custom battery modules or cooling components at a lower cost. This flexibility allows for frequent design adjustments to meet the evolving demands for smaller, lighter batteries without costly retooling or manual interventions. It also ensures that material precision and sealing are tested and verified before large-scale production.<ul><li dir="ltr" style="font-weight: bold;">Supplier Integration for Streamlined Production</li></ul>For EV manufacturers, working with a single supplier from prototype to full-scale production simplifies the process. Rapid prototyping allows seamless supplier integration, reducing the time and costs associated with switching suppliers. This ensures consistent quality and faster production, especially when developing critical components like motor housings and battery enclosures.<ul><li dir="ltr" style="font-weight: bold;">&nbsp;Accelerated Time-to-Market</li></ul>In ECU development, where micro molds with extreme precision are essential, rapid prototyping accelerates the time-to-market by allowing manufacturers to quickly design, test, and refine intricate components like ECU casings and micro connectors. This ability to rapidly iterate and test designs ensures that production can proceed without long delays, meeting the stringent requirements for safety and performance in the fast-evolving EV market.<h2 dir="ltr">RPWORLD’s On-demand Manufacturing Solutions for EV Component Innovation</h2>RPWORLD offers a wide range of manufacturing services, including CNC machining, injection molding, vacuum casting, and a variety of finishing options, providing automotive customers the flexibility to select the best methods for developing and producing components. Whether for traditional ICE vehicles or EVs, our services enable rapid prototyping with the highest precision and shortest lead times. Our expertise in electric vehicle component development is extensive, offering specialized solutions for motors, batteries, and ECUs, such as:<ul><li dir="ltr">Precision motor housings and lamination components for optimal efficiency</li><li dir="ltr">High-quality battery pack enclosures and cooling system components</li><li dir="ltr">Custom-designed battery module connectors and management system housings</li><li dir="ltr">Detailed ECU casings and intricate micro connectors for zonal control units</li><li dir="ltr">Thermal management parts for both battery and ECU systems to ensure efficient heat dissipation</li></ul>As the automotive industry continues to shift toward electric vehicles, RPWORLD is proud to serve as a trusted partner, providing rapid prototyping solutions that help drive innovation and accelerate the transition to an all-electric future.<a href="https://www.rpworld.com/en/about-us/contact-us/" target="_blank">&nbsp;Let’s work together</a> to bring your EV projects to life.

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.

4 Ways Rapid Prototyping Accelerates Innovation in New Energy Vehicles

Every day, millions of glass bottles, cans and PET containers run through a Krones line. <a href="https://www.krones.com/en/index.php" target="_blank">Krones</a> is a leading manufacturer of complete systems for breweries, beverage bottlers and food producers. Its production lines fill packages, add labels, and perform quality control on the products. As a global market player in the beverage and packaging industry, Krones provides comprehensive solutions that customers, such as Coca-Cola and Heineken, rely on heavily.<iframe width="640" height="360" src="https://www.youtube.com/embed/fdjkrFzIk84?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <h2>When every second counts</h2>The production lines of Krones are extremely efficient in producing, filling, and packing products. But with these massive production volumes, every second counts. When a machine is not running, companies could lose out on significant revenue. This is why it’s critical to have the highest possible uptime. While Krones machines are extremely reliable, every part will wear and might need replacing for optimal performance. While most customers keep a selection of spare parts, it’s unrealistic, expensive and unsustainable to keep a large stock of spares as many of these parts will never be used. Every part needs to be produced, checked and shipped.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjM5ODg2LUtyb25lcy11c2VyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Every part produced for a Krones machine is checked for the highest quality.<h2 id="isPasted">3D printing at Krones</h2>To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. Outsourcing the production of prototypes is very expensive and often could take weeks. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases. By prototyping faster, Krones tested and iterated on their designs faster, ensuring that new parts performed better and lasted longer. This has helped customers with more reliable machines, higher uptime and a smaller environmental footprint.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjY3MDU3LUtyb25lcy1hcHBsaWNhdGlvbi02LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">3D printing in-house has enabled Krones to produce critical parts for their machines.<h2 id="isPasted">Benefits of 3D-printed parts over traditional parts</h2>By testing prototypes of parts, Krones discovered that 3D-printed parts met the performance requirements of many final parts. Not only are 3D-printed parts cheaper to produce, their reduced weight is also often a big benefit. Parts can also be printed in different materials depending on the need for different properties, such as more flexibility or ESD-safety. This enabled Krones to shift 3D printing from simply an internal tool to a new revenue stream as an added service for customers.<h2 id="isPasted">On-demand production parts for customers, anywhere</h2>When storing a huge stock of spare parts is not desirable or spare parts are needed urgently, you need to be able to acquire parts fast once they are needed. Ordering and shipping parts can take days to weeks, while local stocks or customs can make certain locations difficult to guarantee certain quality service. 3D printing on location offered a huge opportunity for Krones and its customers.When customers need a spare part for a machine, they can order the part in the Krones.shop - the online customer touchpoint. If the spare part is able to be 3D-printed, it will be produced locally on UltiMaker printers. This way, customers won’t need to store huge quantities of spare parts in all of their locations. They can simply print the parts they need, while minimizing downtime of their production lines drastically. This process reduces part delivery from weeks to days, or even hours.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzAxMjU3LUtyb25lcy1hcHBsaWNhdGlvbi0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Printing parts on-demand have shown to reduce costs and improve operational efficiency.<h2 id="isPasted">Quality assurance of 3D printed parts</h2>The functionality and durability of a part depends on many factors. While the design of a part might be the same, the choice of materials and production settings have a great influence on the performance. Krones defines the right materials and print settings for every part. When a customer orders a replacement part for their Krones line, the spare will be 3D printed using customized settings and Krones-specific materials. This results in a certified part that is sure to meet the quality standards required. Krones quality can only be found where it says Krones Quality on the label.<h2>A flexible 3D printing solution that meets strict quality and IT standards</h2>Choosing the right 3D printing ecosystem can be very challenging. For Krones, UltiMaker was the right choice thanks to its agile, open and secure solutions. UltiMaker 3D printers have been known for their reliable and consistent quality. UltiMaker’s software comes with print profiles for hundreds of materials and brands, making it easy to pick the right material for the job. However, Krones was in need of a custom material with extremely specific requirements. Thanks to UltiMaker’s open materials platform, Krones was able to develop its own material for its own parts and create reliable print profiles.UltiMaker’s professional software also helped Krones to meet the data protection standards set by IT. Print jobs on location are securely monitored by Krones through a custom software solution, assuring customers of the quality of the print job. Regular software and firmware updates also ensure Krones utilizes a future-proof 3D printing ecosystem.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzI4OTM2LUtyb25lcy1hcHBsaWNhdGlvbi00LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">UltiMaker's 3D printing ecosystem and open materials platform allowed Krones to customize their solutions to meet customer demands.<h2 id="isPasted">Moving forward with the Factor 4</h2>Krones has been printing in over 10 locations using a large fleet of nearly 50 UltiMaker S5 and UltiMaker S7 printers. Adding the recently launched UltiMaker Factor 4 to its repertoire has brought new possibilities to Krones.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzUzMDYyLUtyb25lcy1GYWN0b3ItNC0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The addition of UltiMaker's new Factor 4 3D printer has enabled Krones to provide more support to its customers.Johannes Karl, Head of Customer 3D Solutions, at Krones, stated:<blockquote>We’re excited about the potential of the Factor 4. The Factor 4 has taken our capabilities to the next level. With support for stronger and more durable materials, we're able to produce parts that are not only tougher but also offer greater flexibility with softer materials.</blockquote>The new UltiMaker Factor 4 has a direct drive printhead. This makes printing soft materials easier and even more reliable. Because of the direct drive, the Factor 4 enables users to print parts in even softer and grippier materials. These features bring new opportunities for example for grippers, flexible parts or protective parts.The new UltiMaker Factor 4 can also print at even higher temperatures, in a better isolated build chamber. This enables engineers to use materials such as UltiMaker’s PPS CF. A material that can easily substitute for PEEK or even steel.The new features of the Factor 4 push innovation at Krones even further, helping them to deliver even more service to their customers.Bernd Baldauf, Head of Global eBusiness - Global Digital Content Management - Global 3D Customer Solutions, at Krones, concluded:<blockquote>Our goal is to grow closer to our customers and become their solution partner. Providing rapid, high-quality parts on demand, and continuously improving our service offerings in Krones quality. With UltiMaker's innovative solutions, we're well on our way to achieving that.</blockquote>

Printing parts on-demand have shown to reduce costs and improve operational efficiency.

To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases.