BUFFALO MANUFACTURING WORKS

Gardner Carrick

Vice President

The Manufacturing Institute

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The Manufacturing Institute is the authority on the attraction, qualification, and development of world-

class manufacturing talent.

A resurgence in U.S. manufacturing?

Factors Driving Resurgence

• Cost of Business Overseas

• Transportation Costs

• Risk

• U.S. Energy Prices

• U.S. Innovations

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Disruptive Innovations

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ADDITIVE MANUFACTURING

The Good News – 3DP Adoption

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Large vs. Small

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Impacts of 3D Printing

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Barriers to 3DP

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When to Use 3DP? Business Performance

• Specific parts are built in low volumes or have high fixed costs associated with them;

• Special parts have long lead times, or manufacturers want to get new products into the marketplace more quickly;

• Reduce part count or boost performance beyond what is now possible.

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When to Use 3DP?Supply Chain & Logistics

• High inventory storage costs suggest making smaller batches on demand;

• Time-sensitive parts are needed in remote locations with expensive shipping costs;

• High import and export costs eat into profits for simple parts;

• Reduce the leverage that suppliers hold over manufacturers by creating an alternative or replacement source for critical parts.

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FLEXIBLE MANUFACTURING

North American Robot Orders

Innovations in Robotics

Expected Uses of Robots

Robots Stealing Jobs?

INTERNET OF THINGS

The Internet of Things

The Internet of Things

The Internet of Things

Contact Information

Gardner Carrick

Vice President

The Manufacturing Institute

E-mail: gcarrick@nam.org

www.themanufacturinginstitute.org

@TheMfgInstitute

6/19/2015

Meeting the Challenge

Ron Brown

Technology leader

Buffalo Manufacturing Works, operated by EWI, is a one-of-a-kind center for advanced manufacturing technologies

• Part of the Buffalo Billion Investment Development Plan designed to spur economic growth in Western New York

• A groundbreaking collaboration between leading industry, research and academic partners� Industry Founders Council � University of Buffalo� Insyte Consulting� World Trade Center Buffalo Niagara � Workforce Development

• Resources� Applied R&D� Technical Inquires, Design Reviews and Library Retrieval� Academic Research� Process Excellence & Growth Consulting� Market Expansion and Support� Training and Education

Buffalo Manufacturing Works

EWI?

• Applied research and development services company that innovates, matures, and commercializes advanced manufacturing technologies

• Not-for-profit organization founded in 1984 in Columbus, Ohio

• Global thought-leader on manufacturing technologies

• Innovative solutions provider

Talent driven innovators

Highly educated staff of 160 engineers, technicians, industry experts, and member advocates• Buffalo = 12• Columbus = 150• Partnerships with leading universities and institutes

Providing manufacturersaccess to leading-edge capabilities

State of the art facilities and equipment

Providing manufacturersaccess to leading-edge capabilities

EWI Columbus,135,000sqftOver $30 million in capital equipment

Buffalo Manufacturing Works, 20,000sqft$6m in capital equipment currently committed$24m currently uncommitted

Bridging the gap between research and manufacturing implementation

Providing manufacturersaccess to leading-edge capabilities

EWI Focus:Manufacturing Technology

Innovation, Maturation, Commercialization, Insertion

Arc Welding Resistance & SS Welding Laser Processing

FormingMicro-Joining

Ultrasonic Processing

NDESoldering & Brazing

High-Impact Applied R&D Manufacturing Technologies

Flexible Manufacturing Materials & Testing Additive Manufacturing Machining & Finishing

Flexible Manufacturing

• Focus─ Developing, simulating, prototyping, validating, agile automation

and controls solutions.

• Toolbox─ Simulation: robotic cell and discreet event

─ Robotics: various sizes, styles and function

including vision, force control

─ Controls: PLC, PAC, various protocols and sensors

─ Inspection & NDE: optical, laser, ultrasonic and eddy current

Flexible Manufacturing

Automation feasibility pilot laboratoryThe unique capability to assemble materials and equipment in the labto pilot and validate flexible automation processes

Surface Characterization

Technology:Focus-Variation basedRobot MountedCapable of measuring Ra > 6 μinch

SystemAlicona IF-Robot

Differentiating Capability:Fast and modular inspection and in-situ monitoring

Automated Inspection

Flexible Manufacturing

Collaborative Human-Robot

Cobots

Single arm cobots

Soft synthetic rubber armswith force sensors

Kuka Fanuc Universal

Force torque sensors Adjustable Reduced ModeAnd force sensing

Flexible Manufacturing

Dual arm cobots

YuMi

Compliant arms with elastic jointactuators, force detection & vision

Stereo vision and force sensing Soft padded arms combined withbuilt-in force sensing

Nachi ABBBaxter

Flexible Manufacturing

The evolution of robot safety and decreasing costs

InterlockFixed Barrier

InterlockFixed Barrier

Presence SensingPath Barrier

SoftwareForce sensing

Vision detectionNo Safety Barrier

Cobot

>$300k $200k <$100k

Flexible Manufacturing

Some companies are considering cobots as expensed workers not capital equipment, shifting robots from machines to labor

Cobots: A new paradigm

Flexible Manufacturing

Flexible Manufacturing

Making it easy

Making it easy

A team at the University of Maryland recently developed a systemthat enabled robots to process visual data from series of “how to”videos on YouTube. Based on what was shown on a video, robotswere able to recognize, grab and manipulate the correctobject and perform the demonstrated task with high accuracy—withoutadditional human input or programming.

Flexible Manufacturing

Additive Manufacturing

• Focus─ Development, proof-testing, and application of next-generation

additive, digital and rapid manufacturing processes

• Toolbox─ Additive processes for 3-D and functional printing

─ Design, modeling & simulation

─ Operational expertise

─ Prototyping and testing capability

• Application examples─ Application expertise across many platforms,

development of next-generation AM technologies for metal, ceramic, and composite materials, validation and characterization of AM processes

Additive Manufacturing

• Material Extrusion, extrude hot material

• Vat Photopolymerization, UV light cure

• Material Jetting, lay material, UV cure

• Binder Jetting, lay material and binder

AM Process Technologies

Stratasys uPrint

B9 Creator

Stratasys Objet30

Inovent

Additive Manufacturing

• Powder Bed Fusion, laser or EB fusion

• Direct E Deposition, powder direct into beam

• Sheet Lamination, ultrasonic welding

AM Process Technologies

Arcam A2X

Fabrasonic

RPM

Additive ManufacturingColumbus

� Enables complex 3D shapes─ Internal passages for cooling, light-weighting

� Properties comparable to conventional (depending on alloy and heat treatment, and surface condition)

Heat

Exchanger

Titanium Spinal Implant

EOS M280

Questions