MT Magazine July/August 2023

PLANES, TRAINS, AND AUTOMOBILES (MORE OR LESS) ON THE GROUND OR ABOVE IT, THE TRANSPORTATION LANDSCAPE’S EVOLUTION IS REMINISCENT OF THE WRIGHT BROTHERS AND HENRY FORD

THE IMPORTANCE OF ER&D by Douglas K. Woods | 01

IMTS+ ‘ROAD TRIPPIN’ WITH STEVE’ SHOW PREMIERES JULY 27 by Michelle Edmonson | 28

NICKEL ALLOY (INCONEL) LORE by Stephen LaMarca | 30

by Gary S. Vasilash | 13

AN

PUBLICATION

JULY/AUGUST 2023 THE TRANSPORTATION ISSUE VOLUME 2 | ISSUE 10

IS

MANUFACTURING TECHNOLOGY

650+ Members in the Manufacturing Technology Community

Our members make, sell, service, and supportU.S. manufacturing technology in a global market. We advance the industry byfacilitating t he adoption of transformative technologies,producingcommunity events,promotingMT standards,supporting international business growth, and enhancing industry knowledge. Make the most out of your AMT membership. Reach out us at membership@AMTonline.org. f t i t h l i l b l k t W d Our members make sell service and support U S

A VIEW FROM THE WOODS

JULY/AUGUST 2023

1

The Importance of ER&D Recently I came upon a term that I was unfamiliar with but which expresses a concept that is really quite important to our industry: engineering R&D. While we’re all familiar with R&D, which is generally performed in places other than the shop floor and typically associated with Fortune 500

advantage is extensive. And there are developments like AI and edge computing that you’ve heard about that might be beneficial to your operations. But danger comes when someone goes all-in on something – be it additive or AI – without having a thorough understanding of what they are trying to do with it, what problem they are trying to solve, or what advance it will provide. There are plenty of things that can be done for a few thousand dollars that can dramatically move the needle forward for a company. A young engineer in the organization can be given a small budget to address a problem – such as integrating sensors into some production equipment to obtain operational data – and a comparatively short time limit. The results will likely be more useful and actionable than launching a massive campaign that transforms everything. Some years back, Foxconn, the contract manufacturer most widely known for its work with Apple, was interested in deploying MTConnect in its facilities. But it wasn’t about to shut down its lines to network the equipment. One clever engineer came up with a way to understand how MTConnect could be deployed to the company’s advantage. One of Foxconn’s factories occupies three floors. Each floor is laid out the same. And on each floor, there is a bottled beverage vending machine. A vending machine has actuators, switches, motion controllers, scanners, and the like. It is a fairly sophisticated piece of machinery. Foxconn put MTConnect on the vending machines. It switched up the beverages in each of the machines and was able to not only learn about the machines’ operations but also about the amount of caffeinated beverages sold on a given floor, which could then be compared to production data. By learning on this small level, the company was able to confidently roll out MTConnect to other machines – ones that weren’t vending Pocari Sweat drinks. As you well know, in this industry, business is never consistent. Because there are always ups and downs, it is beneficial to make small investments in time, resources, and money on a consistent basis to learn how to improve your products or services so that when customers look for product, your company has something that has a clear competitive advantage over those who didn’t make those investments.

companies or startups in Silicon Valley, ER&D is more applicable to what we do and how we work (which is not to say that the other types of companies can’t benefit). The concept comes out of consultancy Bain & Co. In a report, the authors write: “Today, a growing number see ER&D as a strategic capability that will determine their future success and shape new business models. Investments in ER&D not only improve products but also increasingly reinvent or disrupt parts of the business.” They point out five aspects that ER&D helps companies address: 1. Shorten time to market 2. Make new tech more affordable 3. Embed digital capabilities into hardware-centric engineering teams 4. Explore new value creation 5. Re-engineer for environmental, social, and corporate governance (ESG) strategies If R&D can be considered theoretical, then ER&D is practical. One of the issues that will likely face industry within the next several months is a recession. While it is predicted to be mild, even a papercut is troubling to an otherwise healthy person. So, if there is an economic downturn, there is a tendency to batten down the hatches and to harbor resources, preserving cash and capital. One of the things I learned from my grandfather, who started and operated a manufacturing company during the second half of the 20th century and so was familiar with economic downturns (in 1973-75 there was the oil crisis and a stock market collapse), was to take advantage of economic downturns. This took various forms, from acquiring equipment and competitors to making product advances. While it might seem that pursuing ER&D during a downturn would be unsustainable, it is actually a sensible approach. Let’s face it: When you’re busy, you’re not likely to have your people do anything other than focus on their main tasks. But when they have some time on their hands, that time can be put to good use by dealing with issues that may be holding back your operations. The amount of manufacturing technology that is presently available – both physical and digital – that can provide a great

Douglas K. Woods President AMT – The Association For Manufacturing Technology

1:1 interchangeable replacing heat shrinking toolholders Hydraulic Expansion Toolholder

Up to 5 -sided complete / simultaneous machining Manual Clamping System KSX

Up to 90% set-up cost savings

Quick-change

Pallet System

©2022 SCHUNK Intec, Inc

Everything for your Machining Center

More than 7,500 components for workpiece and tool clamping.

schunk.com/equipped-by

MT MANUFACTURING TECHNOLOGY

JULY/AUGUST 2023

3

Masthead

Editorial Team

Executive Team

Membership & Sales

Kristin Bartschi Director, Marketing & Communications kbartschi@AMTonline.org

Douglas K. Woods President dwoods@AMTonline.org Travis Egan Chief Revenue Officer tegan@AMTonline.org Peter Eelman Chief Experience Officer peelman@AMTonline.org Becky Stahl Chief Financial Officer bstahl@AMTonline.org Tim Shinbara Chief Technology Officer tshinbara@AMTonline.org

Bill Herman VP, Sales & Membership bherman@AMTonline.org Technology Benjamin Moses Senior Director, Technology bmoses@AMTonline.org Intelligence Ian Stringer VP, Data Strategy istringer@AMTonline.org Smartforce Greg Jones VP, Smartforce Development gjones@AMTonline.org Advocacy Amber Thomas VP, Advocacy athomas@AMTonline.org International Ed Christopher VP, Global Services echristopher@AMTonline.org

Mary Cecile Neville Director, Content mcneville@AMTonline.org

Chris Downs Director, Audience Development cmdowns@AMTonline.org Kathy Webster Managing Editor, Content kwebster@AMTonline.org Dan Hong Writer/Editor dhong@AMTonline.org Jacob McCloskey Graphic Designer jmccloskey@AMTonline.org

Tiffany Kim Graphic Designer tkim@AMTonline.org

Hailey Sarnecki Graphic Designer hsarnecki@AMTonline.org

IMTS

Peter R. Eelman Chief Experience Officer peelman@AMTonline.org

M

E

O

C

E

B

Michelle Edmonson VP, Exhibitions medmonson@AMTonline.org

Want to learn more about AMT membership? To learn how to make the most of your AMT membership, email us at membership@AMTonline.org.

JOIN AMT

Mark Kennedy Senior Director, Exhibitor Services mkennedy@AMTonline.org

R

E

B

A

M

M

E

AMT – The Association For Manufacturing Technology 7901 Jones Branch Dr. Suite 900, McLean, VA 22102-3316 Tel: 703-893-2900 | Fax: 703-893-1151

OCTOBER 10-11, 2023 SUBURBAN COLLECTION SHOWPLACE | NOVI, MI

Usher in the Age of Automation We’ve saved you a spot at our dynamic new event designed to educate and inspire CNC job shops during the journey toward manufacturing automation. Join us for two motivating days including:  Pioneering technical content delivered in classroom-style sessions  Networking with the industry’s best and brightest minds in automation  Interactive exhibits showcasing the tools and technology needed for success  In-person facility tours led by the experts who run them

Learn About... · Multitasking and Multiprocess Machine Tools · Closed-Loop Systems · Cobots, Robots and Peripheral Equipment · Digital Simulation · Chip Handling Equipment

· Done-in-One Machining · Automated Inspection · Robotic Machine Tending · Unattended Lights-Out Production · Workholding for Automated Routines

POWERED BY

Learn more about SPONSORSHIPS, EXHIBITING and ATTENDING here!

TASCevent.com

MT MANUFACTURING TECHNOLOGY

JULY/AUGUST 2023

5

Table of Contents

07

Click See what’s trending on AMTonline.org

09

Manufacturing Matters Get details on the latest industry news

11

AMT Upcoming Events Important manufacturing technology dates and events to bookmark

13

Planes, Trains, and Automobiles (More or Less) by Gary S. Vasilash

18

The Big Picture Fleet Modifications May Shape the Aerospace Industry’s Resiliency

Head South for Summer Travel: Make Plans for Formnext Forum Austin by Peter Eelman

26

IMTS+ ‘Road Trippin’ with Steve’ Show Premieres July 27 by Michelle Edmonson

28

30

Nickel Alloy (Inconel) Lore by Stephen LaMarca

32

Flying Lessons

by Chris Chidzik

COVER DESIGN Hailey Sarnecki | Graphic Designer

INFOGRAPHIC DESIGN Fleet Modifications May Shape the Aerospace Industry’s Resiliency Jacob McCloskey | Graphic Designer

MT Manufacturing Technology (ISSN # 2836-2896), July/August 2023, Issue 10, is published bi-monthly by AMT – The Association For Manufacturing Technology, 7901 Jones Branch Drive, Suite 900, McLean VA 22102. Periodicals Postage Paid at Merrifield, VA and at additional mailing offices. POSTMASTER: Send address changes to MT Manufacturing Technology at 7901 Jones Branch Drive, Suite 900, McLean VA 22102.

To manage your subscription, contact Chris Downs at cmdowns@AMTonline.org.

America’s New Event for AM Innovation

Hands-On Technical Tours

Products and Equipment on Display

Entertainment and Networking Events

Expert-Led Presentations and Demos

Unique Only-in-Austin Experiences

Formnext Forum – Austin is the first in a series of events to drive industrial 3D printing innovation and growth in the Americas. Hosted in one of the world’s most tech-forward manufacturing communities, Formnext Forum – Austin will connect leaders from across the industrial additive manufacturing supply chain.

Start shaping your AM experience! Visit us at formnextforum.com

August 28-30, 2023 / Austin, Texas

PRESENTED BY

CLICK

JULY/AUGUST 2023

7

Click MT Magazine is more than just paper pulp and ink. Explore our content on AMTonline.org and engage with discussions on a wide array of topics affecting manufacturing technology now.

Importance and Diversity of Data Sources Data from CNCs, PLCs, industrial PCs, robots, sensors, and other external sources form the foundation of any digital manufacturing solution. The challenges are in determining which data is important, understanding it, cybersecurity, and data validation. Read on at AMTonline.org/article/importance-and-diversity-of-data-sources In their third and final season together, explore along with father-son duo Travis and Max Egan as they focus on the future of automotive and additive. In Season Three, sponsored by Mazak, Travis and Max take a closer look at EVs and the chips that make them go. They’ll also visit a tier one automotive supplier and the world’s only sustainable production company for advanced materials. Stay tuned for the season premiere on Sept. 28. View the trailer and catch up on Season Two on IMTS+ at IMTS.com/watch Save the Date for the ‘Manufacturing Explorers’ Premiere Event IMTS 2024 Floor Plan Reflects Manufacturing Strength and Growth “To meet the needs of a robust manufacturing industry, IMTS 2024 will have even more exhibits that feature robotics, advanced motion systems, vision and imaging, data analytics, systems integration, software, artificial intelligence, and connected technologies,” says Peter Eelman, chief experience officer at AMT – The Association For Manufacturing Technology. “Every pressure on the manufacturing industry requires OEMs and job shops to implement technologies and processes that make them more efficient.” Learn more at AMTonline.org/article/imts-2024-floor-plan

Swiss Expedition: Precision with Heart, Part I and Part II Summer getting too hot? Chill out with some cool Swiss technology and get cozy with some warm Swiss hospitality. Earlier this year, Fritz Studer AG welcomed nearly 100 attendees to its Steffisburg campus to unveil new products and share some of the joys of Swiss life. AMT invitee Kathy Keyes Webster found every detail was meticulously crafted with heart and soul, uniting precision and art. Read about her visit at:

AMTonline.org/article/swiss-expedition-precision-with-heart-part-i AMTonline.org/article/swiss-expedition-precision-with-heart-part-ii

Don’t Wait for Your Manufacturing Technology News Subscribe to AMTNow for the latest manufacturing news, technology breakthroughs, legislative updates, and much more. Carefully curated by AMT experts and leaders, this bi-weekly newsletter keeps you informed on the full scope of industry to make better business decisions – right from your inbox. Scan the QR code or learn more at AMTonline.org/resources#newsletters

Networking That Will Ignite Your Success

LOCATION October 18-21 Indianapolis, IN

OPENING KEYNOTE

SAM GOODWIN Winning Through Uncertainty

Indianapolis Marriott Downtown Room Rate: $209 per night

Sam is an American entrepreneur and featured keynote speaker. Goodwin shares his experiences through speaking engagements worldwide, including to audiences of elite athletes, faith groups, corporate conventions, the US Military and others.

Special Thank You to Our 2023 Event Sponsors

PLATINUM SPONSOR

GOLD SPONSORS

SILVER PLUS SPONSORS

SILVER SPONSORS

BRONZE SPONSORS

CONTACT Kristen Hrusch, Events Manager at NTMA, for more information - khrusch@ntma.org or 800.248.6862.

MANUFACTURING MATTERS

JULY/AUGUST 2023

9

Manufacturing Matters Check in for the highlights, headlines, and hijinks that matter to manufacturing. These lean news items keep you updated on the latest developments.

TECHNOLOGY

Lightweight Is the Future of Transportation Material science is the path to get there. The need for more powerful and efficient vehicles continues to grow as external factors such as population growth, fossil fuel supply, and global warming force change. Integrated computation materials engineering (ICME) will pave the way for new, more robust, lighter, and application-specific materials. ICME depends on several underlying technologies, such as artificial intelligence, high-performance computing, and simulations, to drive previously unsolvable solutions. Artificial intelligence has enabled the process to bypass trial-and-error design techniques. Simulations validate the form, material, and process of the specific applications. The advances in computing power drive both of these technologies. Movement is life, and lighter solutions enable freedom of movement.

INTELLIGENCE

Hydrogen Internal Combustion Engines: Porsche’s Sustainable Alternative Thanks to Porsche’s strides in developing hydrogen internal combustion engines, the technology is now positioned as an alternative to gasoline engines, matching V-8 performance while reducing fuel consumption and emissions. The global hydrogen combustion engine market is projected to grow at a CAGR of 9.78%, reaching a value of $46.31 billion by 2033. Hydrogen internal combustion engine vehicles offer sustainability advantages over full-electric vehicles, emitting only water vapor and enabling production with renewable energy sources. They also provide faster refueling times and longer driving ranges. Porsche’s dedication to hydrogen technology demonstrates their commitment to innovation and sustainable mobility. This investment not only establishes them as a pioneer in sustainable transportation but also highlights hydrogen internal combustion engines as a cleaner and viable alternative to full-electric vehicles.

SMARTFORCE

Navigating the EV Workforce If consumer demand, government policies, and automaker commitments are driving the EV market, is there a workforce to take the wheel? Public-private partnerships are answering the call for a skilled talent pool to manufacture, maintain, and repair electric vehicles and their components. Here are some examples. • The American Association of Community Colleges will use an $8 million grant from the U.S. Department of Labor to create EV apprenticeships with partners such as Tesla, Panasonic, and Truckee Meadows Community College in Nevada. • In North Carolina, Siemens is partnering with Wake Technical Community College to offer a four-year apprenticeship that prepares high school and college students for EV careers in affiliation with its nearby e-mobility manufacturing hub. • Alongside 15 employer partners, the Michigan Economic Development Corp. announced the $350,000 Michigander EV Scholars Program to fund scholarships for up to 350 students, which marks the nation’s largest recruitment effort.

MANUFACTURING MATTERS

THE TRANSPORTATION ISSUE

10

ADVOCACY

Finding Funding After passing the bipartisan debt ceiling bill, Congress now turns its attention to the budget for fiscal year 2024 and funding the government within the spending limits set by the deal. That requires approving 12 appropriations bills by Oct. 1. Congress rarely meets that deadline. The last time it did was more that 25 years ago. Instead, usually, one or more short-term funding bills are approved to buy lawmakers more time to iron out a comprehensive package. This year, House Speaker Kevin McCarthy has vowed to pass all 12 spending bills. Manufacturers could be vulnerable as Congress looks for ways to cut spending programs and/or raise taxes to meet the debt ceiling requirements. AMT is working with several coalitions and organizations to defend important programs and incentives that strengthen the MT industry.

INTERNATIONAL

Hitch Your Cart to the Right Car If you traveled by road in 1923, chances are you were still saying “giddy up” to the horse pulling your buggy. In the United States, only about 13% of the population had a car, and that number was much lower in Europe. Now, 100 years later, an estimated 1.5 billion cars travel the world’s roads. Manufacturing technology came along for the ride to the point that automotive manufacturing consumed the lion’s share of MT. Today’s evolving global transportation landscape is seeing significant changes impacting MT suppliers. Electric and autonomous vehicles, shared and micromobility, high-speed and hydrogen rail, smart infrastructure, urban air mobility, etc. all represent a shift that creates both challenges and opportunities – different components, sensors, batteries, lightweight materials, additive processes, connectivity and data analytics, and supply chain dynamics. If you stay agile and adaptive, embrace R&D, collaborate, investigate new processes, and be proactive, you can evolve, stay competitive, and thrive.

The Manufacturing Technology Series 2023 will bring

the most important manufacturing technology events in the U.S. in 2023.

Feb. 21-23, 2023 Houston, TX

May 16-18, 2023

Oct. 24-26, 2023 Greenville, SC

Nov. 7-9, 2023 Long Beach, CA

Visit mtseries.com to learn more.

MT_Series_Engage_ME_AMT_6.75x3.795.indd 1

6/20/23 1:27 PM

WHAT’S HAPPENING

JULY/AUGUST 2023

11

AMT Upcoming Events Learn more or register at AMTonline.org/events. Your datebook will thank you.

MTForecast brings the latest economic news, forecasts, and industry trends straight to you. Industry leaders, executives, and key decision-makers will connect and learn better business strategies through customer industry insights, economic forecasting, and deep dives into market data. MTForecast 2023 October 4-6, 2023 | Detroit, Michigan INTELLIGENCE The Certified Manufacturing Technology Sales Engineer (CMTSE) Program is the only nationally recognized program to measure and celebrate the skills, knowledge, and ability of sales engineers to perform effectively. More at www.cmtse.org. CMTSE Exams SMARTFORCE

MFG 2024 April 24-26, 2024 | Orlando, Florida TECHNOLOGY

The Manufacturing For Growth (MFG) Meeting is the ultimate gathering of manufacturing technology minds, bringing together a community of solutions and solvers. Learn how to keep pace with growing demand, make lifelong connections, and see what opportunities lie on the horizon.

Formnext Forum Austin August 28-30, 2023 | Austin, Texas FORMNEXT

This is the first in a series of Formnext events to drive industrial 3D printing innovation and growth in the Americas. Created from a partnership between AM industry leaders Mesago Messe Frankfurt, AMT, and Gardner Business Media, Formnext Forum Austin will feature top-notch speakers, high-value attendees, and ample networking. The Formnext family is growing in the United States.

October 11, 2023 Upcoming Exam Dates

IMTS IMTS 2024 September 9-14, 2024 | Chicago, Illinois

The largest manufacturing technology trade show in the Western Hemisphere. Find new equipment, software, and products to move your business forward, connect with industry experts and peers, and attend conference sessions to boost your industry knowledge.

009 FIRST ‘A.I.’D

Nan0 BYTES

One short business trip later...

NanO, are you excited for your o r conference? It has an amazing ? I a maz spa, restaurants, the beach... auran beach

Don't worry! I’ve got this!

Why does it say paper jam when there is no jam?!

I look forward to the “Augmenting Your Workforce With Augmented Reality” session. Will you be okay alone, AerO? You’ll install MTConnect on the legacy equipment? And manage production for the ENTIRE week?

Written by Dan Hong // Illustrated by Jacob McCloskey

After all, I’m an artificial tific intelligence just like you. I put the “A.I.” in “aid”!

ERROR

Well, all right...

Well, the production numbers u e production numbe look great!

Yes, of course.

I got it! Stop worrying!

What’s that smell? Sal, did you microwave fish again?!

THE TRANSPORTATION ISSUE

12

JULY/AUGUST 2023

13

Planes, Trains, and Automobiles (More or Less) The transportation landscape – above and on the ground – is changing in a way that brings to mind the likes of the Wright Brothers and Henry Ford: a major transformation.

By Gary S. Vasilash CONTRIBUTING EDITOR

The Rise of Urban Air Mobility The Inflation Reduction Act of 2022 will have profound consequences on many parts of the U.S. landscape and economy as only something with a spend of some $437 billion can. For those in the manufacturing space, the IRA has a very large carrot: Companies can get $35 per kilowatt-hour of battery cells produced, $10 per kilowatt-hour for battery modules

FEATURE STORY

THE TRANSPORTATION ISSUE

14

The Archer Midnight electric vertical takeoff and landing vehicle . Stellantis will help build the urban mobility aircraft, and United will put it into service in New York and Chicago. ( Image: Archer Aviation )

built, and a 10% tax credit on costs used to produce materials. And there’s the National Electric Vehicle Infrastructure (NEVI) program: $5 billion for the construction of a national EV charging network, including requirements for charger assembly in the United States as well as the fabrication of the steel or aluminum enclosures, and will, in 2024, require 55% of components to be sourced domestically. But in March 2023, the “National Aeronautics Science & Technology Priorities” report came out of the executive office with important implications. One way of looking at this is that the Wright Brothers put the United States in pole position at the start of the aviation industry, and the U.S. government wants to keep it there. From the report: “The aeronautics enterprise is an integral part of the U.S. economy, annually generating 4.9 percent of U.S. gross domestic product—$1.9 trillion in total economic activity in 2019—and more than 10 million jobs. The aeronautics sector is also a major exporter, the second largest manufacturing export sector in the United States, generating $148 billion in exports in 2019. … Continued investment in state-of-the-art aeronautics research and development (R&D) is critical to ensure the continued vitality of this important sector.” On the one hand, it is about national defense. And on the other, the commercial space, which, according to the priorities, “accommodates approximately 2.3 million passengers and 66,000 tons of cargo on 25,000 flights daily.” And: “These numbers are projected to increase.”

The aeronautics enterprise is an integral part of the U.S. economy, annually generating 4.9 percent of U.S. gross domestic product—$1.9 trillion in total economic activity in 2019—and more than 10 million jobs. The aeronautics sector is also a major exporter, the second largest manufacturing export sector in the United States, generating $148 billion in exports in 2019. … Continued investment in state-of-the-art aeronautics research and development (R&D) is critical to ensure the continued vitality of this important sector. — National Aeronautics Science & Technology Priorities report

FEATURE STORY

JULY/AUGUST 2023

15

Among the technologies that the government plans to prioritize in this space, “with the potential to transform aviation … creating new industries and jobs,” are advanced air mobility (AAM) vehicles, including electric vertical takeoff and landing (eVTOL) aircraft. And if there is something that is going to transform air travel in a way that is analogous to how electric vehicles are going to change the way people go about their daily drives, it is eVTOLs – and they’re going to be making the change sooner, not later. Economic Approach Commercial companies are developing eVTOLs and advancing technologies while taking economic factors into account. They are working on craft that can attain FAA certification to transport people. They are also working to assure money will be made on building and operating these aircraft. In Archer Aviation’s 2022 fourth-quarter earnings call this past March, Archer’s chief financial officer, Mark Mesler, explained that the Archer model has two approaches. One is Archer Direct, which will sell the Midnight eVTOL directly to customers; and the other is Archer Air, which will provide a service with its equipment. He anticipates a 50-50 revenue ratio. Mesler said that an eVTOL flight between Manhattan and Newark Liberty International Airport, which takes approximately 10 minutes, could be priced at $6 per passenger mile – similar pricing to a terrestrial ridesharing vehicle – and assuming that its four seats are occupied on each trip and there

are 25 trips per day, 365 days per year, that would be revenue of $3.2 million per year. This is not simply a theoretical calculation. On Nov. 10, 2022, Archer and United Airlines announced they plan to operate flights between the Downtown Manhattan Heliport and Newark International. Then, on March 23, 2023, the two announced a route between downtown Chicago and O’Hare Airport. Both routes are expected to be operational in 2025. Not a Few, but Many United is committed to eVTOLs: in August 2022, it made a $10 million pre-delivery payment to Archer for 100 aircraft. “Wait a minute,” you think. “100 aircraft? How long is it going to take for that delivery?” Potentially quite a bit less time than you might think. That’s because there is another company that is working with Archer: Stellantis. This global automotive OEM is collaborating with Archer on a factory being developed in Covington, Georgia. This 350,000-square-foot plant, expected to open in 2024, will have a capacity of 650 aircraft a year. There are already plans on paper to build out the plant for a 2,300 unit capacity. Not only is Stellantis providing Archer with high-production expertise, but it is also providing up to $150 million in equity capital. Thomas Paul Muniz, Archer’s chief operating officer, said that they’re looking at achieving high volumes by leveraging automation and using “processes that are more similar to what you see in automotive.”

The carbon fiber fuselage for the Joby Aviation aircraft . Delta announced it plans to use the eVTOLs in Los Angeles and New York. Toyota, an investor, is helping Joby use the Toyota Production System. (Image: Joby Aviation)

FEATURE STORY

16

The Toyota Production System, Too Archer isn’t the only eVTOL company in this space with a somewhat analogous approach to developing an entirely new passenger aircraft. In late April 2023 Joby Aviation announced signing a long-term agreement with Toyota Motor Corp. for powertrain and actuation components. What’s more, Toyota

Our mutual goal is mass production of eVTOL and helping Joby apply the best practices of the Toyota Production System in meeting high quality, reliability, safety, and strict cost standards. — Keiji Yamamoto, president of Connected Co., Toyota Motor Corp.

has been working with Joby on the design of the pilot production line for the aircraft, as well as participating in various projects. Keiji Yamamoto, president of Connected Co., Toyota Motor Corp., said, “Our mutual goal is mass production of eVTOL and helping Joby apply the best practices of the Toyota Production System in meeting high quality, reliability, safety, and strict cost standards.” JoeBen Bevirt, founder and CEO of Joby, said of Toyota, which also happens to be the largest external shareholder in the company with an investment of approximately $400 million, “Their expertise has helped put us on track to deliver, at scale, an aircraft that we believe is truly best-in-class.” Another company participated with Joby in the development of the eVTOL. According to a company spokesperson, “The airframe is a carbon fiber composite we have developed in house, in collaboration with Toray.” Toray Industries is one of the leading composites suppliers on the planet. While Joby is currently operating its pilot production facility in Marina, California, the company will soon announce the location of its major production operation.

Delta and the Air Force It is also worth noting that Joby also has a relationship with a major air carrier: Delta Air Lines has made an upfront equity investment of $60 million in Joby, with the potential of investing up to $200 million. And there is an operational relationship between them, with the aircraft providing services to Delta’s airline customers, initially in New York and Los Angeles. And although this has concentrated on the commercial aspects of the two companies, going back to the “National Aeronautics Science & Technology Priorities,” Joby also has a $131 million contract with the U.S. Air Force (e.g., it will be delivering two of its five-seat eVTOLs to Edwards Air Force Base early in 2024). Things like flying cars are still fanciful. The creation of eVTOLs is the real thing.

FEATURE STORY

JULY/AUGUST 2023

17

The Wabtec FLXdrive locomotive: a full battery electric locomotive. Wabtec is also working with GM on the development of a hydrogen-powered locomotive. ( Image: Wabtec )

EVs on Rails When Chevrolet launched the Volt in 2019, it didn’t want the vehicle to be referred to as a “hybrid.” After all, Toyota pretty much owned that word with the Prius in the same way that Kleenex owned the term for the paper facial tissue. The Volt has an electric motor and an internal combustion engine. But that engine functions mainly as a generator, charging the battery that powers the motor that turns the wheels. It is a series hybrid. The Prius is a parallel hybrid. So instead of calling the Volt a “hybrid,” the folks at Chevy insisted that it be called an “extended-range electric vehicle.” While that may have seemed somewhat innovative at the time, if not revolutionary, do you know what else is an “extended-range electric vehicle”? Locomotives. And these hybrids have been commercially available since 1925 (as switchers in railyards). Through the 1930s, a leading manufacturer of diesel-electric locomotives was Electro Motive – which was owned by General Motors (it sold the business in 2005).

Efficiency for the Distance Today the architecture of a locomotive has a diesel engine (with roughly 4,500 hp) that powers an alternator; its electrical output goes to the traction motors that power the wheels and pull the freight. According to the most recent figures from the U.S. Bureau of Transportation Statistics, there are 23,544 freight locomotives (i.e., not passenger trains) on the nearly 140,000 miles of freight rails in the United States. The Association of American Railroads calculates that a train will move a ton of freight some 480 miles on a single gallon of fuel, making a freight train three to four times more fuel efficient on average than a truck. The organization points out that while railroads handle about 40% of the long-distance freight volume in the United States, they are responsible for 1.9% of transport-related greenhouse gas emissions.

While railroads handle 40% of

long-distance freight volume in the country, they only account for 1.9% of transport related greenhouse gas emissions.

Continued on Page 20

THE BIG PICTURE

THE TRANSPORTATION ISSUE

18

THE AEROSPACE INDUSTRY FOLLOWING A RECESSION

Value of Aerospace MT Orders Following a Recession

The value of aerospace orders tends to grow at a slower pace than the overall market for machinery following a recession.

100 120 140 160 180

0 20 40 60 80

0 1 100 = Peak Prior to Recession

8 9 1011 121314

2 3 4 5 6 7

15 16

Quarters Since Peak COVID-19 GFC 2001 Recession Benchmark

Source: USMTO

Units of Aerospace MT Orders Following Recession

100 120 140

However, the number of units tends to return to pre-recession levels much quicker.

0 20 40 60 80

100 = Peak Prior to Recession

0 1

8 9 1011 121314

2 3 4 5 6 7

15 16

Quarters Since Peak COVID-19 GFC 2001 Recession Benchmark

Source: USMTO

Wide will be added They plan to planes in the

AIRLINES ARE INVESTING IN UPGRADED FLEETS THROUGH 2023

JULY/AUGUST 2023

19

Short-haul air transport electrification will not reduce oil demand by much. Most oil consumption comes from long-haul flights. AIRLINES CAN’T ZAP AWAY FROM OIL LIKE THE AUTOMOTIVE SECTOR

Forecast for World Energy Demand for Air Transport

Electricity

0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10

Oil

Million Tonnes of Oil Equivalent

2022 Q1

2032 Q1

2028 Q1

2038 Q1

2024 Q1

2026 Q1

2036 Q1

2042 Q1

2034 Q1

2048 Q1

2030 Q1

2046 Q1

2050 Q1

2044 Q1

2040 Q1

Source: Oxford Economics

The aerospace industry’s link to oil prices will require ongoing modernization. Investments in increased efficiency and new technology may offer more resiliency in the aerospace industry for upcoming recessions.

-Body Planes d to United’s fleet. o have more than 700 eir fleet by 2033.

New Aircraft American Airlines plans to take delivery of 19 new narrow-body and 4 wide-body planes in 2023.

A339’s & A350’s Delta is close to buying new Airbus A330 and A350 airplanes.

FEATURE STORY

THE TRANSPORTATION ISSUE

20

(Continued from Page 17)

As efficient as these giant hybrid vehicles are, there is still that fuel: diesel. The combustion of diesel fuel results in particulate matter, nitrogen oxides, carbon monoxides, and other pollutants. So railroad companies and locomotive manufacturers are looking at alternatives in order to reduce their carbon footprints.

diesel-electric locomotives used GE motors. Today, Wabtec has a global installed base of locomotives of about 23,000 units. Wabtec is taking a portfolio approach to reducing emissions in the locomotives it produces, such as using liquified natural gas and performing research on various biofuels. Importantly, Wabtec has developed FLXdrive, a fully battery electric locomotive. No diesel. Just electricity. In a three-month pilot – revenue service, so this wasn’t an engineering trial – conducted with BNSF Railway in San Joaquin Valley, California, they found the locomotive, which has 2.4 megawatt hours of lithium-ion battery storage, saved what would have been more than 6,200 gallons of diesel fuel and prevented 69 tons of carbon dioxide emissions from being produced during the 13,320-plus miles of freight hauling. This performance was an industry first. Presently FLXdrive locomotives are in production at the company’s complex in Erie, Pennsylvania. One will be delivered this year to Australian mining company Roy Hill. It has an energy capacity of more than twice that of the pilot locomotive: 7 MWh. Roy Hill will be using it in an iron ore hauling operation – trains that are on the order of 1.6 miles long.

The Wabtech Portfolio Approach One company with a strong position in this space is Pittsburgh based Wabtec Corp., a leading manufacturer of locomotives. It has been in the train business for more than 150 years. It originally began in 1869 as Westinghouse Air Brake Co. and since then has grown both organically and through acquisition. The latter included the 2019 merger with GE Transportation, which had been around since 1907 and produced its first locomotive in 1912. Interestingly, those early Electro-Motive

The BrightDrop Zevo 600: GM went from concept to product in just 20 months, a record for the company. ( Image: BrightDrop )

FEATURE STORY

JULY/AUGUST 2023

21

BrightDrop: Bringing EV Delivery Vehicles to a Neighborhood Near You One of the abiding consequences of the pandemic is that people discovered that they could buy essentially everything from the comfort of their own home or office. For parcel deliveries – USPS, UPS, FedEx, Amazon, etc. – seven days a week became the rule, not the exception. According to the Pitney Bowes Parcel Shipping Index, in 2022, U.S. companies and consumers shipped, received, and returned 21.2 billion parcels. That’s 58 million a day, some 674 parcels per second.

(If you want to know how small the world is, consider this: The batteries that Wabtec is using are Ultium batteries – developed by General Motors.) If you’ve ever seen the front of a freight train (given the lengths, you’re more likely to see the railcars) you might have noticed that there is generally more than one locomotive. (This grouping of locomotives is known as a “consist,” with the emphasis on the first syllable.) The Roy Hill consist that the FLXdrive will be used with has four diesel locomotives. Although FLXdrive will replace just one of them, Roy Hill estimates a double-digit reduction in fuel costs and emissions. Optimization Philip Moslener, Wabtec’s vice president, advanced technology, says one of the important elements to operating the consist efficiently is the use of what is, in effect, a railroad-scale version of an automotive smart cruise control system. The Trip Optimizer system takes into account the makeup of the train, terrain, and other parameters and then operates the engines in an optimal manner. An important element of achieving operational efficiency for the FLXdrive is – again, something you might be familiar with if you have an electrified vehicle in your driveway – is regenerative braking, taking the kinetic energy of the brakes and using it to charge the batteries (otherwise, it would mainly be lost to heat). There is another undertaking, Moslener explains, with great potential: using hydrogen to power locomotives. Last November Wabtec, Argonne National Laboratory, and Oak Ridge National Laboratory announced cooperative research and development agreements (CRADAs) to develop the hardware and software control strategies that could be used to use hydrogen in existing engines. Moslener says locomotives can be in service for up to 50 years and that the modification “would help decarbonize more quickly without having to get rid of equipment.” And Soon H2 Then there is the second hydrogen track Wabtec is taking: fully powering a locomotive using Hydrotec hydrogen fuel cell systems – which happen to have been developed by GM and are being produced at Fuel Cell Systems Manufacturing in Brownstown, Michigan, a joint venture between GM and Honda. In this case it would be a replacement of the diesel engine with the fuel-cell modules. Moslener points out much of this depends on the availability of economical green hydrogen (i.e., hydrogen produced by using renewable electricity for the electrolysis of water). He says that the U.S. Department of Energy’s Hydrogen Shot program could go a long way to accomplishing this cost competitiveness. The goal of this program is “111”: $1 per kilogram of green hydrogen in one decade. Here’s something to consider: The Industrial Revolution was largely powered by the development of the steam engine. One of the uses of the steam engine that literally transformed transportation was the locomotive.

FEATURE STORY

22

And Pitney Bowes sees growth: a 5% CAGR between 2023 and 2028, reaching 28 billion parcels in 2028. So there is room for more delivery vehicles that can efficiently, economically, and environmentally do the work. Our need for reliable, sustainable transportation has never been more important. BrightDrop is a perfect example of the innovations we are adopting to transform our company as time-definite express transportation continues to grow. A New Brand General Motors, while known more for its passenger vehicles than its commercial products, has plenty of truck-building experience: The GMC brand was known as General Motors Truck Company when it was established in 1911. In January 2021, with growing demand for commercial trucks, especially electric versions – and associated software and services – GM announced the establishment of BrightDrop, described by Mary Barra, GM chairman and CEO, as “a new one-stop shop solution for commercial customers to move goods in a better, more sustainable way.” GM cited analysis from the World Economic Forum that was released in January 2020 (before any lockdowns) that showed that among last-mile deliveries, same-day delivery was growing 36% per year and instant delivery by 17%. So, the idea of electric delivery vehicles – vans as well as carts – made tremendous sense to GM. Rather than simply thinking, “Yes, this looks like a good opportunity, so let’s pursue it,” people at the corporation worked with FedEx, so the day BrightDrop was announced, Richard Smith, FedEx Express’ regional president of the Americas and executive vice president of global support, was able — Richard Smith, regional president of the Americas and executive vice president of global support, FedEx Express

FEATURE STORY

23

General Motors retooled its plant in Ingersoll, Ontario , from producing Chevy Equinoxes to BrightDrop Zevos. ( Image: BrightDrop )

THE TRANSPORTATION ISSUE

24

SAVE THE DATE FOR

SEPTEMBER 9 – 14, 2024 MCCORMICK PLACE, CHICAGO

IMTS, the largest manufacturing technology trade show in the Western Hemisphere , showcases the transformative technologies that are enabling our industry to reach new levels of productivity and profitability.

STAY UP TO DATE AT IMTS.COM

FEATURE STORY

JULY/AUGUST 2023

25

to say, “Our need for reliable, sustainable transportation has never been more important. BrightDrop is a perfect example of the innovations we are adopting to transform our company as time-definite express transportation continues to grow.” FedEx was the first customer for the electric delivery vans. The Demand The first five of what was then an order for 500 vans were delivered to FedEx by Dec. 21, 2021. (By June 2022 there were 145 more delivered.) And there have been plenty more multiple vehicle orders from companies, including Walmart, DHL, and Merchants Fleet. There are now over 25,000 ordered on the books. To accommodate the demand, GM invested some $800 million to retool its CAMI production facility in Ingersoll, Ontario, Canada, which had been producing Chevrolet Equinoxes prior to the BrightDrop vans. The Development BrightDrop’s Matt Armstrong says the development of the Zevo 600 (the first of the delivery vans, with the smaller Zevo 400 launching in 2024) was predicated on people from the GM Global Innovation organization and design staff being essentially embedded with drivers from companies, including FedEx, to see what their days were like. GM didn’t want to make just another step van but something that was a marked improvement. The electric technology contributes greatly. For example, typically, delivery drivers get in and out of their vehicles over 100 times a day. The Ultium battery platform is placed low so the step-in height is lowered, making it easier on drivers’ knees. They designed the seat not only for comfort, but to facilitate ingress and egress. The typical lever to set the parking brake is replaced by a push-button. Cargo lights in the storage area (over 600 cubic feet and a payload capacity of about 2,200 pounds) are turned on and off by motion sensors.

The Parts Bin Notably, the BrightDrop vans are the fastest-built vehicles – from concept to market – in GM’s history. Twenty months. Part of that, Armstrong explains, is predicated on the Zevo engineers being able to take advantage of the learnings from another large electric vehicle that was being developed at the time, the GMC Hummer EV. What’s more, while there is sometimes criticism leveled at companies like GM for using the “parts bin” in developing vehicles (i.e., using the same components in a Chevy as in a Cadillac, for example), Armstrong notes that the GM parts bin provided BrightDrop with an advantage because the parts bin contributes things from the steering wheel to push-buttons to the Zevo 600, thereby keeping down costs. The Outlook While the uptake of electric vehicles by consumers in the United States remains to be determined, Armstrong says they see a huge opportunity going forward with electric delivery vans for several reasons. For one thing, fleet operators are looking at total lifecycle costs, and BrightDrop calculates that in terms of maintenance and fuel costs, the Zevo 600 can save over $10,000 per year compared to a comparable diesel-powered vehicle.

For another, companies like FedEx have publicly committed to transforming their pickup and delivery fleets to all-electric vehicles (in FedEx’s case, it intends to do so by 2040). So, we go back to the start of this: In mid-April, after the U.S. Treasury announced its guidance regarding the critical mineral and battery component requirements as related to the Inflation Reduction Act, GM announced: “Fleet customers including for BrightDrop and the Chevrolet Silverado EV will benefit from the $7,500 commercial incentive.” The transportation transformation has a lot to do with what the U.S. government is doing.

If you have any questions about this information, please contact Gary at vasilash@gmail.com.

THE TRANSPORTATION ISSUE

IMTS

26

Head South for Summer Travel: Make Plans for Formnext Forum Austin BY PETER EELMAN CHIEF EXPERIENCE OFFICER

If there is a Silicon Valley of the South, it’s Austin. Organizations expanding their presence in this Texas tech hub include giants such as Apple, Advanced Micro Devices

Manufacturing magazine and related AM products). The event fits right in with Austin’s embracement of technology, venture capital, and attracting talent. If you want a deep dive into the latest AM innovation that can help your industrial business evolve, then your late-summer travel plans need to include three days in Austin. Meet Our Collaborators, New and Old Formnext might be a name that is new to those of us in North America, but it has more than a decade of history as an exhibition and conference dedicated to additive manufacturing and industrial 3D printing. Formnext 2023, which will be held Nov. 7-11, 2023, in Frankfurt, will feature more than 800

(AMD), Tesla, SpaceX, Oracle, and many more. This migration of tech activity now includes additive manufacturing and the first Formnext event held in the United States, Formnext Forum Austin, coming Aug. 28-30. AMT is thrilled to be part of the team of international AM industry leaders bringing this event to you, along with our partners – Mesago Messe Frankfurt (the owner of Formnext) and Gardner Business Media (GBM, the producer of Additive

FORMNEXT FORUM AUSTIN FEATURES:

• Technical sessions, with 12 sessions for production, 12 sessions on design for AM (DFAM), and 20 sessions on AM equipment and application technology. • Keynote sessions from Gregory Hayes, senior vice president, applied technology, at EOS, and Matthew Sermon, executive director at PEO Strategic Submarines for the U.S. Navy. • Facility tours of EOS and Cumberland Additive. • The Cool Parts Showcase, presented by Additive Manufacturing magazine and GBM. • Tabletop exhibits from more than 60 AM tech and service suppliers. • And of course, plenty of networking opportunities, including receptions on Monday and Tuesday night.