MT Magazine May/June 2024

IS A COBOT RIGHT FOR YOU? KEY QUESTIONS TO CONSIDER WHEN DEPLOYING COLLABORATIVE ROBOTS — BETTER KNOWN AS 'COBOTS'

FORMNEXT CHICAGO: A COMPREHENSIVE SHOWCASE OF ADDITIVE MANUFACTURING by Peter Zelinski | 16

WHAT'S NEXT IN AUTOMATION? by Michelle Edmonson | 21

THE CURIOUS HISTORY OF ROBOTS by Andra Keay & Chris Cavallo | 27

by Gary S. Vasilash | 13

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MAY/JUNE 2024 THE AUTOMATION & ROBOTICS ISSUE VOLUME 3 | ISSUE 3

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A VIEW FROM THE WOODS

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Achieving Active Intelligence Although artificial intelligence (AI) is likely to have an impact on your operations at some point – assisting with things like predictive maintenance, quality control, and process optimization – I’d like you to consider another type of AI, something that can help improve your operations right now. And this type of AI is based simply on your willingness to make it happen – on more shoe leather and less silicon.

knowing its condition and productivity; (2) the new developments that can have an impact on your operation’s performance. While you can simply Google any subject and watch a YouTube demonstration, there is no substitute for actually seeing things in their physical, not digital, form. This is an IMTS year, so I would strongly urge you to put that on your calendar and make plans to be in Chicago. There is no single event that is both as convenient to you and comprehensive for you as IMTS. But you should also visit tech expos in other parts of the world, such as EMO in Europe and JIMTOF in Japan. Why go that far? Because often smaller and medium-sized companies have interesting technologies but don’t have the budgets necessary to attend events in the United States. Consequently, the only place you are likely to see it is in its home market. I know that this is a large time and expense commitment without a guaranteed ROI, but discovering new technology early can provide a competitive advantage. Another way to gain some useful intelligence is to attend events that might be adjacent to your market (say an event held by companies like NVIDIA and Autodesk) or that are the end markets of your customers (like medical equipment or aerospace). This awareness can be invaluable for your own decision-making as well as your ability to talk to your customers on their terms. Finally, there is the issue of active intelligence and your employees. You’ve got to meet them where they are, which means your facilities. I learned an important lesson from my grandfather about this. He ran several operations in the Rochester, New York, area. When he’d drive to work, he’d regularly stop at one of these shops to get a firsthand look at what was going on. He’d consult the data and reports when he got to his office. But he found it was extremely valuable to have on-the-ground knowledge. Here’s an important thing he did: He didn’t go through the front door but started at the loading dock. That way he could see what was incoming and, importantly, outgoing. He talked to the people in shipping, then made his way onto the factory floor, where he chatted with operators about their jobs. By the time he got to the front offices, the plant manager was fully aware he was there and ready to discuss how things were going. Maybe it added an hour to his day, but for him, it was important, and nowadays, when labor is in short supply and it is hard to keep good employees, I can think of no better way to get to know your people outside of deliberately and regularly talking with them. Active intelligence is one part commitment and one part consistency. It may not get the attention of the other AI, but it is likely more important to your success for the foreseeable future.

It’s “active intelligence.” There is no software required. This is about getting out of your office and going to the places where actionable things can be learned and subsequently acted on. For many people, COVID created a habit that isn’t beneficial: relying on communications that are through a screen, not face-to face. For active intelligence to be implemented, if that’s one of your habits – emails, Zoom meetings, phone calls – you need to kick it. Not entirely of course. But get out of your office on a regular basis. Trust me: This is something that I’ve had to remind myself of. Let’s consider three areas where active intelligence can make big differences: customers, technology, and employees. With customers, the folks that keep your lights on, it is far too easy to let the relationships run on autopilot – until something unexpected happens, at which point it may be too difficult to regain control. Acquiring active intelligence can take different forms, all of which are useful. Because you’ve shipped equipment to a customer’s shop, have your staff check in with the people who work with the equipment. Find out how it is performing. Ask if they can get a read from the customer’s purchasing department on how things are going. More importantly: Get out there yourself. Chances are you have a handful of key customers. Schedule visits with each of them. Say you have nine. Group them in three. Each month, carve out a couple days to see a group. This means you’ll see all nine during a quarter. Not only is this important for firming up the relationships with them, but you can get a firsthand look at what’s happening there, from the number of cars in the parking lot to the activity on the shop floor. I’ve found that spending time on the ground with customers makes a big difference – for both of us. Additionally, make yourself aware of how the segments your customers are working in are doing. Read trade magazines. Consult with organizations like AMT that have market data. If your customers are public companies, look at their quarterly reporting information. To learn about trends and factors that might affect them – and if it affects them, it will affect you – pick up publications that might not be on your regular reading list, whether it is Barron’s or Fast Company. (I don’t have subscriptions to them, but when I take a flight to visit customers, I buy copies and make it my airplane reading.) On the technology front, stay current on two aspects: (1) the equipment and systems that you have on your floor right now, as in

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

Executive Team 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

Membership & Sales Bill Herman VP, Sales & Membership bherman@AMTonline.org Technology Benjamin Moses Senior Director, Technology bmoses@AMTonline.org Intelligence Kevin Bowers VP, Research" kbowers@AMTonline.org Smartforce Catherine Ross Director, Community Engagement cross@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

Elissa Davis Writer/Digital Community Specialist edavis@AMTonline.org

Advocacy Amber Thomas VP, Advocacy athomas@AMTonline.org International Ed Christopher VP, Global Services echristopher@AMTonline.org

Jacob McCloskey Senior Graphic Designer jmccloskey@AMTonline.org

Tiffany Kim Graphic Designer tkim@AMTonline.org

Hailey Sarnecki Graphic Designer hsarnecki@AMTonline.org

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Table of Contents

Click See what’s trending on AMTonline.org

07

Manufacturing Matters Get details on the latest industry news

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AMT Upcoming Events Important manufacturing technology dates and events to bookmark

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Is a Cobot Right for You? by Gary S. Vasilash

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Formnext Chicago: A Comprehensive Showcase of Additive Manufacturing by Peter Zelinski

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The Big Picture A Machine Shop’s Automation Journey

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What’s Next for Automation? by Michelle Edmonson

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The Manufacturing World in a Word by B0nnie Gurney

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The Curious History of Robots by Andra Keay and Chris Cavallo

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‘Tom & Lonnie Chat’: Using AI in Manufacturing by Stephen LaMarca

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Navigating Automation Adoption: A Historical Perspective by Chris Chidzik

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COVER DESIGN Tiffany Kim | Graphic Designer

INFOGRAPHIC DESIGN A Machine Shop’s Automation Journey Tiffany Kim | Graphic Designer

MT Manufacturing Technology (ISSN # 2836-2896), May/June 2024, Issue 3, 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.

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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.

Knee-Deep in Automation at SPS “Adventures with Doug Woods at SPS" dives knee-deep into automation at the SPS – Smart Production Solutions show in Nuremberg, Germany. AMT President Doug Woods provides a closer look at the show’s newest automation technology, as well as gives the audience a sneak peek at what’s coming to the United States when

SPS Atlanta debuts Sept. 16-18, 2025. IMTS.com/AdventuresWithSPS

SOTU and Biden’s Budget: Are Tax Increases on the Horizon?

2025 will be here before you know it, and with it comes … taxes? Amber Thomas, AMT’s vice president of advocacy, dives into President Joe Biden’s State of the Union address, his budget for fiscal year 2025, what they mean for the industry – and what your business can expect in the new year. AMTonline.org/article/sotu-and-the-presidents-budget-are-tax increases-on-the-horizon

AMT Tech Trends: Pennies From Heaven What is one thing better than technology? Pets! In this episode of the “Tech Trends” podcast, the Tech Friends discuss the importance of a pet’s name before breaking down stainless steel corrosion, heading for the moon with Japan, and recapping the Boeing saga. AMTonline.org/article/amt-tech-trends-pennies-from-heaven

Sustaining the Growth of Additive Manufacturing Through Market Development Ecosystems aren’t just for the animal kingdom! Formnext, along with AMT and Gardner, are bringing the world’s largest additive manufacturing (AM) event to the United States in 2025 with the introduction of Formnext Chicago, where the entire AM ecosystem will be on display. Get to know the A-Z of AM and learn why it’s more than just another tool for your factory. Register for Formnext Chicago today! AMTonline.org/article/sustaining-the-growth-of-AM

CINCINNATI JUNE 19

BOSTON JUNE 5

CHICAGO JULY 24

INDIANAPOLIS JULY 17

MANUFACTURING MATTERS

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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

Is Automation the New Lean? Since its early stages, automation has been seen as a way to increase output. Recent advancements have improved automation’s productivity in the same manner that lean principles would – by eliminating waste. Transport, inventory, motion, waiting, overproduction, overprocessing, and defects are the seven types of waste. The growth of enabling tech and digital manufacturing pushes automation, which provides a broader set of solutions than a robotic arm, as a potential answer to waste. Some operations can be automated with fixturing. For example, vision systems can guide robots and inspect parts in a static fixture. Automating material handling from stock to stock can reduce transport, waiting, and motion. Coupling automated data capture can reduce defects. While the technologies are available, this emphasizes the importance of humans, who still have to identify, design, and implement such solutions.

INTELLIGENCE

A Measure of Industrial Automation Adoption The evolution of industrial automation has been underway for decades, consistently transforming the manufacturing landscape. This transformation is not new, but the pace at which automation is being integrated into manufacturing processes has significantly accelerated in recent years. One method to assess the impact of automation in manufacturing is through total factor productivity (TFP), which evaluates the efficiency of all inputs to a production process. From 2017 to 2023, TFP saw a growth of 4.1%, outpacing the 3.1% increase noted in the previous six-year span. However, an even more meaningful metric for understanding the adoption of automation is capital intensity. This measures the amount of capital utilized per unit of labor, and it witnessed an impressive surge of nearly 12% over the same period, nearly tripling the growth rate of the previous six years. Such a significant increase indicates a significant shift toward more capital-intensive and labor-efficient manufacturing processes facilitated by automation.

SMARTFORCE Smartforce Summit: Unveiling the Power of Education Tools in B2B Strategies The Smartforce Student Summit at IMTS 2024 will unveil a best-kept secret: the link between education tools and real-world applications! Discover how classroom training equipment and software can deliver results in B2B sales and pave the way to a better understanding of advanced technologies among small to medium-sized businesses. All IMTS visitors are invited to visit the Summit and take a crucial step toward empowering clients, customers, and partners on all sides of the supply chain. Best-in-class brands will offer hands-on demonstrations and interactive exhibits to showcase the accessibility and adaptability of everything from robotics to additive. Join us in the East Building, Level 2, at IMTS.

Subscribe to the Smartforce newsletter to keep up with the latest at IMTS.com/smartforce. Want to learn more? Contact Catherine “Cat” Ross at cross@AMTonline.org. See you at the Summit!

MANUFACTURING MATTERS

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ADVOCACY

Are Major Tax Increases on the Horizon? Campaign season is in high gear with the race for president in a virtual dead heat. Every seat in the House of Representatives and a third of the Senate seats are also up for election. The razor-thin majority in both chambers means control of either could shift. With the stakes so high, be prepared for more political posturing and less action in Congress as the clock runs down to November. Manufacturers should pay attention to where candidates stand on increasing taxes since most of the tax cuts implemented in 2017 will expire at the end of 2025, necessitating a major tax bill in the 119th Congress. In his budget framework for fiscal year 2025 released in March, President Joe Biden called for $5 trillion in taxes on corporations and high earners to pay for deficit reduction and new spending programs aimed at families and lower-wage earners. The framework serves more as a policy document and stands no chance of passing in a GOP-controlled House.

INTERNATIONAL

AI Changing the Game: Automating Automation? As manufacturers around the globe grapple with a dwindling workforce while striving to sustain or boost production, integrating automation has emerged as a crucial strategy. Automation can help mitigate worker turnover and allow for the upskilling of employees from repetitive manual tasks to more skilled positions. Contrary to fears, it has become evident that automation has fostered job creation at certain levels. The question people are asking now, however, is: Will artificial intelligence change that? The integration of AI is a significant trend in automation and could be a game changer, particularly concerning the synergy between autonomous robots and machine learning. The most noteworthy outcome of this is the potential to use measured data points acquired directly from the factory floor to autonomously optimize manufacturing processes. This could potentially reduce high-mix, low volume manufacturers’ dependency on skilled robot programmers and enable them to automate their operations successfully. Look to South Korea for developments here. They have the largest ratio of robots per industrial worker in the world.

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WHAT’S HAPPENING

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

Enjoy free food and drinks while making valuable connections with local manufacturing professionals! AMT Meetups boost community growth and innovation by bringing together diverse perspectives from every corner of the supply chain. Upcoming Dates June 5: Boston June 19: Cincinnati July 17: Indianapolis July 24: Chicago 2024 AMT Meetups COMMUNITY IMTS presents the free IMTS Online: Exhibitor 101 Learning Series. Tune in to learn the ins and outs of exhibiting at IMTS, whether you’re a first-timer or a seasoned veteran. To learn more and register, visit IMTS.com/exhibitor/education. Upcoming Dates June 13: This Is Your Sign To Hang Signs June 20: 3+ Simple Steps To Empower Your Booth Staff for IMTS 2024 and Beyond July 11: What To Expect When You Are Expecting To Get to IMTS July 18: Let's Get Social Exhibitor 101: An Education Series for Exhibitors IMTS

MTForecast 2024 October 9-11, 2024 | Chicago, Illinois INTELLIGENCE

MTForecast breaks down the latest industry news, forecasts, and trends. Industry leaders, executives, and key decision makers connect and learn better business strategies through customer industry insights, economic forecasting, and deep dives into market data.

MFG 2025 February 19-21, 2025 | San Antonio, Texas TECHNOLOGY

Remember the manufacturing in San Antonio, Texas! At MFG 2025, visionaries, experts, and leaders from across the world of manufacturing technology blow into the Alamo City for exclusive networking opportunities, educational sessions, and a whole lot of fun. See you there, pardner!

Formnext Chicago April 8-10, 2025 | Chicago, Illinois FORMNEXT

Formnext is known as the international meeting point for the next generation of intelligent industrial AM production. This inaugural show will create one event in the United States dedicated to all aspects of additive manufacturing and industrial 3D printing.

SPS Atlanta September 16-18, 2025 | Atlanta, Georgia SMART PRODUCTION SOLUTIONS

SPS is a renowned global trade event for the automation industry and represents the complete spectrum of smart and digital automation – from simple sensors to intelligent solutions, from what is feasible today to the vision of a comprehensively digitized industrial world.

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

The largest manufacturing trade show in the Western Hemisphere inspires the extraordinary! 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.

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Is a Cobot Right for You? Key questions to consider when it comes to deploying collaborative robots – better

known as “cobots.” BY GARY S. VASILASH CONTRIBUTING EDITOR

Statistics from Statista show that in 2018, 11,550 collaborative robots – aka “cobots” – were sold in the U.S. market. The statistical source projects that in 2025 that number will reach 134,400 units. Given that that’s a whopping 1,064% increase, this raises the questions of just what a cobot is in the context of industrial robots as well as use – and not-use – cases for the equipment. But some people may recall the early days of what are now considered “typical” industrial robots – the six-axis manipulators that come in sizes from small to gargantuan. In some cases companies were purchasing one fundamentally because they wanted to be considered current (and possibly cool). This was, in effect, somewhat like putting an industrial robot in the lobby for bragging rights and not on the factory floor, where it would be used to do actual work. Then there were those instances when management figured that they were making a big investment in robots, so they were going to install that equipment in the most difficult applications they had on the factory floor. After all, wasn’t that what they were good for? Well, yes, but not for one’s first outing with the programmable manipulators. So, whether it was having one as a “showcase” or putting the equipment in places that were extraordinarily complex, there was undoubtedly a delay in what could have been a quicker and more widespread deployment of this automation. But while that tech has become common in factories – generally in medium to larger facilities but even in some smaller ones – cobots, while growing in number, are still somewhat new to many companies, filling a niche between the now-traditional six-axis devices and manual workers – or directly adjacent to other automation and humans. What’s more, this equipment can be of greater interest not only to those with larger facilities but small ones, as well.

FEATURE STORY

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Designed to be easy to use, easy to program, and easy to attain an ROI: the cobot. (Image: Kuka Robotics)

Machine load/unload is a good application for cobots, as seen here at Go Fast Campers with a unit from Universal Robots. (Image: Universal Robots).

As there is an increased need for reliable productivity, cobots can provide the way to achieve that even for organizations that don’t have deep familiarity with automation or programming skills. While those six-axis arms – so physically imposing that they served as little more than lobby ornaments – were once so challenging to set up and run that they required massive resources, cobots are designed and engineered for comparative simplicity in their appearance and in their setup. If it is the right task, this simplicity can equate to productivity. So, if you’re interested in the potential of deploying cobots in your operations, here are some key things you should know. This information was garnered from leading suppliers of cobots: ABB Robotics, Fanuc America, Kuka Robotics, Universal Robots, Yaskawa Motoman. 1. What Makes a Cobot a Cobot Versus a Robot? The operative term is “safe” because it is meant to work collaboratively – or at least in the same space – with people. As Yaskawa America’s Bill Edwards, senior manager, collaborative robots, puts it: “A cobot is a robot that has some combination of safety features and sensors in place that allow it to operate in the same space as a human worker. Typically, these sensors are going to be presence detection (laser scanners, lidar, light curtains) and/ or power force limiting (PFL) sensors built into the robot arm. The RIA/A3 had also introduced criteria where the arm must also have a safe design, such as smooth finish and no sharp edges.” Which is not to suggest that traditional robots aren’t safe. But they do require more in the way of protective barriers that keep people away from the work zone while the robot is in operation. 2. What Are the Ideal Applications for Cobots? Cobots are ideally suited for applications that require an operator to frequently interact with the robot – like in the

case of high-mix, low-volume production runs. The reduced time it takes for an operator to enter the collaborative robot cell, whether behind a fence or not, makes changeovers far quicker and less disruptive. Also, for tasks that require a lot of path programming, a cobot solution can be a good fit due to the simplified programming methods that have been recently developed, says Tim Paton, ABB Robotics, general industry segment manager. Another way to consider whether a cobot is applicable comes from Travis Langford, channel development manager at Universal Robots: “The easiest way to think about it is that a cobot is human, not superhuman. Most industrial robots have superhuman speeds and can handle massive payloads. Cobots are more in the realm of human speeds and payloads.” Adam Willea, district manager-Florida, Fanuc America, cites a couple of specific applications: “Ideal applications are slow material handling projects or inspection projects. With slow throughput material handling, this could be machine load/ unload, packaging, palletizing, assembly, and so on. “For inspection, this would either entail the robot carrying a camera/sensor and working it around a part for quality checks or, alternatively, carrying a part to present various angles to a fixed sensor/camera for the same inspection.” 3. What Are the Applications Best Avoided? Universal Robots’ Langford provides a great image of what not to attempt: wrapping a shoebox with paper. A person should do the wrapping. Then the cobot can pick it up and stack it on a pallet. (Shoelace-tying is another example he provides that cobots are not well suited for.) Cobots are comparatively simple devices and they should not be deployed in complicated tasks. Fanuc’s Willea lists other tasks to be avoided: “Anything that requires high speeds, high payloads, dangerous tooling, or dangerous parts. Cobots are legally required to run much slower than industrial robots to maintain

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the contact-stop safety ratings. The current ISO standard is 150N force maximum at 1,000 mm/sec maximum speed (pending only fingers and arms are at risk of contact). If chest area, abdomen, other, are exposed to the cobot, speeds must be limited to 300 mm/sec.” 4. Why Would Someone Get a Cobot Rather Than a Conventional Robot? ABB Robotics’ Paton answers: “Cobots are straightforward to program, deploy, and use, lowering the barriers to automation for first-time users and small to medium enterprises. There are a wide range of reasons an organization would opt to install one or more cobots rather than traditional industrial robots. Some of the most prominent reasons include the lower initial investment and overall operating costs of cobots, the ability for cobots to be more easily integrated into existing production lines, the ability to install and operate cobots without having to hire a robot programming expert.” 5. What Is the First Application That Someone Ought To Try With a Cobot? This is a variation on a theme we’ve seen more than once already: “Something simple. Very simple. A simple application with quick deployment,” says Kuka’s Ryan. You want a win, so going simple is a way to get one. Yaskawa Motoman’s Edwards provides some general specificity: “This is subjective to the industry they are in, but look around for someone that looks like a robot doing a task and try a robot there. Simple, repetitive motions with limited payloads and reasonable speeds. Packing, picking, placing, palletizing, and simple welding are all easy ones to try. With welding, you can do more complicated welds, but a basic T-joint or fillet weld can be learned and taught in a matter of minutes. These are opportunities to automate a basic task that is otherwise wasting your skilled welder’s time.” 6. What Familiarity Does Someone Need With Automation To Install and Operate a Cobot? “Organizations can install cobots with very little experience and familiarity with automation,” says ABB Robotics’ Paton. “But any organization adopting cobot automation must be careful to thoroughly define the structure and motion of the task that a newly installed cobot is to do on the production floor, especially if it is something that a human has traditionally done. “People accomplish complicated tasks very easily, and when you automate these tasks, it is very easy to miss when an operator reorients a part or looks to see what side of the part has a specific feature that allows proper positioning – or quality control. It is very important to talk through the process with an ‘expert’ so that the cobot adeptly and accurately is able to accomplish the desired task.” Fanuc America’s Willea says there’s another thing to keep in mind: “There are ancillary sensors, tools, machines, etc., that must be interfaced. So in order to be successful, someone should at least be familiar with 24VDC circuits, I/O handling,

basic logic control, and have an understanding of sequence control.” 7. What Level of Robotic Programming Skills Are Needed for Cobots? “Generally very little,” says Kuka Robotics’ Ryan. Most cobot vendors provide the ability to program the arm by physically manipulating it. They’ve developed programming wizards. And there is simple, graphical block programming. 8. Can Cobots Work Directly With People (Such as Handing a Part to Someone) or Is It Better To Have Distance Between Them? The simple answer, of course, is “yes.” But there is always a “but.” “They can work directly as long as the application is safe,” says Yaskawa Motoman’s Edwards. “Just because the robot is deemed ‘safe’ does not always mean the application is. You would not want a cobot doing ultrasonic cutting or laser welding within reach of other workers.” As for any manufacturing operation, risk assessments must be made and deployments undertaken accordingly. 9. If Cobots Can Work Directly With People, What Makes the Person Safe? Cobots can detect external forces (e.g., bumping into something – or someone) and safely stop. This stopping is facilitated by the comparatively low speeds they operate at. And given the rounded surfaces of the cobot arm, force is dissipated across a wider area. There are no pinch points on the cobot arm. 10. Are Cobots a Good Solution for the Ongoing Labor Shortage, and if so, How Is ROI Achieved With a Cobot? Fanuc America’s Willea responds: “Most definitely! With the ease of use, quick deployment, safety, and low cost, a cobot can very quickly resolve labor issues within a plant. Consider that the cobot can run 24/7/365; which means you’ll essentially gain the productivity of having a three-shift employee at less than the cost of a one-shift employee. The ROI on most cobots is typically 12 to 16 months when compared to a typical full burden labor rate employee.” As Universal Robots’ Langford notes, “As we are reshoring and near-shoring manufacturing, cobotics technology and automation in general are going to make that possible.”

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

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FORMNEXT

Formnext Chicago: A Comprehensive Showcase of Additive Manufacturing BY PETER ZELINSKI EDITOR-IN-CHIEF, ADDITIVE MANUFACTURING MEDIA

Formnext Chicago is set to arrive next year. AMT President Doug Woods and Sascha Wenzler, vice president Formnext at Mesago Messe Frankfurt, talked to Peter Zelinski, editor-in chief of Additive Manufacturing Media, about the long road to this event, the importance of Formnext coming to additive manufacturing’s biggest market, and the 2025 event landscape in a highly competitive market. There are U.S. trade shows that already address the 3D printing industry, like Rapid + TCT and IMTS. For current and future users of additive manufacturing, what is the purpose and promise of Formnext Chicago? Doug Woods First, this is an additional location for what has become the best-known, most attended, and most important additive show in the world – Formnext. Until now, the only U.S. trade show showcasing 3D printing technology for industry – a show that, to its credit, has run for over 30 years – was Rapid + TCT, which began as Rapid. The show started as a rapid manufacturing show and morphed over time. It has started paying attention to the maker movement and 3D printing applications beyond industrial production, including by offering additive solutions to manufacturing. Meanwhile, IMTS is the best place to find all things manufacturing technology. But Formnext offers something different from both of these events. What we’re all missing is the concept that makes Formnext the most successful additive show in the world: the way it brings together

not just 3D printing; AM as an innovative production solution involves much more. Formnext provides a venue for everything involved in AM, from the materials providers to additive equipment, post-processing solutions, engineering, inspection, and software needs. Sascha, since 2015, you and your team have developed Formnext in Germany. It has become the largest and arguably the most important AM event worldwide. Why do you now want to bring Formnext to the United States? Sascha Wenzler With international Formnext-brand events, we’re following a strategy of holding locally adapted Formnext formats in relevant AM markets based on our highly successful flagship event in Frankfurt. That’s why we have a Formnext expo format in Shenzhen, China, and a Formnext Forum in Tokyo, Japan, for instance. As Doug said, in the United States – the largest marketplace for AM – we see a huge need for a professional B2B trade fair for investment goods that focuses clearly on the whole industrial process of additive manufacturing and the needs of the various industries using this fascinating technology. With Formnext in Chicago, we and our partners can leverage AM in the United States to reach the next level of innovative manufacturing technologies. There’s huge potential among U.S. companies that still haven’t encountered or taken advantage of AM. Together with our partners AMT and Gardner

the entire AM value chain. It’s

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(L-R) Doug Woods, Richard Kline Jr. (blocked), president of Gardner Business Media, and Sascha Wenzler

Business Media, our approach is to exploit this potential just as we’ve done very successfully since founding Formnext in Frankfurt. This is the only way to expand the application of AM beyond the core of professionals into a broad range of industries and ultimately significantly increase the business contacts of our exhibitors. The organizers of Rapid + TCT 2025 have decided to hold their trade fair on the same dates that have been announced for Formnext Chicago. What does AMT think about this? Doug Woods It’s important to understand the sequence of steps. When Mesago began considering its entry into the U.S. market – when the partnership had begun, but we hadn’t decided on a date for a U.S. event – we went directly to SME and the Additive Manufacturing Users Group (AMUG) to look for ways to collaborate. Unfortunately, these discussions did not lead to a collaboration. I can appreciate the difficulty for an exhibitor wondering how to handle this. Unfortunately, we now find ourselves in a situation in which many market participants have to make a decision. There’s always competition, especially in the United States. In a market as large as the United States and with a technology as important as additive manufacturing, there’s room for more than one format, but we’re consciously positioning ourselves in this environment with the unique selling proposition of a dedicated technology trade fair like Formnext.

There is also the Additive Manufacturing Users Group (AMUG) Conference. In 2025, the date of Formnext Chicago is close to that of this conference, also in Chicago. Sascha, what is your perspective on this? Sascha Wenzler You’re right, and Doug already mentioned it regarding Rapid + TCT. It’s a really unfortunate situation when you look at 2025. We were the first ones to announce our date back in 2021. Now, with 2025 coming up very soon, there are three events scheduled close together, or even on the same date. In this context, AMUG is a very different format compared to Formnext. This makes 2025 a real challenge for all the players, be they exhibitors, visitors, or organizers. However, AMUG is a conference in a hotel atmosphere where the users of AM meet and share their ideas. It’s not a traditional trade fair with a much wider reach and range that’s also designed for showing and selling machines, products, and solutions to customers. Both formats create value for the community. In our group of partners, we’ve always been open to discussing possible ways to realize synergies with AMUG or support each other. I’m always more about looking to the future than dwelling on the past. That’s why I’m convinced there are opportunities if everybody moves out of their comfort zone and thinks about how a full year can offer possibilities for different events and formats that benefit the industries we serve and create added value. This is where AMUG and Formnext can complement each other very well.

Visit AMTonline.org/article/FormnextChicago2025ShowcaseAM to read the full conversation.

MT MANUFACTURING TECHNOLOGY THE BIG PICTURE

THE AUTOMATION & ROBOTICS ISSUE

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Workforce challenges, technology advances, and an increasingly competitive environment have led to more shops implementing automation solutions. While each shop’s automation journey typically begins in a similar way, their paths soon diverge as problems grow increasingly unique, requiring a varied set of smart production solutions. Here are the five key stages that every shop will encounter.

Consolidating Setups A crucial first step in implementing automation focuses on consolidating setups, moving from many people conducting many operations on dierent machines to higher-end machine tools that serve a more all-in-one function.

Loading and Unloading Next, shops often look to automate mundane tasks, such as loading and unloading. Gantry machines and robotics solutions tend to be the focus at this stage.

Developed in partnership with

THE BIG PICTURE

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Increased Lights-Out Reliability Optimizing lights-out manufacturing includes ensuring an unattended machine's reliability – even through a weekend. At this stage, needs become specific to a shop’s operations: liquid level systems, temperature sensing, autonomous solutions to replace filled bins, etc.

Addressing Lights-Out Problems Roadblocks will appear due to lights-out production relating to the post-processing and downstream steps a ected by parts pile-up, such as deburring, assembly, packaging, and

inspection. Solutions include sensors, customized control systems, and conveyors.

Implementing Lights Out After automating more-mundane tasks, shops look at implementing lights-out manufacturing, often beginning with running longer to finish a job. Machines loaded via bar feeders provide a natural starting point.

Ready To Start? Map your automation journey at IMTS 2024 in the Automation Sector, accelerated by SPS – Smart Production Solutions.

For even more automation solutions, stay tuned for Smart Production Solutions Atlanta 2025 in Georgia on Sept. 16-18, 2025.

Still need a room for IMTS? The Global Housing Solutions Team, powered by AMT, is here to assist! If you have any questions, please email housing@IMTS.com or call 1-800-957-7714.

GET THE BEST RATES BOOK TODAY

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What’s Next for Automation? BY MICHELLE EDMONSON VICE PRESIDENT, EXHIBITIONS

When it comes to automation, the answer to the question, “What’s next?” – in the form of predictive analytics – is part of the solution visitors can find at IMTS 2024,

that we were going to use to fulfill a new contract in a conference room above the Okuma booth, where our FANUC representative was also present.” Okuma will be in IMTS booth #338500 and FANUC will occupy IMTS booth #338919. New Automation Education Events For the first time at IMTS, automation is the theme of the ELEVATE: Job Shops program, titled “The Shop of Our Future,” and will be presented by AMT on Tuesday, Sept. 10, at 1-4 p.m. Job shop professionals will experience firsthand practical applications and discuss the future of digital transformation with automation experts representing multiple exhibitors to gain valuable insights and actionable tips for implementation. Topics encompass automation today, machine-to-machine learning, an automation panel in partnership with the Technology & Manufacturing Association (TMA), and a discussion on business success by the "Shop Rescue" team. An ELEVATE: Job Shops reception will also be held on Tuesday at 5:30 p.m., providing additional networking opportunities. In addition to the job shops programs and automation-related conference, educational presentations by industry experts and technologists will take place on the show floor on the new SPS Stage (IMTS booth #236000). These sessions are open to all IMTS attendees, do not require advance registration, and offer ample time for questions. New Automation Partner AMT has entered into a partnership with European trade show producer Mesago Messe Frankfurt GmbH, which produces SPS – smart production solutions. This collaboration will debut at IMTS 2024 with the Automation Sector, accelerated by SPS – smart production solutions, where it will host 108 exhibitors on 75,000 square feet of space. Looking Around the Corner Another result of AMT’s collaboration with SPS – smart production solutions is SPS Atlanta, to be held at the Georgia World Congress Center on Sept. 16-18, 2025. SPS Atlanta will showcase a multitude of practical solutions, offer a spectrum of digital innovations (learn more in this video), and provide a vision of a fully digitalized industrial future.

held Sept. 9-14 at McCormick Place in Chicago. The follow-up question – “Where can you find automation at IMTS?” – is better rephrased as “Where won’t you find automation?” Start with the Automation Sector, accelerated by SPS – smart production solutions. But it doesn’t end there: Automation solutions will be found in every aisle at IMTS 2024. Even conversations about hardware are now about hardware’s role in an automated, connected, and digital environment. Visitors to IMTS 2024 will find a broad range of cutting-edge, smart, intelligent, and digital solutions. Most importantly, these solutions can be applied at every stage of production and are ready to implement now. In fact, solutions such as a collaborative robot (cobot) can arrive at your loading dock in the morning and be welding or loading parts by the afternoon. Know What’s Next To answer the “What’s next?” question in automation, here are a few previews from IMTS 2024 exhibitors: • Linear motion guide pioneer THK America (IMTS booth #236207) will show how its OMNIedge IoT system combines connected sensors and artificial intelligence to detect part failures before they occur. “We can improve machine operating rates, make maintenance more efficient, and reduce inventory management costs,” says John Dykas, marketing and events manager at THK. • A paradigm shift has occurred with cobots. “The breakthrough occurred because of a hyper focus on simplifying integration and improving the cobot operator experience,” says Will Healy, global industry leader – welding, Universal Robotics (IMTS booth #236131). “At IMTS 2024, conversations will center around how artificial intelligence, 3D vision systems, and cobots combine to pick a wider variety of parts with an unprecedented reliability.” • One-stop shopping. “You simply can’t talk about the advances in automation and machining without talking about them together, and IMTS is where everyone comes together,” says Scott Harms, president of MetalQuest Unlimited and a longtime IMTS visitor. “For example, we committed to the machining and automation strategy

If you have any questions about this information, please contact Michelle at medmonson@IMTS.com.

IMTS+

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The Manufacturing World in a Word

BY BONNIE GURNEY VICE PRESIDENT, STRATEGIC CONTENT & PARTNERSHIPS

To make a long manufacturing story short, we asked industry leaders to summarize manufacturing technology in just one word in our new series “The World According To…” presented by IMTS+. The words of these visionaries – speed, excitement, continuous, change, promising, optimistic, digital transformation, technology and training, integrity, opportunity, and disruption – shine an optimistic light on the future of manufacturing. With a combined experience exceeding half a millennium, these leaders represent a who’s who of the manufacturing technology world. Our goal with ‘The World According To…’ is to capture insight from the people guiding our industry as we head into IMTS 2024,” says Peter Eelman, chief experience officer at AMT. “These leaders have an innate understanding of how technology, trends, and the world’s macro issues converge to shape our lives. Viewers will learn that the steady hand of leadership produces a compelling sense of untapped opportunities. The world is moving at supersonic speeds, and these leaders show us how they stay ahead of the curve.”

Here Are Just a Few Highlights From the Videos Now Available on IMTS+:

I believe that EVs are a disruptive technology. For many of us in the machine tool business, where you’re going from thousands of parts that are machined to hundreds, that really does create a change in our thinking. Jim King President and COO Okuma America Corp. My vision is a world where there's a continuous pipeline of young, excited, energetic, skilled folks entering manufacturing in North America. Dan Janka President, Mazak Chairman of the Board, AMT

Customers need higher accuracies, faster speeds, more throughput, more reliability. If you don't have a product that's flexible, you really do your customers a disservice. Larry Robbins President & CEO SMW Autoblok USA

Change is inevitable, so we must adapt. We must embrace the change and look for what’s coming. The progress behind change is a very attractive thing. Mike Defer President & CEO JTEKT Machinery Americas Corp.

Stay Tuned for Upcoming Episodes Featuring These Industry Visionaries:

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Brendt Holden, president, HAIMER USA

Ken Merritt, COO, SolidCAM Inc.

• Erik Gershwind, president and CEO, MSC Industrial Supply Co. • Brian McMinn, business segment manager, Siemens Industry Inc. • Brian Such, president and COO, Marubeni Citizen Cincom Inc.

• Michael Mugno, president, Tsugami America, with special guest Salay Quaranta, vice president sales of North America, Tsugami America • Michael Csizmar, chief marketing & sales officer, Horn USA Inc. • Pat McGibbon, chief knowledge officer, AMT

From automation to AI to digital technologies, a theme emerges as manufacturing visionaries use terms that describe an unstoppable forward movement – a world of positive, unending motion. Catch the spirit of “The World According To…” presented by IMTS+. Keep an eye out at IMTS 2024, Sept. 9-14, to meet and greet these leaders driving our industry forward. Register today at IMTS.com/Register.

If you have any questions about this information, please contact Bonnie at bgurney@IMTS.com.

Watch all the videos now at IMTS.com/World-According-To