Industry

Prototype machining services are crucial in the manufacturing process. You can’t build a house without blueprints. Prototyping in some industries requires a fast turnaround for testing and adjustments. Take into consideration the medical sector. Hospitals require implants and other parts. These parts are mainly made of Titanium due to their biocompatibility. The structural composition of Titanium makes it strong and hard to corrode with bodily fluids. To make parts or prototypes using Titanium, you will require a method with equipment capable of slicing through hard metal. Since these parts are used to replace human organs, they are required high precision and quality surface finishing. The slightest mistake can cause discomfort or even harm to the people using them. Customization is another necessity in the medical sector since one part cannot fit everyone.

In the past, creating a part or prototype with all these necessities intact was unthinkable. The main disadvantage of making these parts manually is human error. However, the invention of CNC machining changed everything. Believe it or not, CNC machining started about a half-century ago. Of course, the equipment used was not as complex as the ones we have, but the concept behind them was the same. Prototype machining allows you to created parts fast at a lower cost with high precision.

Just like other prototyping methods, there are specific parameters you should consider when choosing prototype machining services.

Volume

CNC prototype machining is suitable for low or medium production. Today, you can find CNC machines ranging from simple tabletops to complex multi-axis units. This gives you the freedom to develop multiple prototypes at the same time. CNC machines are controlled by numerical programs meaning that if one unit is making several prototypes, uniformity is maintained.

Material

You can’t blindly choose prototyping services without putting into consideration the type of materials you are using. There are certain materials that a CNC machine cannot work with. In this case, it would be best if you went for alternatives like 3D printing.

Precision and Consistency

Some prototypes require high precision and quality surface finishing, as seen in the medical and automotive industries. CNC prototype machining is the best option for high precision part production.

Geometry

The geometry of your prototype plays a crucial role in determining the choice of production. CNC machining supports geometric complexity since on prototype can pass through different stages in the machining process and is guided by a computer program, meaning that errors rarely occur. A CNC shop has different tooling, each specialized to perform a task efficiently. If a drill will not give you what you need, there is always the mill or the cutter.

Benefits of CNC prototype Machining

1. Unlike 3D printing, metals used in CNC machines are not heated, and as a result, they maintain structural integrity. Structural integrity is key in industries like automotive and aerospace since parts are placed under extreme conditions.
2. CNC prototype machining allows you to choose from a wide range of materials since the tools used can work with very hard metals.
3. If you have the materials readily available, you can produce parts in a couple of hours, making your production cycle shorter—rapid tooling further aids in reducing the time required to develop parts.

You can find in Germany most of the big companies in manufacturing. It is a place with lots of opportunities for companies all over the world. Most of its residents live in urban areas. Because of this, Germany is considered one of the biggest and in-demand markets in the world of products and services.

Products Germany Imports

Germany has an open economy and a wide variety of goods that it imports. Businesses in the country add value to parts and raw products. Here is the Germany import list from China:

• Agricultural products
• Chemicals
• Data processing equipment
• Electric equipment
• Foodstuffs
• Machinery
• Metals
• Oil and gas
• Pharmaceuticals
• Vehicles

Besides China, other top countries that export to Germany include the Netherlands, France, Italy, and the US.

Europe comprises 70% of its total imports, Asia at 20%, and the remaining 10% is from other continents. It only shows that if you have a product with quality or cost advantage over European products, you can do business in Germany.

Germany Exports and Imports

In 2015, the worth of Germany’s exports was around 1,410 billion dollars as compared to 1,130 billion dollars of total imports. It’s because of this, the trade surplus in Germany is 280 billion dollars during that year. Germany is the top exporter of vehicles, household equipment, machinery, and chemicals thanks to the efficient and highly-skilled labor force.

Trade Relations of Germany with China

Germany has been exporting to China for many years. In 2000, the total export was over € 9 billion and had grown to € 67 billion in 2013. German exports to China are mostly in the engineering sector. Cars components and vehicles comprise one-fourth of Germany’s export to China. Next is the machinery, followed by the optical industry, chemical goods manufacturers, and the aviation industry.

Germany’s import from China has increased from € 18 billion in 2000 to around € 73 billion in 2013. China is the second most source of import of Germany next to the Netherlands. Most of the products being imported from China are electrical and electronics (27%) and the machinery products (21%).

Furniture, toys, and garments are among the essential import goods before, but now it is decreasing rapidly as China’s export process is becoming more advanced.

China’s Investments in Germany

When it comes to investment volume, Germany tops the destination for Chinese industrial investment. The skilled labor force and infrastructure is the main reason for this. Germany is the best option for outbound investment when it comes to China’s policy.

Chinese investment in Germany is distributed over various industries. The main recipients of Chinese include the automotive, chemical, machinery, telecommunications, and energy and other sectors.

The trading between the two countries continues and is building a better relationship when it comes to importing and exporting their products. However, both countries need to comply with the changing rules and regulations to have worry-free and stress-free trading. They need to find a reliable air or sea freight services to help them process the necessary documents to complete the shipment.

Slewing rings have been widely used for the last four decades. Ideally, a slewing ring is a type of component used in machines. It is commonly used in construction machinery such as cranes and excavators, and military machinery. It is also known as turntable bearing, slew bearing, and slewing bearing. This type of bearing can handle large radial and axial loads.

The slewing ring has parts such as outer ring, spacer, sealing, and inner ring. Depending on the external structure, this type of bearing has types such as external gear type, internal gear type, and non-gear type. For the internal structure, this bearing can be into four-point, double row, crossed roller, and cylindrical roller.

Slewing Ring Features

If you want a bearing solution that is flexible with your applications and handles large loads, slewing ring bearing is the right option. The slewing ring bearing has a high load capacity. In fact, it can handle combined loads, including radial, tilting movement, and axial load.

As far as flexibility is concerned, the slewing ring provides different options you can choose from. Also, this type of bearing is highly customizable. These are some of the features of these bearings:

Location and size of hole patterns vary

It is available with an external or internal gear

Availability of preloading options

Two or single row ball bearing options are available.

If the above features do not suit your application, you can reach out to your bearing supplier to customize them further.

Uses of Slewing Ring

Considering the flexibility and load capacity of the slewing ring, many industries use this type of bearing. For instance, slewing ring bearings are widely used in:

Packaging machinery

Robotics

Off-highway equipment

Wind power

Cranes

Satellite equipment

Drilling and mining

Installation of Slewing Ring

It is advisable to check the surface before you install the slewing ring. Ensure components supporting it has adequate rigidity. Also, the matching surface must be machined to achieve inclination and flatness of required standards. Every set of slewing bearing is marked with “S” that ought to be placed on the non-loading area.

Position your slewing ring radially and then tighten mounting bolts and check rotation of the bearing. Since smooth rotation is important, you need to check the condition of the meshing before you tighten the bolt. Most manufacturers lubricate the ring properly before it is shipped.

After you install the bearing, you need to have it inspected before it leaves the factory. If your application involves high temperatures, you should shorten the cycle of greasing. Moreover, if the bearing is stored for quite long or your machinery has not been in operation, you need to re-grease it.

Selecting Slewing Ring

When choosing the most economical and efficient slewing bearing for your application, you need to consider various factors. For instance, you need to consider the loads that are added, application type, frequency of movements, and torque applied.

Your choice of slewing ring can be based on static and dynamic load ratings. Also, you need to consider applied loads and requirements regarding service life and reliability.

Milling is an important machining and manufacturing technique. Traditional milling machines ought to be operated by trained technicians or engineers. The modern machines utilize computer-numerical control (CNC) technology. CNC milling services offer a lot of advantages over the traditional milling services. That explains why manufacturers and fabricators in the plastic and metal industries are embracing these services.

Key Advantages of CNC Milling Services

Cost-Effective

First, the CNC milling service does not need individual machine operators. Instead, after programming the desired cuts, the machine cuts them automatically. Therefore, one programmer can oversee operations of multiple CNC machines, including grinders, routers, lathes, and more.

This manufacturing technique helps lower the labor costs as it streamlines the process of equipment set up and machining. On the other hand, a conventional milling machine required that operators set the gears manually for desired cuts. CNC milling eliminates such time-consuming processes. This helps reduce the number of employees and work hours they spend on various milling tasks.

Quality Results

Since CNC milling machines are automated, they have a competitive advantage over their conventional counterparts when manufacturing various parts. For instance, it provides higher accuracy and repeatability.

Repeatability is also known as precision, and it is the ability of a machine to make similar cuts continuously. Accuracy of CNC machining service refers to the ability to cut pieces to accepted tolerances. Higher accuracy means that components or parts made will fall within acceptable dimensions or tolerances.

Since CNC milling is controlled by powerful computers, it offers better results that are accurate and precise. Conventional milling service is prone to errors. Moreover, it relies on the skill of the operator. Production of parts that do not fit the intended purpose cost you more.

Improved Safety

CNC milling machines use advanced cutting tools that can cut metal or plastic to the required shape. The cutting tools create potential hazards that can cause accidents and injury to operators of traditional milling machines. Since most milling tasks are repetitive, it is easier for an operator to get bored and tired, resulting in injury if the operator loses focus.

Future Proof

You should note that CNC technology is currently used in different industries. Nevertheless, their applications will keep increasing. That is because CNC milling services supports seamless integration with different design and manufacturing software applications. For instance, integrating CAD-CAM helps improve the productivity of the milling service by over 40%. That is because it allows the design and programming of high-speed tool paths that support machining.

Lots of Applications

With CNC milling service, a wide range of plastic and metal parts can be made. Many industries require consistent, complex, accurate parts. Some of the industries that benefit from this service include aerospace, construction, automotive, metalwork, electronics, transportation, and military. Also, a wide range of materials can be used. Some of the materials used are aluminum, plastic, fiberglass, copper, wood, titanium, steel, brass, and foam.

The truth is that CNC milling services continue to revolutionize different aspects of the manufacturing sector. It is now easier to generate parts within a few hours.

Rapid prototyping is a manufacturing technique used to fabricate physical parts using 3D computer-aided design (CAD). Prototypes are convenient for developers, users, designers, and investors to validate and communicate their ideas. The process involves collaboration among designers, managers, engineers, and end-users.

Rapid Prototyping Benefits

Being a manufacturing process, it has its share of pros and cons. Ideally, this technique reduces development time, reduces risk, improves user involvement, and reduces development costs. The major issue is that it requires skilled labor.

These are some of the advantages of rapid prototyping.  

Quick Testing

With rapid prototyping, designers can iterate and test various design methods and ideas. Also, it allows for the use of intuitive visuals to complement verbal descriptions. Every person involved in the process will have a consistent understanding of important needs.

Time-saving

When designers employ rapid prototyping, they can get feedback quickly, which they can use to improve the final design. Moreover, the process helps minimize changes during product development and improves productivity.

Cost-effective

Experts at Rapid Done argue that when rapid prototyping tests are done at the early stages of product development, you can save a lot of time and cost (Contact RapidDone to know more ). That is because time spent on back-end product architecture is considerably reduced. The prototype can be tested before it is available for development.

Rapid Prototyping Process

Brainstorming

Rapid prototyping starts with brainstorming. It is an effective way of building a profile for your parts and products. In fact, failure is common in the process, and brainstorming allows designers to work on both bad and good ideas in a low-cost, safe manner before investing energy and time into the development of prototypes.

Production of 3D Files

Production of three-dimensional files of the product is necessary. The use of 2D plans is recommended for parts with critical tolerances. Also, project specifications ought to be drawn up. Specifications depend on both technical constraints and the end-use of the product. After creating specifications and 3D files, a rapid prototyping company comes in.

Costing

Every rapid prototyping project is costed by a prototyping company based on the technical features and quantity of parts. Features consist mainly of material, geometry, and finish of a prototype. This step is that it helps determine the feasibility of the project. At this stage, there is room for modification of the parts.

Evaluation

Prototypes are shared with users, designers, and experts to evaluate whether they meet the intended purposes. This stage aims to establish that the final product performs the expected function. If the product is not found to be valid, it is returned to the first step of brainstorming.

The success of any given prototype depends on the prototyping technology used. Each technique has its competitive advantage in terms of speed, material compatibility, development stage, fidelity level, and cost. Rapid prototyping does not have to be limited to a single process. Multiple manufacturing processes can be used to assemble a prototype. The following are the common rapid prototyping technologies used:

CNC machining

Investment casting

Binder jetting

Stereolithography

Fused deposition modeling

Vacuum casting

Aramid fibres are some of the strongest and the best heat-resistant types of threads in the market. These fibre strength can get attributed to the high proportion of the chemical bond that exists in the structure of these fibres. They are synthetic types of threads that got introduced into the market in the early 1960s. Traditionally, the fibres were used in aerospace and military industry for a wide range of applications. Currently, their applications have increased, and one of the many applications of the fibres is in the manufacture of aramid packing material. The characteristics of aramid make the product the best choice for the production of high pressure sealing options. 

Characteristics of aramid packing

Below are some of the most significant attributes of aramid packing;

1. Structure

The structure of aramid packing is significantly influenced by the construction of the fabric from which it is manufactured. The structure of the aramid fibre features a series of polymers, each of which is synthetic. Secondly, the polymers appear in a repeating unit that resembles enormous phenyl rings that are linked together. Lastly, aramid packing features a unique structure that is unlike anything else in the market. 

2. Strength

One of the most attractive features of aramid packing is that it has the highest tensile strength. This is a component that most products of its kind in the market do not possess. The strength of the packing is influenced by the structure of the fibres from which it is manufactured. The type of packing also features a unique kind of resistance to wear. This means that it is highly durable.

Additionally, the product is resistant to chemical and temperature-related damages. Aramid fibres feature amide links that are resistant to a wide range of organic solvents as well as salt. This is also a unique feature that users love about this type of packing. Regardless of the chemical resistance, the products are still prone to susceptible damages from chemical products like acids. 

3. Durability

Aramid packaging is also highly durable because of the strong features that are mentioned above. Additional features that influence the durability of aramid packing are that it does not have a melting point, and it is resistant to cut. This means that packing can be used in high-pressure conditions. This means that you don’t worry about the packing catching on fire quickly because aramid fabric features low flammability. It is also resistant to absorption hence is one of the most durable types of fibres in the market. 

Applications of aramid packing
Aramid packing can be applied in a wide range of industries. Some industries where aramid packing is used include;

· Mining and mineral

· Municipal wastewater

· Oil and gas refineries

· Power generation

· Aerospace and mining industry among several others

Conclusion

In different industries, aramid packing is used in various application media. Examples of some application media include abrasives, water, oils streams, and slurries. TeflexGasket, one of the leading manufacturers of aramid packing, manufactures the product by impregnating it with PTFE. The design allows for additional benefits and strength of the packing. 

For many components and products made from metal, including cars and utensils, rust is a devastating condition. In rainy climates such as those of the United Kingdom and Brazil, metal surfaces rot and crumble away quite quickly when water is absently left to collect in any crevice present on the metal surface. The traditional ways of dealing with rust on metal components and products included grinding, cutting, and selective choice fabrication. However, the efficient application of a quality laser rust removal tool has been proven to be much more efficient and faster than all the other techniques combined. Laser rust removal works magnificently to clean up metal parts quickly. Let’s focus on the advantages of laser rust removal.

How the laser rust removal and cleaning works

In general, the procedures involved in removing contaminants of various types such as oil, rust, and oxides from steel surfaces by utilizing laser technology are collectively called laser cleaning. Thus, to clean rust from a metal surface, lasers use ablation, where any surface that absorbs the laser beam light appropriately enough is heated to a plasma. For example, a carbon dioxide-based laser can generate up to 1000 Watts of power that can be focused on a spotless than one millimeter squared.

The metal surface that absorbs the laser rust removal tool’s wavelength is heated extremely fast, exposing the clean metal surface beneath. This cleaner metal surface then begins to reflect the remaining laser beams off the metal surface, preventing them from eating away at the iron underneath.

Advantages of laser rust removal

• The technology applied in laser rust removal tools is reliable and fast

Lasers enable the efficient and rapid cleaning of metal parts of various shapes by eliminating rust accumulated on their surfaces.

• Laser rust removal involves low consumable cost and low maintenance costs for the laser rust removal tools. Such tools and systems are so low-maintenance they have almost no consumable costs.

• Laser rust removal tools consume very little energy, and the new fiber laser cleaning techniques feature even lower electricity consumption rates.

• Improved productivity and versatility – the fact is, laser rust removal tools and associated cleaning systems are superior alternatives to chemical and manual rust cleaning methods since the trajectories of the laser beams can be quickly altered using software inputs.  

How laser rust removal is possible

• It is always possible to remove contaminant material in a particular way – considering the presence of an ablation threshold for each material. Cleaners can distinguish between two or more layers when trying to remove an unwanted layer from a surface.
• Every material (including metals) has an ablation layer. In this instance, laser ablation occurs when a layer of rust deposited on a metal surface is easily removed by applying a laser beam from a laser rust removal tool.
• Laser beams are environmentally-friendly and consumable-free – the laser beams are only focused on the surface to vaporize the rust layer, meaning that the process has no consumables.

Conclusion

Laser cleaning is a fantastic new technology that is set to overcome many of the previous challenges that existed in the process of rust removal from metal surfaces. Laser rust removal tools are fast, clean, and efficient for metal cleaning.

Surgical masks, also known as medical face masks, are very popular at this time with the continued spread of Coronavirus. The virus has led to the introduction of the masks to the public. Before this, the masks were only used by professional health care workers. The role of the mask was solely to prevent infections during medical processes like surgeries. However, countries like China and Japan, among others that are highly populated, have recorded the use of masks in public places. Also, traditionally, face masks were manufactured manually. However, currently, most manufacturers use face mask making machines for the process. In this post, we look at the cost of face mask production.

Factors that Affect the Cost of Face Mask Production

The Features of the mask

The first element that influences the cost of manufacturing face masks is physical features. They include;

• Material- The material from which the mask is made greatly influences the cost of production. For instance, all-natural ingredients are harder to find and more costly. Therefore, making a mask from scratch using all-natural materials is more expensive than the latter. Materials like plastic are the most commonly used. However, the type of plastic used differs, and this affects the cost of the manufacturing process. For instance, some ingredients have to be imported from different parts of the country. This increases the cost of production.

• Color- The color of the mask also affects the cost of manufacturing. For instance, sometimes, to achieve the desired color, manufacturers are forced to use coloring chemicals. These chemicals have to be acquired at a cost. The coloring process also requires money.

• Scent- Face masks are worn on the mouth and nose. For this reason, they are mostly scentless. However, the materials used in the manufacturing process normally have peculiar scents. Therefore, in the manufacturing process, the scent has to be eliminated. This may warrant the use of certain chemicals in a process that needs financial resources.

The process of manufacturing

The manufacturing process is also a significant influencer. The process requires both time and money. There are different steps in the process. The first process is carried out by chemists or engineers. The human resource is one of the major factors that influence the cost of production. For a face mask manufacturing company, hiring freelance chemists and engineers is less costly than hiring a staff to work within the company.

The next step of the process usually involves using automated production machines. Using machines in the manufacture are more beneficial than manual manufacturing. The cost of running the machines is also a factor. The cost of electricity and maintenance differs from one machine to the other.  

Quantity of production

Contrary to common belief, the higher the number of production means, the lower the cost of production. The materials used in production will be more if the quantity is high. However, the cost of running the machines, time spent, and human resources are reduced when production is done in mass than the latter.

Conclusion

In this current state of the world, face mask manufacturing companies have more work than ever. However, not all face masks are efficient against bacteria and viruses because of their design and material.

CNC is short for Computer Numerical Control. It is a modeling technique that emphasizes computer precision capacities over human efforts. A CNC milling machine uses a set of computerized instructions or codes to cut through the material to produce high-precision models and precision parts. Apart from being useful in industries, there are other wide applications where CNC milling can be very helpful. If you are a structural engineer or an artist, there is more to gain from CNC milling parts if you use it for your project.

Why use CNC milling for your project?

• Make models/prototypes faster

Since CNC milling parts automate the machining process, less amount of human effort is required. The mill works seamlessly and efficiently to produce models and prototypes as quickly as possible. This means you need less time than produced using manual methods. The CNC milling can help you complete your projects faster.

• Save cost

The manual machining process requires hiring expert technicians to manage different parts of the machine. CNC milling reduces the number of experts required to one or two per mill. You can also learn to operate the mill by yourself. Ultimately, the cost of starting and finishing the project is reduced. Money saved on modeling can be channeled into other essential aspects of the project to improve project quality and value.

• Stay safe

Since very little human effort is required on CNC mills, you can expect low cases of injuries to workers during operation. Unlike manual machining processes that expose technicians to lots of hazards, CNC mills are custom built with safety accessories. As the machine does the majority of the work, users only need to control and monitor the milling process from a safe distance.

• Quickly detect deficiencies 

Most CNC mills make use of internal detectors to evaluate the integrity and quality of the model or prototype being produced. The machine can quickly draw the operator’s attention whenever corrective efforts are needed before the work is complete. Users can quickly make necessary adjustments in the process. This feature helps to give higher quality models and components in good time.

• Use materials you prefer

CNC mills are majorly known to use steel material. However, they can also use plastic, wood, acrylic wax, and other machining materials. This versatility makes CNC milling a helpful process when one is trying to find out which material better suits a model. Since the same machine can use the materials you are considering, you save costs and time in the process of finding the best material for your creation.

Conclusion

Although CNC mills are not perfect for producing tools en-masse, they are very useful if you need to create a particular tool for your project. CNC mills can do all that the regular milling machines can do. CNC mills add automation and precision to the equation, which makes it a veritable tool in the hands of many project designers and managers. As an individual, you can also use CNC mills to boost your creativity in design, arts, and architecture.

As a core component of the brewing process, fermentation is a straightforward process through which yeast converts glucose into ethyl alcohol and carbon dioxide gas. This is what leads to the beer containing alcohol and carbonation. In using the stainless steel fermentation tanks, the wort (cooled down) is moved to the fermentation tank containing yeast. The wort is kept at 68F for two weeks straight to produce ale. Note, the wort is kept at a constant temperature of 48F for six weeks to obtain lager.

With that process going on, a significant amount of heat gets produced, and that’s why the stainless steel fermentation tanks must be cooled regularly to maintain the desired temperature. Each container can hold approximately 2400 gallons of ale or lager, which translates to four batches of wort to obtain maximum capacity in a tank. In this write-up, we shall take a look at the beer fermentation process involving stainless steel fermentation tanks.

Stage one: adding wort to yeast

After the addition of wort to ferment, the mixture’s specific gravity is measured. The measurement process can be done at a later stage, too, to establish the alcohol content of the beer. It also serves as an indicator to know when to stop the process. Usually, the fermentation tank is sealed off from the air, but a long narrow vent pipe is left open to allow carbon dioxide to escape the fermenter. A consistent flow of carbon dioxide through the pipe prevents air from the outside from entering the fermentation tank. This procedure also keeps the mixture from being contaminated by foreign yeasts.

Stage two: the settling of yeast

Near the end of the fermentation process, the yeast will settle at the bottom of the fermentation tank. This bottom is usually cone-shaped, which makes it relatively easy to scoop and remove the fungus. The collected yeast can then be re-used in the next beer batch. Each yeast collection can be utilized several times before it ever needs replacement. Replacement is usually done when the yeast has mutated and therefore yields a different taste. Consistent taste and alcohol levels need to be maintained at all times to succeed as a commercial brewer.

Stage three: capping the carbon dioxide vent

When the desired specific gravity of the mixture in the stainless steel fermentation tank is obtained, the vent tube for releasing carbon dioxide is closed off. The fermentation tank is now sealed. The more the fermentation process continues, the  more pressure is built up inside the tank. This is the process that gives many beers their carbonation. More carbon dioxide is added later in the process. From this point moving forward, the beer is kept under pressure. The only time when the pressure is relieved is during the bottling.

Stage four: post-fermentation

The resultant beer can now be cooled to roughly 32 F. This also enables the yeast produced to settle to the bottom of the fermentation tank. Many other unwanted proteins that are generated by the solution also come out at this low temperature. After solids get settled at the bottom of the fermentation tanks, the beer can now be pumped from the tank and then passed through a filter to remove any stray solids. Afterward, the beer is injected into a different container, called a bright beer tank. The carbon dioxide level is adjusted by pumping extra CO2 into the beer right through a porous stone.

Conclusion

The beer crafting process requires many years of experience to perfect. The best beer brewers have learned to rely on some of the best stainless steel fermentation tanks to maintain consistency and taste across all their bottles of beer.