Browse Topic: Manufacturing systems
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional sheet metal fabrication and finishing operations of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in Polyethylene Terephthalate Glycol with Carbon Fiber (PETG-CF) are compared to conventional fabrication aluminum benchmark. The analysis is integrated in the product and process design following ISO 14040/14044 standards and is implemented using the Environmental Footprint 3.0 methodology within the 3DEXPERIENCE platform. Results outline that Material Extrusion (MEX) composite manufacturing achieves the lowest environmental impact across all evaluated categories. Compared to conventional manufacturing, the PETG-CF solution enables an approximate 50% reduction in Global Warming Potential and an almost complete elimination of mineral depletion. Unlike metal additive manufacturing, which remains constrained by high process energy demand, MEX benefits from low processing temperatures, minimal auxiliary systems, and highly efficient material deposition. Crucially, these sustainability gains are achieved while maintaining functional performance through design-driven topology optimization. AM composite solutions, by merging advanced material science with additive flexibility, may lead to design approaches which cease to be ‘potential’ enablers of sustainable manufacturing for the Industry 5.0 transition.
Metal-elastomer bonded components can suffer from manufacturing defects such as porosity and bond-line voids. Nondestructive evaluation (NDE) methods can replace or supplement existing destructive tests; however, implementation can be challenging for manufacturers due to the initial equipment cost, time required per test, and imaging quality. These criteria were used to evaluate shearography, high-resolution ultrasound testing (UT), 2D projection X-ray, computed tomography (CT), and acoustic emission (AE) testing, culminating in trade studies for different sample part types. Experimental work was performed on three samples of varying geometries and sizes with seeded defects, applying feasible NDE methods to each. Shearography succeeded in detecting void defects and flow fronts. X-ray and CT failed to detect flaws in 2 out of 3 part types due to energy and time constraints. UT could not reliably detect defects in parts with complex geometries because of scatter. Acoustic emission reliably detected a seeded knit-line defect.
Researchers recently helped Skydio, the leading U.S. drone manufacturer, demonstrate compliance to the Federal Aviation Administration's rules for safe flights over people and vehicles. Virginia Polytechnic Institute and State University, Blacksburg, VA Operators using a drone from the leading manufacturer in the U.S. can now conduct missions over people and vehicles much easier and with even greater confidence in their safety. In January, the Federal Aviation Administration (FAA) accepted a declaration of compliance for such flights for the parachute-equipped Skydio X10 drone from Skydio, a San Mateo, California-based company that supplies its drones to customers in public safety, utilities, and national security. The acceptance came as the result of working with Virginia Tech's Mid-Atlantic Aviation Partnership (MAAP) and Center for Injury Biomechanics to complete their FAA-approved means of compliance testing.
MSIL (Maruti Suzuki India Limited), India’s leading automotive manufacturer, offers a diverse range of SUVs (Sports Utility Vehicles) in its portfolio. Traditionally, SUVs are associated with an assertive stance and a commanding road presence; however, this bold design language often compromises aerodynamic drag performance. Over the past decade, demand for this segment has surged, while CAFE (Corporate Average Fuel Economy) regulations have become increasingly stringent. To address this growing market need, MSIL conceptualized a new SUV - Victoris - targeted to deliver best-in-class aerodynamic efficiency in MSIL SUV portfolio. This paper details the aerodynamic development process using CFD (Computational Fluid Dynamics) and full-scale WTT (Wind Tunnel Testing). Initially, the aggressive styling of Victoris negatively impacted drag performance. Strategic exterior surface refinements and integration of aero components enabled recovery of aerodynamic efficiency. Key interventions included redesigned front and rear bumpers, roof-end treatment, quarter spoiler profiling, bumper corner vents, and aero-cut alloy wheels. Victoris successfully retained its bold styling while meeting ambitious aerodynamic targets. The optimized aerodynamic silhouette comprising hood-to-windshield transition, roof contouring, backdoor spoiler, and side body profiling - along with underbody elements such as covers, strakes, and air curtains improved drag performance by 14% compared to the initial design. Achieving this improvement required significant shape modifications and aero part additions without compromising SUV identity. This paper explains how these measures were implemented and the resulting airflow characteristics.
In Marina, California, just north of the Monterey Bay, sits a small airport. In a previous life, it was a helicopter-focused military base. Currently, Joby Aviation is one of a handful of businesses occupying the space. The eVTOL (electric vertical take-off and landing) aircraft company is one of a few such companies that people have actually heard of and is still around. Established in 2009, Joby has been developing, building, and testing its eVTOL aircraft in Marina. During SAE Media's recent visit to the location, Joby showed off its latest aircraft but, more importantly, talked about how it's been able to leverage a nearly $900-million investment and partnership with automaker Toyota to build its eVTOLs.
How engineers can ensure safety, reliability and quality in aerospace systems. Courbevoie, Île-de-France In an industry where failure is not an option and precision is paramount, aerospace manufacturers and suppliers are constantly seeking components and system solutions that deliver trusted reliability, performance, and compliance. Industry standards are a key part of achieving these high expectations, bringing together global leaders in the mobility industries to create defined, repeatable methods and consistent processes. One of these aerospace standards is AS1895 developed by SAE International - a critical standard due to the need for durable components that can withstand extreme conditions and offer high performance: high-temperature resistance, pressure sealing, and long service life with a cost-effective installation method. Leading aerospace companies such as Eaton and Honeywell have been manufacturing components that meet this standard for a long period of time.
Like many from Poland, Tomasz Łuczyński moved to the UK for better wages. Following Poland's joining of the UE in 2004, hundreds of thousands of people from Poland have settled in the United Kingdom. Currently, over 1% of the UK population is Polish. But Tomasz Łuczyński didn't stick around. After working in a facility that remanufactured automotive parts, he returned to Poland to start his own large-vehicle parts refurbishing company, Elerte. Poland has a history of rebuilding. Much of Warsaw needed to be rebuilt after the Nazis razed the city following an uprising of the Polish people. The country's break from communism in the late '80s and early '90s required the entire system to be rejiggered into a market economy. As of 2024, the country's GDP is 21st in the world. To see how Poland is increasing its stake in the world of automotive suppliers and technology, I visited a wide range of individually owned and government-funded companies and research facilities to where the country is and where it's going. At the center of all this is PGM (Polska Grupa Motoryzacyjna), the Polish Automotive Group.
The objective of this study was to examine the effect of Correlated Colour Temperature (CCT) of automotive LED headlamps on driver’s visibility and comfort during night driving. The experiment was conducted on different headlamps having different correlated colour temperatures ranging from 5000K to 6500K in laboratory. Further study was conducted involving participants of different age group and genders for understanding their perception to identify objects when observed in light of different LED headlamps with different CCTs. Studies have shown that both Correlated Colour Temperature and illumination level affect driver’s alertness and performance. Further study required on headlamps with automatically varying CCT to get better solution on driver’s visibility and safety.
Safety improvements in vehicle crashworthiness remain a primary concern for automotive manufacturers due to the increasing complexity of traffic and the rising number of vehicles on roads globally. Enhancing structural integrity and energy absorption capabilities during collisions is paramount for passenger protection. In this context, longitudinal rails play a critical role in vehicle crashworthiness, particularly in mitigating the effects of rear collisions. This study evaluates the structural performance of a rear longitudinal rail extender, characterized by a U-shaped, asymmetric cross-section, subjected to rear-impact scenarios. Seventy-two finite-element models were systematically developed from a baseline configuration, exploring variations in material yield conditions, sheet thickness, and targeted geometric modifications, including deformation initiators at three distinct positions or maintaining the original geometry. Each model was simulated according to ECE R32 regulation standards, ensuring validity and compliance with relevant safety criteria. Specific energy absorption (SEA), load uniformity, and structural acceleration were used as key measures of crashworthiness. Simulation outcomes indicated that reductions in thickness significantly increased SEA due to enhanced deformability. Thinner configurations demonstrated greater energy absorption and improved load uniformity, whereas thicker components increased structural rigidity, resulting in decreased energy absorption and higher accelerations transmitted to the vehicle’s B-pillar. Material properties had moderate influence, with higher-strength materials elevating accelerations. Geometric modifications, particularly deformation initiators at specific positions, substantially improved SEA, achieving enhancements up to 42% compared to baseline. These findings highlight the potential of strategic adjustments in geometry, material selection, and thickness to significantly enhance vehicle crashworthiness and occupant safety.
As advanced technologies reshape the medical device landscape, the demands placed on contract manufacturers are evolving. Today’s partners are expected to do more than deliver components — they must anticipate disruptions, adapt quickly, and bring a level of technical and strategic depth that supports faster development without compromising quality.
As I'm wont to do come December, with work well underway on the first issue of the new year, I like to take stock of upcoming venues for innovative product reveals and thought-provoking presentations on emerging trends and technologies. Come the first week of January, that means CES in Las Vegas. Traditional equipment manufacturers have increasingly used the event to demonstrate to the broader public that they not only deal in metal but also the digital realm. For example, earlier this year at CES, John Deere revealed its second-generation tech stack featuring camera pods, Nvidia Orin purpose-built processors and Deere's VPUs (vision processing units), along with four new autonomous machines including the 9RX 640 tractor for open-field ag operations. The company is exhibiting again this coming year.
In this Q&A, Audrey Turley, director of lab operations – biosafety at Nelson Laboratories, spoke with Medical Design Briefs about the critical importance of monitoring and managing material changes in medical devices. Even seemingly minor shifts — such as switching suppliers or altering processing steps — can introduce unknown additives or variations that impact biocompatibility and, ultimately, patient safety. Turley discusses how manufacturers can effectively document and justify changes, maintain regulatory compliance, and strengthen supplier relationships to ensure ongoing device safety. She also shares insights into trends shaping post-pandemic supply-chain strategies and the growing emphasis on proactive risk assessment and communication across the product lifecycle.
When manufacturers seek to leverage specialized expertise, advanced processing capabilities, or proprietary technologies without assuming the financial burden of acquiring and maintaining dedicated equipment or facilities, they often turn to toll processing.
Battery technology is at the center of global innovation. From electric vehicles and off-highway machinery to consumer electronics and grid storage, demand for high-performing, reliable batteries has never been higher. This acceleration creates pressure on manufacturers to scale production while safeguarding quality and throughput.
Finland-based Metos Oy, a manufacturer of professional stainless steel kitchen equipment, needed a welding solution that could deliver flawless, pressure-rated welds for small batches of high-spec products, which feature tubular structures and circular shafts that required continuous, precision welding.
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve warranty performance. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns & identify root causes. By integrating these diverse methods, the framework offers a more accurate and holistic understanding of warranty data, enabling manufacturers to make efficient data-driven decisions that improve product quality and customer satisfaction. Conventional tools, like statistical analysis and basic data mining, provide foundational insights into warranty trends. However, advanced techniques such as machine learning and predictive analytics enable detection of potential issues in a more efficient manner. This approach supports decision-making processes related to product design, manufacturing, and quality control, leading to overall improvements in product reliability. In this paper we will illustrate the application and effectiveness of this hybrid approach using sample data, highlighting significant advantages such as deeper insights into failure mechanisms which in turn helps in more effective warranty management strategies in combination with the conventional analytics techniques. Ultimately, this paper underscores the potential of a comprehensive warranty data analytics system that integrates both traditional and modern techniques, efficiently driving continuous improvement in product development and customer services.
Over the past 25 years, the heavy fabrication and construction equipment industry has experienced significant transformation. Driven by a global surge in demand for construction machinery, manufacturers are under increasing pressure to deliver higher volumes within shorter timelines and at competitive costs. This demand surge has been compounded by workforce-related challenges, including a declining interest among the new generation in acquiring traditional manufacturing skills such as welding, heat treatment, and painting. Furthermore, the industry faces difficulties in staffing third-shift operations, which are essential to meet production targets. The adoption of automation technologies in heavy fabrication and construction equipment manufacturing has been gradual and often hindered by legacy product designs that were optimized for conventional manufacturing methods. As the industry transitions toward smart, connected manufacturing environments under the industry 4.0 paradigm, it becomes imperative to re-evaluate existing design and production strategies. This paper aims to establish a framework for aligning product and process design with emerging automation capabilities and strategic business objectives. It advocates for a design-for-automation approach, wherein components are engineered to be compatible with robotic handling, automated guided vehicles (AGVs), conveyors, and other intelligent systems. By doing so, manufacturers can enhance operational efficiency, improve safety and reliability, and reduce time-to-market for new products.
The Operator’s Field of Vision (FOV) test, conducted in accordance with IS/ISO 5006:2017, is a vital assessment to ensure the safety and operational comfort of personnel operating Construction Equipment Vehicles (CEVs) / Earth-Moving Machinery. IS/ ISO 5006:2017 defines rigorous guidelines for evaluating the operator’s visibility from the driver's seat, with particular emphasis on the Filament Position Centre Point (FPCP), determined from the Seat Index Point (SIP) coordinates. The test includes assessment of masking areas, focusing on the Visibility Test Circle (a 24-meter diameter ground-level circle around the machine), and on the Rectangular Boundary on which a vertical test object is placed at a height specific to the machine type and its operating mass. These parameters are designed to simulate real-world operating conditions. This paper introduces a portable testing setup developed specifically for conducting the Operator’s FOV test as per IS/ISO 5006:2017. The setup facilitates include accurate verification of X and Y coordinates of the SIP, Integration of a high-intensity light system to project and assess masking areas, and Quick & repeatable deployment in field conditions, enhancing usability across various types of CEVs and earth moving machinery. The portable design ensures adaptability, reduces overall testing time, and upholds the accuracy requirements stipulated by IS/ISO 5006:2017. This solution not only enables more efficient visibility assessments but also supports enhanced safety compliance for manufacturers and operators. It presents a cost-effective, field-deployable solution for ensuring visibility requirements in construction equipment vehicles / earth-moving equipment.
Direct current (DC) systems are increasingly used in small power system applications ranging from combined heat and power plants aided with photovoltaic (PV) installations to powertrains of small electric vehicles. A critical safety issue in these systems is the occurrence of series arc faults, which can lead to fires due to high temperatures. This paper presents a model-based method for detecting such faults in medium- and high-voltage DC circuits. Unlike traditional approaches that rely on high-frequency signal analysis, the proposed method uses a physical circuit model and a high-gain observer to estimate deviations from nominal operation. The detection criterion is based on the variance of a disturbance estimate, allowing fast and reliable fault identification. Experimental validation is conducted using a PV system with an arc generator to simulate faults. The results demonstrate the effectiveness of the method in distinguishing fault events from normal operating variations. The method is compared with a recursive least squares estimator, showing improved performance in terms of sensitivity. The approach offers a cost-effective and robust solution to improve safety in DC power systems, particularly in PV and electric mobility applications.
Items per page:
50
1 – 50 of 2317