Place, Cast, Lay Large Parts

Megacasting an entire underbody is an incredible manufacturing feat. So is continuously laying 300 feet of carbon fiber composite. But, the Raptor engine redesign may be the most valuable work of art.

Aug 11, 2024

Shop Talk

Capturing this week's zeitgeist

The amount of work required to simplify the Raptor engine, internalize secondary flow paths and add regenerative cooling for exposed components was staggering.

Elon Musk on the Raptor 3 engine, possibly with 3D printing technologies.

“We saw some pretty scary manufacturers. Dirty facilities, flash marks on their injection-molded plastics, very low precision.”

The inside story of the Fitbit as told by founder James Park.

Kaizen Blitz

📊 Survey Says
- Wide variations across the global warehouse automation landscape and new opportunities for growth according to Interact Analysis.
- 🚙🔋 From Jan to June 2024, Global Electric Vehicle Deliveries Posted Approx. 7.159 Mil Units, a 20.8% YoY Growth
🏆 Golden Part
- 🚛 50,000 Autonomous Long-Haul Trucking Miles by J.B. Hunt, Bridgestone and Kodiak
- 🚙🔋 Samsung’s EV battery breakthrough: 600-mile charge in 9 mins, 20 year lifespan.
🏢💸 Corporate Development
- 🇪🇺 EU Startups delivering cutting-edge solutions for industrial challenges
- ⛓️‍💥 Supply Chain Slowdown — Venture Funding Plummets In SCM Sector
- Continental is considering splitting the company by listing its core automotive division.
- TDK announces AI venture TDK SensEI Pte. Ltd to advance industrial machine health through edge AI and sensor fusion.
🏭💰 Production Planning
- 🇨🇳 SVolt chair Yang Hongxin has warned that fewer than 40 Chinese battery manufacturers could survive the wave of consolidation by the end of this year.
- 🇲🇾 Infineon opens the world’s largest and most efficient SiC power semiconductor fab in Malaysia.
- 🇹🇭 HP plans its most aggressive shift of production away from China to Thailand and Singapore.
🏛️📜 Industrial Policy
- 🇨🇳 Getting robots in ‘our own hands’: Structural drivers, spatial dynamics and multi-scalar industrial policy in China.
- 🇺🇸 SK hynix Signs Preliminary Memorandum of Terms with U.S. Department of Commerce for Advanced Packaging Facility in Indiana.

Assembly Line

This week's most influential Industry 4.0 media.

A Chinese Company Just ‘Gigacast’ An Entire Underbody

✍️ Author: Thomas Hundal
🔖 Topics: Large component casting
🏭 Vertical: Automotive
🏢 Organizations: Chery Auto, LK Machinery

Chinese automaker Chery Auto has cast an entire underbody using a 13,000-ton dual-injection press. Huge castings are amazing when they’re warranted. Subframes, suspension arms, drive motor housings, hubs, dashboard support structures, seat frames, if it bolts on, you name it. However, casting an entire underbody in one go seems like a process with downsides for consumers. A car is the second-most expensive thing you’ll buy in your life, so let’s keep them repairable.

It may be that significant R&D was required to get the die design to flow the metal just right without porosity or early solidification. Chery may not want anyone to see flow patterns in the casting that might teach them something. Alternatively, maybe they’re just hiding the geometry of the final part due to its relevance to their upcoming models. Or maybe these castings are full of defects and they’re hiding the evidence? That’s a long shot, though. Why would they boast if they can’t make the castings work?

Read more at Autopian and see the CFD simulation on X

Sereact and Daimler Truck Case Study

🏢 Organizations: Sereact, Daimler

Improving the Quality and Speed of Alloy Die Casting Products in the Auto Sector

🔖 Topics: Die Casting
🏢 Organizations: Creaform, Shanghai Meridian

The implementation of Creaform’s technology into Shanghai Meridian’s production processes was remarkably smooth. The shift from a legacy system to the MetraSCAN 3D’s intuitive interface and ergonomic handling allowed for quick onboarding and simplified, hassle-free remote collaboration across different teams and regions.

With the enhanced capability of real-time display during the 3D scanning process, the team could control and adjust tooling instantly, leading to substantial savings in time and labor, which enabled Shanghai Meridian to remain competitive on a global scale.

Active Ants - Zero Walk Warehouse Automation in Action

🏢 Organizations: GreyOrange

Scaling up high-product-mix metal fabrication

✍️ Author: Tim Heston
🏭 Vertical: Fabricated Metal
🏢 Organizations: 3-Dimensional Services Group, TRUMPF

“When earlier generations of our 2D laser cutters were in use, a fair portion of our manufacturing floor space was consumed by material management,” said Jeff Bischoff, director of engineering. “Since the investment and implementation of TRUMPF’s TruStore in our blanking development, of which we have three systems, much of our material inventory has moved to a warehouse dedicated to sheet metal and tooling. Actively transferring daily material requirements allows existing plant space to be reallocated to manufacturing capital and activity.”

3-Dimensional sells its ability to respond quickly to highly variable demand from various industries, and having the right stock on hand in blanking helps make that happen. Too little inventory could starve downstream processes in a hurry. Here, laser cutting automation helps reduce the blanking footprint and, not least, allows for continuous, unattended operation.

3-Dimensional has more than 50 welding robots from KUKA, FANUC, and Panasonic, and its own cut and etch lab onsite for weld testing and process validation. Most welding robots perform gas metal arc welding, but a fair number also perform resistance spot welding and even gas tungsten arc welding. The lion’s share are traditional articulating-arm robots, but the company also makes use of cobots (from Universal Robots and FANUC) for some light assembly work as well as certain welding applications. One, for instance, positions work at a resistance spot welding station. Several cobots are stocked on shelves to assist at a moment’s notice.

Are You Even Prepared to Run a Lights Out Shop?

A multi-purpose robot perception system enabling closed-loop control for zero defect manufacturing in gluing processes of large parts

✍️ Authors: Loukas Prezas, Zoi Arkouli, George Michalos
🏢 Organizations: University of Patras

Significant progress has been made in robot perception facilitating the deployment of advanced automation across a wide range of applications however typically little solutions are presented for large parts manufacturing. This paper presents a versatile robot perception system designed to enhance the flexibility and precision of robotic adhesive dispensing processes. This solution is capable of addressing the unique challenges of implementing automation solutions in large parts manufacturing, such as flexibility to manufacture small lot sizes, perception for complex task sequences, and handling parts with large dimensions that cannot be captured in single camera frames. A solution based on one single vision sensor is presented for part type recognition, part localization, process monitoring, and quality inspection. This includes algorithms for these perception functionalities and a closed-loop control framework aimed at zero-defect manufacturing. The task planning and execution architecture is based on Behavior Trees to allow modular and scalable robot task modeling and execution, whereas a knowledge database updated with process monitoring results via a module named event manager serves to prevent the propagation of defects to the following production steps. The proposed approach was tested and validated in a robotic cell for glue dispensing for a case study inspired by the bus and coach sector. The results indicate that the system can tolerate position uncertainties and random parts feeding, address disruptions in-process or trigger corrective actions post-process, and easily accommodate new variants.

Read more at Robotics and Autonomous Systems

New Product Introduction

Highlighting new and innovative facilities, processes, products, and services

Rocket Lab Begins Installation of Large Carbon Composite Rocket-Building Machine

🔖 Topics: Automated Fiber Placement
🏢 Organizations: Rocket Lab, Electroimpact

Rocket Lab USA, Inc. (Nasdaq: RKLB) announced it has begun installation of the largest automated fiber placement (AFP) machine of its kind into the Company’s Neutron rocket production line in Middle River, MD. The AFP machine will enable Rocket Lab to automate production of the largest carbon composite rocket structures in history.

The custom-built 99 ton (90 tonne), 39 ft tall (12-meter) robotic machine, American-made by Electroimpact in Washington, has just completed final acceptance testing with the manufacturer and installation has begun at Rocket Lab’s Space Structures Complex in Middle River, Maryland. The new machine will automate the production of all large composite structures of the Neutron launch vehicle including the panels that make up the 91 ft (28 meter) length interstage and fairing, 22.9 ft (7 meter) diameter first stage, and the 16.4 ft (5 meter) diameter second stage tank.

The autonomous machine can move up to 98 ft (30 meters) in length and lay down continuous carbon fiber composite at a rate of 328 ft (100 meters) per minute. The AFP machine also has a fully automated real-time inspection system that hunts for miniscule defects throughout the laminated carbon composite and alerts the machine operator of any issues before the machine begins laying down the next layer, providing additional assurance that these critical structures of the launch vehicle meet Rocket Lab’s high-quality standards required for reusable Neutron launches.

New structure assembly line for A321XLR inaugurated in Hamburg

🏢 Organizations: Airbus

Airbus has taken another important industrial step towards serial production of the A321XLR long-haul aircraft. Together with hangars 260 (pilot line) and 259 (equipment assembly), the new line in hangar 246 forms the infrastructure for serial production of the A321XLR at the Airbus site in Hamburg.

Figure unveils Figure 02, its second-generation humanoid, setting new standards in AI and robotics

🏢 Organizations: Figure

Figure, an AI robotics company, unveils its second-generation humanoid, Figure 02, and introduces the highest performing humanoid robot to market. Figure’s robot combines the dexterity of the human form with advanced AI to perform a wide range of tasks across commercial applications and, in the near future, the home.

Figure’s best-in-class engineering and design teams completed a ground-up hardware and software redesign to achieve Figure 02. Technical advancements were made on critical technologies including AI, computer vision, batteries, electronics, sensors, and actuators.

Business Transactions

This week's top funding events, acquisitions, and partnerships across industrial value chains.

🇺🇸 Anduril Raises $1.5 Billion to Rebuild the Arsenal of Democracy

🔖 Topics: Funding Event
🏢 Organizations: Anduril, Founders Fund, Sands Capital

Anduril Industries announced it has secured $1.5 billion of funding for its Series F round to hyperscale defense manufacturing. This funding will enable Anduril to increase hiring, enhance processes, upgrade tooling, increase resiliency in its supply chain and expand infrastructure. Anduril is also investing in Arsenal, the manufacturing platform for modern warfare. With Arsenal, Anduril’s goal is to manufacture and produce tens of thousands of autonomous weapons systems addressing the urgent needs of the United States and our allies.

Co-led by Founders Fund and Sands Capital, Anduril’s Series F values the company at $14 billion and includes new investors Fidelity Management & Research Company, Counterpoint Global, and Baillie Gifford, as well as major commitments from existing investors including Altimeter and Franklin Venture Partners.

🇺🇸 Seeq Announces $50 million Series D Funding Round Led by Sixth Street Growth

🏢 Organizations: Seeq, Sixth Street Growth, Aramco

Seeq, a leader in industrial analytics, AI, and monitoring, announced it has closed a $50 million Series D funding round led by leading global investment firm Sixth Street Growth, with participation from existing investors including Insight Partners, Altira Group, Second Avenue Partners, and Saudi Aramco Energy Ventures. This round brings Seeq’s total funding to approximately $165 million. Nari Ansari, Managing Director at Sixth Street Growth, will join Seeq’s Board of Directors.

🇺🇸 Datch Closes $15M Series A

🏢 Organizations: Datch, Third Prime

Datch, a pioneer in AI technology for frontline manufacturing, energy and utility sectors, announced the closing of its $15M Series A via an extension led by Third Prime. The fundraise coincides with the launch of Datch’s latest product offering, Asset Insights. Third Prime, a leading venture firm focused on the industrial technology space, led the latest round of funding, and is joined by existing investors including Blackhorn Ventures, Blue Bear Capital and Susquehanna Investment Group. Datch plans to use this funding to invest in market expansion within the enterprise while increasing capabilities within the Asset Insights toolkit.

Datch’s Asset Insights leverages breakthroughs in LLM and graph technology so organizations can turn the unstructured, disparate information within their ecosystem into actionable insights that improve operational outcomes. As the latest installment of Datch’s Frontline Intelligence Platform, it represents the next step in the company’s mission to empower operations that accelerate the world’s economy.

🇺🇸 H3X Closes Oversubscribed $20M Series A to Advance Revolutionary Electric Motors in Aerospace, Defense, and Marine Sectors

🏢 Organizations: H3X, Infinite Capital, Hanwha

H3X, the leading manufacturer of high power density electric motors, announced a $20 million oversubscribed Series A raise. The funding round was led by Infinite Capital, with participation from Hanwha Asset Management, Cubit Capital, Origin Ventures, Industrious Ventures, Venn10 Capital, and follow-on investors that include Lockheed Martin Ventures, Metaplanet, Liquid 2 Ventures, and TechNexus.

In the past 24 months, H3X has successfully validated its high-performance core technology, launched the HPDM-30, HPDM-250, and HPDM-140 integrated motor drives, and delivered these units to leading aerospace and defense customers. They also successfully completed multiple contracts with both NASA and the Air Force. With the Series A funding, H3X plans to expand production and bring its next-generation, multi-sector class of integrated motor drives to the market (HPDM-350, HPDM-1500, and HPDM-2300). The HPDM-1500 and HPDM-2300 are megawatt-class machines that will significantly enhance the performance of electric aircraft through their high power density and fault tolerance. In some cases, aircraft range can be doubled by using H3X motors versus conventional solutions by freeing up weight for additional energy storage onboard. These megawatt-class machines will also unlock new market segments for H3X in both marine and heavy industry.

🇬🇧 PHINXT Robotics raises €2.3 million to redefine warehouse automation

🏢 Organizations: PHINXT Robotics, Sure Valley Ventures

PHINXT Robotics, an AI-led robotics software company, has secured €2.3 million in an oversubscribed funding round led by Sure Valley Ventures with participation from Ada Ventures, Heartfelt and Atlas Ventures. The company will use the funds to grow its engineering and sales teams and begin expansion into mainland Europe where the team sees considerable opportunity. According to its founders, PHINXT’s long-term vision is to extend beyond warehouse robotics automation to encompass delivery drones and autonomous vehicles. Given the core decentralised edge computing technology enables coordinating machines within a distributed network, continued development of the platform will enable PHINXT to deploy solutions in frontier technologies such as autonomous vehicles.

PHINXT has developed a decentralised edge AI software solution to enable robotics automation at any scale. Founded in 2022, the company aims to redefine the landscape of warehouse automation with its cloud-based platform, designed to streamline robotic deployments and support a flexible monthly subscription model. Traditionally, adopting robotics in warehouses has been hindered by exorbitant setup costs – often exceeding £500k – and the complexity of on-site deployment. Consequently, over 90% of warehouses remain fully manual.

🇺🇸 ECI Software Solutions Acquires Smart Manufacturing ERP ProfitKey

🔖 Topics: Acquisition
🏢 Organizations: ECI Software Solutions, ProfitKey

ECI Software Solutions, a global provider of cloud-based business management software and services, announced the completion of its acquisition of ProfitKey International LLC, an ERP platform for discrete manufacturers. The strategic acquisition enhances ECI’s robust manufacturing software portfolio and further solidifies its commitment to supporting businesses within the industry. Terms of the acquisition were not disclosed.

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