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Manufacturing Technology


This program examines how recent advancements in grinding can be optimized to improve surface finish and accuracy in ground parts.

Viewer will first see the benefits of less complex systems that use practical solutions to deliver repeatable and stable grinding results.

This program then explores the use of advanced cylindrical grinding techniques, tool and cutter grinding, and the abrasive belt grinding of parts coated with High Velocity Oxygen Fuel (HVOF) - a thermal spray coating containing a high percentage of carbide.

DVD / 2009 / () / 32 minutes

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If we can't measure a product quickly, precisely, and inexpensively, then we can't build it. This is especially true at the nanoscale. Nanometrology encompasses the cutting edge technologies of measuring structures in terms of a billionth of a meter-significantly below the wavelength of light.

In this DVD you will travel to talk to the world's leading experts at National Institute of Standards and Technology (NIST), FEI Company, and The University of Michigan's Electron Microbeam Analysis Laboratory (EMAL) to learn how advanced nanometrology instruments are aiding the production of high-performance nano-enabled products. Learn detailed information on the two major types of microscopes in use today, which are based on either an energy beam made up of electrons or ions, or a scanning probe with a sharp tip. The energy beam methods may use electrons, such as in an S-E-M (scanning electron microscope), and the T-E-M (transmission electron microscope), or they may use ionized atoms, such as in the F-I-B (focused ion beam). The scanning probes include the S-T-M (scanning tunneling microscopy), and the A-F-M (atomic force microscopy).

DVD / 2009 / () / 33 minutes

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Structural DNA begins by highlighting the four stages of nanotechnology: static nanostructures, active nanodevices, nanomachines and simple nanosystems, and productive nanosystems.

This foundation provides the context to explore the four primary approaches to building productive nanosystems. Two are top-down approaches: Diamondoid Mechanosynthesis, and Patterned Atomic Layer Epitaxy, and two are bottom-up approaches: Bis-peptide Synthesis, and Structural DNA.

In this DVD viewers will then be introduced to researchers at Nanorex, Inc., Bloomfield Hills, MI, and Duke University, Durham, NC. They'll discover how these researchers are harnessing the structural and informational components of DNA to develop methods of altering molecules under programmable control to generate self-replicating productive

DVD / 2009 / () / 29 minutes

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This program uncovers the innovations that are expanding this process beyond robotic resistance spot welding and arc welding. We examine how more high-volume manufacturers of vehicle structures are using laser and hybrid welding to make fast, reliable welds.

DVD / 2007 / () / 42 minutes

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High speed machining (HSM) has steadily been gaining in acceptance with manufacturers. This is due in large part to the technological advances that encompass the high speed machining centers, tooling, programming and software. By integrating these various system components, manufacturers are using HSM to reduce their cycle times, increase throughput, shorten machining time, and minimize non-machining time while yielding high precision parts having a favorable cost/performance ratio.

This program features four companies that have successfully implemented and applied high speed machining systems, including:

~ Trutron Corporation, whose use of high speed machining substantially reduced the number of operations needed to machine their EDM electrodes and precision heat treated parts.

~ Protomatic Incorporated, a high-quality prototype and short-run production machining company who relied on two outside vendors during their transition to high speed machining to overcome some initial coolant and tool vibration issues.

~ Gosiger 3D, an applications engineering company working with its customers to replace time and cost intensive manufacturing processes entirely with both hardmilling and high speed machining systems.

~ Metlfab Incorporated, a prototyping company that boasts a turn around time of eight-hours on some prototypes due to their use of high speed machining.

DVD / 2007 / () / 36 minutes

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Rapid technology and 3D data capture are inspiring a new world of medical innovations from orthopedic implants to biomaterials used in tissue engineering. Medical Applications of Rapid Prototyping takes you inside the medical industry to examine how Rapid is being used to reconstruct anatomy, build parts, and rebuild lives.

First we take you inside Biomet in Warsaw, Indiana where they demonstrate how CT and MRI scans are converted into rapid prototyped models for the purpose of creating custom implants that are specifically matched to the patients' own anatomical data.

Next, Direct Dimensions in Baltimore, Maryland shows us how 3D scanning technology and rapid prototyping are used to produce aesthetic prosthetics. You'll also meet the surgeons, medical illustrators and modelers from Johns Hopkins University who give these prosthetics their realistic look.

Our program closes with a visit to the Medical University of South Carolina, where they're using additive fabrication with living cells and advanced biomaterials to produce pioneering innovations in tissue engineering. Written by noted medical device designer Ted Kucklick, Medical Applications of Rapid Prototyping is the perfect program for any engineer, rapid prototyping provider, or medical practitioner that is looking for an exclusive insider's look at the life enhancing applications of this technology.

DVD / 2007 / () / 20 minutes

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Hundreds of manufacturing operations are finding that methods and tools that support near-dry machining, or minimum quantity lubrication (MQL), provide numerous benefits in both metal cutting and forming operations.

This program surveys four very-different manufacturers: Ford Motor Company, Amerimax, Advanced Mold and World Machinery and Saws System Co., that use MQL to apply only the minimum amount of lubricant needed for each job. Each of these companies had once relied on traditional flood-coolant methods that supply large amounts of fluids to the machining process -- creating high handling, cleaning, and disposal costs, as well as hazards to plant workers' skin and lungs. These shops have found that MQL systems cut these costs and eliminate these hazards, while increasing production rates and tool lifetimes.

DVD / 2007 / () / 40 minutes

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This program delivers the insight of 12 seasoned industry experts from across the globe. Each brings a fresh perspective as they share views on the practical applications and the future of direct digital manufacturing

Viewers go inside Advatech and Loughborough University in the UK to see how rapid manufacturing is transforming the design practices, manufacturing processes and business models across industries. This program also features real products currently being manufactured using rapid technology and discusses direct metal's role in rapid manufacturing as well as other processes in action.

DVD / 2007 / () / 33 minutes

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The use of automation by large manufacturers has been well documented over the years, but what about automation at small- and medium-sized companies? Viewers of this program will learn how automation decisions were made at three smaller manufacturers, covering issues in automation justification, planning, implementation, training, and safety.

Go inside Factory Five Racing, Supreme Corporation, and Peterson Manufacturing to see how these shops automated specific material-removal and assembly processes, using the most flexible of automation systems with either the help of a robotics integrator or by acting as their own integrator. The case studies showcased in this in-depth program show you that automation decisions depend heavily on product type, variety, volume and on a shop's capabilities and culture.

Affordable Automation program is specifically designed for:
~ Small- to medium-sized job shop owners
~ Production designers
~ Corporate trainers
~ Automation consultants
~ Educators and students
~ Manufacturing supervisors
~ Production personnel
~ And any leader who has considered and/or implemented automation in their facility

DVD / 2006 / () / 31 minutes

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Molecular nanotechnology (MNT) promises to usher in the next Industrial Revolution with a new, radically precise, less expensive, and more flexible way of making products. Like steam engines, electricity, and transistors, nanomanufacturing is poised to completely impact business and industry worldwide. Yet every aspect of nanoscale science and the commercial production of nanotechnology will depend on the capacity of these tools to measure, sense, manipulate, and fabricate matter at the molecular level.

Nanomanufacturing highlights the current, near-term, and future applications of this technology. You will see how nanotechnology is transforming the way we manufacture products using innovative top-down fabrication and bottom-up assembly techniques that use matter to build complex products with atom-precision.

PLUS! Only this program can take you inside Nanorex, NanoInk, Zyvex, General Dynamics and NASA to provide an authoritative, first-hand look into the applications of molecular manufacturing. Highlights and case studies will focus on:

~ CAD Simulation Tools for the design and analysis of productive nanosystem.
~ Dip-pen Nanolithography.
~ Molecular Assemblers & Manipulators.
~ The use of carbon nanotubes in commercial viable products.
~ Improved performance characteristics and design functionality of aerospace applications, including NASA's mission to Mars.

DVD / 2006 / () / 37 minutes

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Reverse Engineering offers more than a tool for copying designs. This new program fintroduces you to a broad range of innovative applications that include visualization, documentation, design, analysis and inspection.

Written by industry expert Todd Grimm, "Reverse Engineering: 3D Capture" covers both laser and white light scanners and offers a discussion of their benefits as well as their limitations over portable and stationary CMM's.

Plus, only program can offer a video that will take you inside Roush Manufacturing, U.S. Army, Realadi, GKS Inspection Services, and Direct Dimensions to provide practical applications for anyone that needs to capture the physical world in a 3D, digital form.

A complementary tool for designers, engineers, machinist, molders and quality inspectors, this program shows you how 3D data capture is applied. Hear real-world case studies from industry experts that illustrate:
~ How 3D digital data is collected
~ How full size intricate designs can be created from less than ?-sized models
~ How an entire fuselage from a Columbia Aircraft was reverse engineered to verify tooling
~ How the rear spoiler was made to fit the Roush Mustang
~ and more!

DVD / 2006 / () / 31 minutes

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This program explores several new developments in manufacturing of alternative energy systems and how they will impact the energy generation and utilization markets of the future, while reducing our dependence on fossil fuels.

You will explore three unique companies that are taking advantage of alternative energy technologies:
~ STM Power, developer of advanced stirling engine technology to convert waste heat and gas into electricity.
~ United Solar Ovonic, mass-manufacturers photovoltaics from silicon materials.
~ UTC Fuel Cells, focused on the manufacturing of key fuel cell systems targeted for stationary and transportation applications.

Learn how advanced manufacturing and engineering processes can provide support for these systems to make a significant impact in cost reduction, performance improvement, reliability and the product life cycle.

DVD / 2005 / () / 29 minutes

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Micromachining comprises a growing collection of manufacturing technologies that are being used to create micro-electromechanical systems (MEMS) and new microfluidic and micro-optic devices. Using animation and footage from clean-room production facilities, this program presents case studies of companies and research institutions using various micromachining methods. These organizations include: EIGERlab, a facility supporting the development of miniaturized machine tools for high-accuracy, sub-millimeter micro-milling, cutting and drilling operations.Translume, where lasers and etching are used to create light- and fluid-transmitting micro-channels within glass. Integrated Sensing Systems, where semiconductor manufacturing techniques are used to produce fluid-handling components on silicon wafers. Microfabrica Inc., where complex, three-dimensional MEMS devices are built using a multi-layer technology inspired by rapid prototyping.

DVD / 2005 / () / 32 minutes

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