Digital manufacturing is an integrated approach to manufacturing that is centered around a computer system. The transition to digital manufacturing has become more popular with the rise in the quantity and quality of computer systems in shops throughout the world. As more automated tools have become used in manufacturing plants it has become necessary to model, simulate, and analyze all of the machines, tooling, and input materials in order to optimize the manufacturing process.

As digital technology continues to evolve at mind-blowing rates, we are seeing large numbers of industries adopt a more computer-centric business model to increase capabilities and improve production. The manufacturing world is a key arena where this technological shift is taking place, and many have attributed digital manufacturing as the potential catalyst for a fourth industrial revolution.

By embracing the latest computer software, shops can begin integrating digital tools to help track workflow, monitor production, implement machine automation and so much more. digital manufacturing has become a powerful re-imagining of the machining world, that marries the tools, equipment, and processes of the past with the exciting developments of the present and future.

Critical Elements of Digital Manufacturing

Digital Manufacturing is about leveraging computer technology to seamlessly integrate processes that were previously disparate. From design to production to analysis, Digital Manufacturing provides critical information on key processes so that companies can better identify and address strengths/weaknesses in their business.

CAD Drawings & 3D Models

Gone are the days of hand-drawn prints. Today’s designers rely on computers for fast and accurate digital part files. CAD (computer-aided design) programs have become ubiquitous throughout the manufacturing world and are utilized daily in most modern machine shops. These tools are able to generate 2D and 3D prints/models with incredible efficiency, and design changes can be made in seconds which can then be incorporated on the shop floor. With the emergence of technologies of virtual reality and additive machining, 3D design becomes even more powerful as changes can be seen/experienced in real-time.

CNC Machines

From design, comes creation. CAD files can be integrated seamlessly into the production process. Once a 3D model is finalized, digital software can then generate machine code which is used to manufacture the part on the shop floor. CNC (computer numerical control) equipment like mills, lathes, water jets and more, read and interpret this code to move parts and tools across multiple axes to add/remove material, resulting in a finished product that should mirror its digital counterpart. In many shops, CNC machines can connect wirelessly to CAD systems which allow for seamless integration between the designers and operators on the floor.

Manufacturing Analytics

One of the biggest benefits of Digital Manufacturing is the data it provides. From tracking production time, tool/material usage, machine utilization and more, digital technology can be used to streamline processes and identify weak points in the production chain. This digital feedback provides businesses the opportunity to evaluate their processes in real-time, as make key planning decisions to eliminate stoppages and increase productivity. Information is power, and in the world of Digital Manufacturing, it has never been easier to glean the necessary data when it is needed most.

Benefits of Digital Manufacturing

The benefits of Digital Manufacturing cannot be overstated, and we will continue to see increased adoption of these technological tools over time. By providing constant feedback through every step of the manufacturing process, businesses become better equipped to improve the quality of their products and spot/tackle challenges they could potentially face.

Optimize the Manufacturing Process

In the past, manufacturers have been resistant to change. The old adage “if it ain’t broke, don’t fix it” were commonplace in many a machine shop, but those days are long gone. With today’s software and technology, changes can be made to a part/program and tested on the fly to compare setups, machine time, material usage, and more. This information can then be used to optimize processes and increase part production, which in turn saves customers and companies money.

Reduce Costs

Better processes mean better parts in less time. From CAD/CAM software and job-tracking systems to machine automation and more, today’s technology is helping manufacturers increase production and minimize downtime. These tools can be used to streamline design, increase tool life, minimize material waste, speed up machining operations and better track inefficiencies. All of these factors play a part in reducing costs and saving businesses/customers money.

Test Changes Virtually

Three-dimensional design software has been a game-changer in the manufacturing world. In the past, engineers would need to draw up a print and have a prototype machined to test their design and identify problem areas. The processes were costly and highly inefficient. With today’s software, designers can generate highly detailed renderings of their models without ever leaving their desks. They can run simulations to test for weak points or design flaws, and they can make changes in real-time. Combine these design tools with the technology of additive manufacturing (3D printing) and things really begin to change. Before a part ever reaches the shop floor, engineers can simply print out working models on the fly to test and evaluate in the real world. In the past decade, additive manufacturing has been responsible for more than 30% growth in the industry, with a 19% increase in US GDP. These numbers will only continue to grow as the technology becomes more widespread through the manufacturing world.