Twice a year, ThomasNet releases their Industry Market Barometer which is a survey that helps to get a better idea on how different buyers and sellers are feeling about their businesses and what they are doing to overcome challenges. This particular survey asked nearly 3,400 buyers and sellers of industrial goods a series of questions to gauge their success moving forward.

The majority of those surveyed are from small companies—fewer than 100 employees and less than $10 million a year in revenue. What was found in the survey is that there is a growing optimism toward things and that they are anticipating more demand for their goods.

Two groups, specifically, that emerged in this survey are the “Outperformers” and the “Optimists.” The “Outperformer” is someone who had growth in the second half of 2010 and had anticipated more growth by June 2011. The “Optimists” anticipated growth by June 2010, but experienced a steady or declining growth in the second half of 2010.

Across the entire industrial marketplace, 45 percent of industrial companies are continuing to grow in comparison to 18 percent who aren’t. In every region and every sector of business, these numbers are true.

This growth can be attributed to two things: a heavy reliance on customer retention and service and utilizing their websites and the Internet to market their company.

The IMB revealed that 68% of respondents found customers cutting back or closing shop to be their top challenge. To try and prevent this from being a challenge in the future, 31% of companies are hiring customer service positions.

Demand is up, according to these companies. Thirty-seven percent of respondents anticipated hiring new employees through June 2011. Of those companies, 43% are hiring skilled trade workers and 36% are hiring engineering staff. Demand is, as these numbers would show, up and that is something that will convert into jobs.

Many more companies are realizing the need to move online and market themselves there. By utilizing their own website and a directory such as ThomasNet, companies are finding an increase in revenue growth. Of all IMB respondents, 76 percent reported that their website made a contribution to growth from July to December 2010.

Over half of the “Outperformers” revealed that their website opened up new sources of business which resulted in new revenues.

There are still things that need to be to make the online experience more worthwhile. Buyers are looking for websites that include product comparisons so that purchasing is easier. More importantly, they want to see the prices and product information to ensure that the product they are getting is exactly what they want.

The economy is obviously hurting and companies are hesitant to hire. However, what the IMB shows is that there is growth in the industrial sector and companies are beginning to add people to ensure that they can reach the demand presented to them by their customers.

Since 2006, thousands of amateur scientists, artists and hobbyists alike have attended the annual Maker Faire (http://makerfaire.com/), a large-scale science exhibition that showcases technology and engineering creations, and provides a chance for attendees to share their expertise and inventions. The event— to be located in New York, the Bay Area, Detroit and the UK this year— was started and organized by MAKE Magazine’s Dale Dougherty, who has described the attendees as experimentalists. “Essentially these are people that are playing [with] the technology. They don’t necessarily know what they’re doing and why they’re doing it. They’re playing to discover what the technology can do and probably to discover what they can do themselves, what their own capabilities are,” he said at a conference.

Technology Showcases

While there have been hundreds of exhibits since the show’s inception, the showcases have highlighted technological products that are available through large-scale manufacturers, including 3-D printers. The 3-D open-source printer exhibited at the show enables its users to participate in personal manufacturing without the costly result. Other 3-D technology showcased has included motion capture display technology, which has been increasingly used in film production. Devices that incorporate LED technology  screens have also been featured at the show.

Creative Tech

Some creative devices featured at the Maker Faire have included electric “muffin mobiles,” and two giant constructed neurons that mimic how brain cells function using lights. Also featured at the show: a “rain swing set” featuring a controller at the top of the swing set that automatically shuts off water when a person swings. Another “maker” invention is a radar speed detector constructed from a Hot Wheels toy.

Robot Devices

DIY devices constructed from recycled items at past shows include robots constructed from old devices, such as computer monitors, that can be operated from remote locations. One attendee from the R2 Builders Club, (a group that builds homemade “Star Wars” inspired R2-D2 androids) demonstrated his personal R2 robot creation, which was constructed from aluminum and featured a compact flash reader that controls the sound. Other past creations include a giant robotic spider, a robotically maneuvered chess game and a robotic giraffe.

To see more show highlights, what the video below:

Laser, Waterjet and Plasma Cutting Basics

In order to fabricate a variety of intricate part designs, appliance pieces and tools, manufacturers commonly use cutting technologies including waterjet, laser, and plasma processes. Each of these standard cutting methods employs different application tools; they are not always compatible with the same type of materials. Plasma cutting involves melting material surfaces via a high speed gas process. Another heat-centric process, laser cutting, involves using high temperature to melt materials while a gas jet propels excess materials out of the cuts. Waterjet cutting, which is used as an alternative to both aforementioned processes, does not involve heat treatment and employs jet streams to cut materials.

Here is an overview of the three cutting processes:

The Waterjet Cutting Process and Applications

Waterjet cutting—also known as pure waterjet cutting—was first available for commercial manufacturing use in the 1970s. The process, which is often used instead of plasma and laser technologies, incorporates a high-pressure stream of water that cuts a wide volume of materials. The process is commonly used for replacing milling operations. During the process, an orifice ejects a jet stream at speeds which exceed the speed of sound. This cutting technique is distinguishable for its ability to create precision cuts and is an efficient process for timely jobs that require intricate detail.

Another form of this process, abrasive waterjet cutting, involves incorporating an additional abrasive, such as garnet or aluminum oxide. Once these abrasive materials are added to a small chamber in the cutting tool, harder materials, such as concrete and steel, can be cut. Standard materials compatible with the water process include metal, foam, foods, rubber, plastics and glass, and flammable materials. Common applications associated with this process include parts for the automotive and shoe industry and standard products fabricated with this process include tissue paper and diapers. The process is also distinctive because it does not involve heat treatment and cause deformations as with other cutting technologies.

Some Advantages of Waterjet Cutting

• Detailed, precision cuts result in material savings;
• Minimal material loss in the pure cutting process;
• No thermal distortion;
• Short set-up time;
• Good to use in hazardous zones where heat is restricted;
• May be used for flammable materials;
• Cuts a wide variety of thick and thin materials

Waterjet Cutting Considerations

Although the waterjet cutting process is compatible with a vast amount of materials, there are limitations to consider. Experts note that the pure cutting process should not be applied to diamonds, which are too dense, or tempered glass, which will crack when under pressure. Additionally, the process is not efficient when it is used for fabric or material bundles, as the jet stream loses power after cutting through the first several layers of material. It is also helpful to note that water jet may be slower than the speed of a laser cut component.

Laser Cutting Process and Applications

The laser cutting process is a thermal method that employs energy to melt material. Typically, this process is used to melt material in a localized area, and lasers are able to achieve extremely thin cuts. An assist gas, typically CO2, is transmitted through a beam that treats the material. The gas jet is typically co-axial to the beam and works by blowing the excess metals out of a cut slit. As with flame cutting, laser treatment involves cutting work pieces along lines and curves. The process is sometimes used complementary to CNC/Turret cutting.

Overall, laser cutting is efficient for its precision and the ability to cut numerous materials such as precious and non-ferrous metals, (excluding reflective metals) wood, glass and plastics. The process is often used as an alternative to plasma and oxyfuel cutting, as it is distinctive for accuracy and heat input control and the ability to produce high-quality cuts without additional finishing.

Advantages of Laser Cutting

• Quick set up time;
• Ability to produce thin cut widths;
• Minimal waste clean-up;
• Low distortion rate;
• Applicable to small batches;
• Efficient alternative to mechanical processing

Laser Cutting Considerations

As with all cutting procedures, it is essential to consider safety precautions and wear appropriate gear when processing materials with laser tools. Although lasers work with a number of metals, they are not suitable for reflective materials, such as aluminum and copper alloys. In order to avoid partial burring on thin work pieces, a proper application distance must be applied when processing the material.

The Plasma-Arc Cutting Process

Materials processed with the plasma cutting process are treated with a high-temperature ionized gas arc. The gas content may be oxygen, nitrogen, argon. As the gas passes through nozzle, the restricted opening of the tool causes it to exit at a high speed, enabling it to cut through metals, and an electric arc ionizes the gas. Standard materials that can be treated using this process include aluminum, steel and stainless steel sheets. Typically, this process is used for heavier cuts, including processes such as welding and for cutting aluminum alloys and is commonly used as an alternative to mechanical saw cutting.

Advantages of Plasma-Arc Cutting

• Popular alternative to mechanical oxyfuel cutting;
• CNC is cost effective for thick metals;
• Ideal for cutting thin non-ferrous materials (up to 1 inch);
• Suitable for cutting various expanded materials;
• Efficient for producing non-linear cuts

Plasma Cutting Considerations

It is essential to consider plasma cutting limitations, specifically when compared to other processes. For example, plasma cutting machinery may cost more than other cutting methods such as oxyfuel cutting. In addition, keep in mind that the edges of the processed material may be rough, specifically with thicker materials. Professionals also note that warping may occur when processing intricate parts. Additionally, whereas laser and waterjet cutting may be used to achieve fine precision cuts, the CNC plasma cutting process is most effective for cutting 2D shapes that require less intricate details.

1)      Bed milling machine: The milling machine where the spindle is on a pendant that moves up and down to move the cutter into the work. They are generally more rigid.

2)      Turret Milling Machine: The milling machine more commonly referred to as Bridgeport-type milling machine. The spindle can be aligned in many different positions for a very versatile, if somewhat less rigid machine.

3)      Knee-type milling machine: The knee is a massive casting that rides vertically on the milling machine column and can be clamped rigidly to the column in a position where the milling head and milling machine spindle are properly adjusted vertically for operation.

4)      Ram type milling machine: The ram type milling machine is characterized by a spindle mounted to a movable housing on the column to permit positioning the milling cutter forward or rear ward in a horizontal plane.

5)      Universal ram-type milling machine: These machines are similar to horizontal milling machine, the difference being as its name implies, the spindle is mounted on a ram or movable housing.

6)      Swivel cutter head ram-type milling machine: The cutter head containing the milling machine spindle is attached to the arm. The cutter head can be swiveled from a vertical spindle position to horizontal spindle position or can be fixed at any desired angular position between vertical and horizontal.

7)      Box-Milling machine or Column Milling machine: These are very basic bench-mounted milling machines that feature a head riding up and down on a column or box way.

8)      C-Frame Milling machine: These are larger, industrial production milling machines. They feature a knee and fixed spindle head that is only mobile vertically. They are typically much more powerful that a turret mill, featuring a separate hydraulic motor for integral hydraulic power feeds in all direction and a twenty to fifty horsepower motors.

9)      Floor milling machine: These machines have row of rotary tables, and a horizontal pendant spindle mounted on a set of tracks that runs parallel to the table row. These mills have predominantly been converted to CNC, but some can still be found under manual control.

10)   Gantry milling machine: The milling machine whose head rides over two rails (often steel tubes) which lie at each side of the work surface.

11)   Horizontal boring milling machine: These machines are large, accurate bed horizontal mills that incorporate many features from various machine tools. They are predominantly used to create large manufacturing jigs, or to modify large, high precision parts.

12)   Planer-style milling machine: These are large milling machine built in the same configuration as planers except with a milling spindle instead of a planning head. This term is growing dated as planers themselves are largely a thing of the past.

Laser Cutting:

Laser cutting is a cutting process that severs material with the heat obtained by directing a laser beam against a metal surface. Hence laser cutting is a technology that uses a laser to cut materials, and is typically used for industrial manufacturing applications. Laser cutting works by directing the output of a high power laser, by computer, at the material to be cut. The material then melts, burns, vaporizes away, or is blown away by a jet of gas, leaving an edge with a high quality surface finish.

Types of material used in Laser Cutting:

• Carbon dioxide laser (CO2): The CO2 laser produces a beam of infrared light with the principal wavelength bands. CO2 lasers are frequently used in industrial applications for cutting, boring, scribing, and engraving.

• Neodymium-doped laser (Nd): Nd lasers are used where high energy but low repetition speed are required around 1 kHz and also used for boring.

• Neodymium-doped Yttrium Aluminum Garnet laser (Nd:YAG): The Nd:YAG is a crystal that is used as a lasing medium for solid-state lasers. Nd:YAG lasers are frequently used in Medicine, Dentistry, Military and defense, manufacturing applications for very high energy pulses, boring, engraving, and trimming.

Methods to cut metals using Laser Cutting:

There are many different methods to cut metal using lasers. Some of the methods are vaporization, melt and blow, thermal stress cracking, reactive cutting etc.

• Vaporization Cutting: The process where a focused beam heats the surface of the material to boiling point and generates a keyhole. As the hole deepens and the material boils, vapor generated erodes the molten walls blowing eject out and further enlarging the hole. Non melting material such as wood, carbon and thermoset plastics are usually cut by this method.

• Melt and Blow: The process in which a high pressure gas is used to blow molten material from the cutting area, greatly decreasing the power requirement. First the material is heated to melting point then a gas jet blows the molten material out of the kerfs avoiding the need to raise the temperature of the material any further. Materials cut with this process are usually metals.

• Thermal stress cracking: The process a beam is focused on the surface causing localized heating and thermal expansion. This results in a crack that can then be guided by moving the beam. It is usually used in cutting of glass.

• Reactive Cutting: It is also known as burning stabilized laser gas cutting or flame cutting. The process in which oxygen torch with a laser beam as the ignition sources is used. It is mostly used for cutting carbon steel in thickness over 1mm. This process can be used to cut very thick steel plates with relatively little laser power.