What is Digital Transformation?
Table of Content What is Digital Transformation? Automation is the first step in digital transformation Digital transformation allows businesses to collect and analyze customer data Challenges in digital transformation Digital Transformation across different industries Future of digital transformation Digital Transformation is a term that is often used to describe an organization’s attempt to create a better user experience. It usually involves using technologies like artificial intelligence and machine learning, mobile apps, and social media to boost employee experience. Companies are also embracing the benefits of digital technology to improve the customer experience and make their company more competitive. What is Digital Transformation? In a nutshell, digital transformation is a process that transforms the business to provide a more efficient and consistent customer experience. For example, a clothing company may wish to digitize its backend inventory to provide a more unified experience between brick-and-mortar stores and online shoppers. It could be done by introducing new apps to support business operations and streamline workflows. While the term can seem confusing, the reality of digital transformation isn’t easily described by this term. In many ways, the phrase refers to changes in society, economic conditions, and even regulations. In other words, it’s a radical change in organizational competencies and processes. Companies are attempting to use these new technologies to make their organizations more customer-centric, increase productivity, and reduce costs. However, the phrase can also refer to the necessity to meet the human need to interact with the world. Businesses can transform their businesses using a wide variety of digital technologies. The key to digital transformation is looking at every business aspect and changing it accordingly. A social media presence may replace traditional department and team structures, and marketing and service functions may be tied together using a digital platform. However, not all these changes are reasonable. You can implement some of them if you know what they are before implementing them. Several factors make a business embrace digital transformation. Once you get started, you’ll have a clearer picture of the changes you need to make. Read Carving a roadmap to Digital Transformation for more. Digital transformation allows businesses to collect and analyze customer data Previously, data might have been scattered among disconnected platforms, and companies may have struggled to collect it. Now, digital transformation can help companies collect, centralize, and analyze their data, facilitating better corporate decision-making. The benefits of digital transformation go far beyond just data analysis. With digital transformation, data is consolidated and organized into a single database for business intelligence. In the future, this data can be leveraged to inform business strategy. Data-driven improvements translate into improved customer service, sales channels, and offers. When combined with an effective digital strategy and an efficient team, these benefits can lead to business growth. Digital transformation is lengthy, so be prepared to spend time and money to get it right. However, it can be well worth it in the end. Automation is the first step in digital transformation Automation can streamline processes and reduce the workload of human employees. Organizations can optimize performance and increase revenue by streamlining workflows and implementing API integrations. The next logical step is hyper-automation, which can automate itself. Your organization can use new technologies and integrate them into existing systems. For example, eBay’s popular e- commerce website implemented API integration into its systems, increasing its revenue. Automation works in synergy with Big Data, and big data has the potential to change operations and business models. Big data allows organizations to organize their data in meaningful ways and extract useful information. This information is crucial to model and make relevant decisions. These technologies also facilitate digital transformation. 5G and IoT are some of the leading examples. These technologies are already transforming business processes. Your one-stop shop for Digital Transformation From Smart Design to Smart Manufacturing or from Business Process Automation to Custom Built Solutions, Prescient can provide value to your Digital Transformation needs. Challenges in digital transformation The increasing adoption of new technologies in the manufacturing sector has made digital transformation necessary for most companies. However, these new technologies aren’t without their challenges. For instance, rampant cyberattacks pose the biggest hurdle to widespread adoption of digital transformation, especially in data-intensive industrial sectors. Nevertheless, these risks will gradually be overcome, as the benefits of this technology will outweigh any risks. Overall developments regarding data security will have a significant impact on the market over the next few years. One identifying aspect of digital transformation is its ability to capture, store, analyze, and share massive amounts of data. It allowed businesses to collect, process, research, and share vast data. However, as networking and the internet became more widespread, big data created new challenges for digital data management and analysis. Thus, data centers, warehouses, and lakes were created to address these challenges. Despite these challenges, digital transformation continues to be a critical factor in the progress of any economy. Digital Transformation across different industries There are many benefits to implementing Digital Transformation across different industries. These benefits range from reducing support tickets to enhancing customer satisfaction. These companies successfully implement various technologies to improve their business and create new revenue streams. By implementing these technologies, companies can improve supply-chain efficiency and optimize their factories through self-diagnosis capabilities. But before implementing Digital Transformation across different industries, businesses must first understand what drives it and how to implement it in the best way. It’s important to note that any new technology must fit into the company’s ecosystem and tech stack. While these new tools can increase ROI, they may require significant investment to implement and train employees. Future of digital transformation The evolution of customers is driving the adoption of digital technologies. Today’s tech-savvy consumers expect an excellent experience across multiple touchpoints, transforming customer experiences. While this trend affects all industries, it also affects every job function. Digital platforms will improve access to remote operations. Organizations will also make employee well-being a top priority. Edge computing and quantum capabilities will enable predictive analytics. And
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How 3D Product Configurators propel sales and customer satisfaction
Introduction Interaction with 3D Product Configurators What are 3D Product Configurators? Boosting sales and satisfaction Introduction Customers are often reluctant to buy customized products because they don’t know the outcome. People are often hesitant to purchase made-to-order or engineered-to-order products after being disappointed. Sometimes, people may order something they thought was great but get a completely different product. It can be challenging to return custom-made products purchased online. Customers can overcome this fear with 3D product configurators. Increasingly popular in the build-to-order industry, 3D product configurators help customers visualize and feel their purchasing product. The 3D product configurator software does not require a third-party plugin, and they work offline as well. They encourage customer participation by allowing them to virtually test product combinations. They enable customers to customize their options to their liking, and they’re available on any device without requiring plugins. As a result, this software has various applications for different industries and sectors. Interaction with 3D Product Configurators 3D product configurators allow you to estimate complex products quickly and accurately. It is vital for those manufacturers that must handle increased product complexity. Customers have always wanted to have their own customized stuff, and today they have no problem paying a premium for it. They want to be involved in the design of products and have the opportunity to influence their development. It puts pressure on manufacturers to find ways to make their processes more accessible to people outside of their four walls. It was long before consumers could be expected to accept standardized products that fit all. Modern customers desire the ability to customize and personalize products according to their individual needs. This is one of the most demanding competencies manufacturers have to focus on. It means a gradual relocation to mass customization from mass production. The rise of 3D product configuration software has prompted many online retailers to integrate product visualization into their eCommerce sites seamlessly. In the past, customers had to select a pre-made model. Now, they can choose a product by selecting from thousands of combinations. Customizing a product is the key to attracting and retaining customers. Whether your customers choose a color or material, they can easily envision it with the help of 3D configurators. What are 3D Product Configurators? In today’s visual economy, interactive product experiences are a must for customers. 3D product configurators are valuable tools for illustrating how products can be customized. In the past, a person could only see the final product or design iteration in full detail in a physical location, such as a showroom or with manufacturing samples. This has been changed by digital 3D configuration tools, which allow products to be created directly at the customer’s fingertips, giving them unique options rather than standard off-the-shelf designs. Using the visualization tool, users can see designs in real-time. It includes rotating the model or zooming in to view the fine details of each option. 3D models react instantly to changes in color and dimensions. Users can then immediately reconsider their selections and reselect the features and options that are most important to them until they find the best design. It is significant for designers of complex products, as it can be challenging to visualize how features and options related to each other. Boosting sales and satisfaction The increasing use of 3D configurators has increased customer satisfaction, engagement, and average basket value, increasing sales and conversion rates. These tools can monitor customer behavior and combine this information with other marketing data to create more relevant products and personalized interactions. And the best part is that they’re free to use in any way you see fit, allowing you to create a customized experience for every customer. 3D configurators can help you boost customer satisfaction and sales. They enable customers to select and change various aspects of products, including color, wheel configuration, seats, and even lighting and vision. By allowing customers to personalize their purchases, 3D product configurators enhance the experience of online shoppers. They create an emotional connection with the products, increasing the chances of making a purchase. Understanding customer behavior is one of the essential pillars of an e- commerce business. By giving customers a chance to see products and choose the features that matter to them, 3D configurators smooth out this process and make it easier for companies to track and measure it. Boosting customer satisfaction and sales with 3D configurators will give you a competitive edge over other brands and make you stand out from the competition. What does the future say? 5G, the next generation in high-speed mobile networks, will provide more data, and thus more detail, to users. As such, rich content is expected to continue to increase. However, augmented reality is the most significant development and opportunity. Manufacturers will be able to present an immersive experience to customers thanks to the rapid advancement in augmented reality technology’s usability and capability. This will allow them to educate them about the specific capabilities and fit of particular products or configurations. Seamless experiences like these are crucial to increasing brand awareness and loyalty and ultimately generating additional sales orders. The future of 3D configurators for customer satisfaction and sales will involve new technologies and innovations. AR and 3D technologies are becoming more affordable and accessible. The cost of 3D image configurators can be recovered within two to three months of investment. By allowing consumers to customize their products in AR, retailers will be able to create a direct-to-consumer sales channel. A 3D product configurator can be an essential tool for businesses looking to enhance customer engagement and boost sales and ROI. This technology makes it possible to provide customers with a 360-degree view of a product before purchasing it. With the 4th Industrial Revolution coming close, brands must start putting consumers in the driver’s seat. Brands can quickly and efficiently fulfill their needs when customers know exactly what they want. By letting them customize products and make them unique, brands can quickly meet customer demand and boost sales. As the customer becomes an integral part of the
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Carving a roadmap to Digital Transformation
Table of Content Creating a digital transformation roadmap SWOT analysis Defining mini-projects Identifying challenges along the way Define Corporate Values Do you have a strategy for digital transformation? According to a Statista survey published in 2021, about 60 percent of executive search firms declared that they had implemented a digital transformation strategy or improved their efforts in developing one due to the effects of the COVID-19 crisis. But before you can build a digital transformation strategy, you must establish a foundation. If your retail business operates both in physical stores and online, you must invest in the capability of the online channel to improve the customer experience. Invest in tools that map the user journey and resources to collect data. Moreover, your roadmap should include all the challenges that will come up along the way. Please go through some of the common roadblocks faced by companies undergoing digital transformation and the steps to overcome them. Creating a digital transformation roadmap It is essential to create a step-by-step roadmap to digital transformation that will provide clear directions and a clear destination. While there are many factors to consider when determining the best way to drive digital transformation, team alignment is one of the most important. The people responsible for executing the business strategy must share the vision and embrace open communication. Failure to be specific about the transformation details will leave things to chance and lead to misguided initiatives. A well-developed digital transformation roadmap should focus on integration and alignment. All stakeholders must be on the same page, and the technology must be integrated with existing systems and processes. In the digital age, companies can’t afford to have one piecemeal approach because it can leave gaps in security and undermine the overall goal. A comprehensive roadmap integrates technologies, software, and processes to maximize the chances of success. A digital transformation strategy aims to eliminate inefficiencies, improve customer service, and increase revenue. It is important to remember that digital transformation is a process that takes years to complete. While the result may differ for each company, it will help to have a general idea of how to approach the process and plan accordingly. For example, the end goal should be “Point B” in the roadmap, while the next step is to fill in the gaps between where the company currently is and where it wants to be. SWOT analysis Next, you need to consider your competitive position and identify the challenges ahead. While it’s essential to be realistic when determining your competition’s strengths, identifying threats is equally important. Keeping rose-colored glasses on will prevent you from making the best strategic decisions. However, assessing threats is key to your business’s digital transformation success. Make sure you’re honest and objective in evaluating the current position of your business. Using SWOT analysis in the context of digital transformation can effectively help your office transition. To create a successful SWOT analysis, you’ll need a diverse team composed of executive and mid-level employees. Include people from various departments so everyone can contribute their knowledge and expertise. The more varied the team, the less likely it will be to make a mistake. The best approach is to separate internal and external strengths and identify what your business can do to take advantage of them. The most effective way to identify internal and external strengths and weaknesses are to divide the categories by controllable and uncontrollable factors. It will help you make a more accurate SWOT analysis. The main mistake people make is to confound weaknesses and opportunities and make the SWOT analysis process more difficult. Once you have done this, you’ll be better prepared to determine what your next steps should be. A proper SWOT analysis can help you identify your company’s strengths, weaknesses, opportunities, and threats. It can also help you determine how to capitalize on these factors to strengthen your competitive position. Performing a SWOT analysis can help you formulate wise business strategies that will boost your company’s competitiveness and position in the market. It’s also a good idea to consider external factors like population growth, competitive trends, and economic climate, as they can affect your company’s ability to compete. If you haven’t incorporated SWOT analysis yet, it’s time to do so. Defining mini-projects Creating a digital transformation initiative roadmap should start with defining the key activities. These activities include technology projects, supplier ecosystem changes, and business process modifications. It should also identify high-level cost-benefit projections for each activity. Then, define each activity on the roadmap as a mini-project. By defining these mini-projects, the roadmap can be used as a guide to determine which activities are the most critical and which ones are not. Clearly define the goals and objectives for each mini-project. Identify the purposes and responsibilities of each team member. Determine how each member of the team will contribute to the project. Make sure they are aligned with the overall strategy. Assign roles to individuals, assign responsibility for specific tasks, and set milestones for success. After each project is completed, evaluate results, and determine if the project has met expectations. Identifying challenges along the way Businesses may face many challenges while embarking on a digital transformation journey. They may lack the skills and resources to implement a full-fledged digital strategy. Assessing an organization’s readiness for digital transformation is necessary to avoid getting stuck in a rut. While the organization may be reluctant to use new technologies and processes, it may still be able to work with early adopters that are prepared to implement these technologies in operations. As companies begin their digital transformation journey, they should analyze the data collected by their existing processes and measure the impact of these changes on their business. Data analysis should be conducted to identify trends and patterns. For example, some prominent OEMs produce enhanced equipment that can improve fuel efficiency, predict downtime, and streamline maintenance processes. These advanced features are known as Equipment-as-a-Service (EaaS). Embedding digital technology within an organization requires the buy-in of every employee,
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The Manufacturing sector’s road to Digital Transformation
For the last 20 years, the digital revolution has cast its shadow over every area of a well-functioning society, be it commerce, banking, or education and healthcare. The common thread throughout this digital revolution has been that those who do not embrace technology will eventually be left behind and replaced. It especially applies to manufacturers, who face the challenge of reducing costs and constantly keeping up with the global marketplace competition. This article will define what Digital Transformation is, explore its implementation, and discuss the challenges it presents. Finally, we’ll look at the ideal Digital Transformation strategy. Taking advantage of new technology such as 5G can improve visibility, lower costs, and increase flexibility; the benefits of digital transformation in the manufacturing sector are significant. But how can companies get started? Let’s look at some of the challenges and opportunities of digital transformation in manufacturing. What does digital transformation mean? In simple words, digital transformation is the large-scale exodus of the manufacturing sector and other domains from the traditional, analogue, manual mode of work toward digital technologies. It isn’t just about putting a few computers onto the table. It is about embracing digital technology from top to bottom, end-to-end levels. Digital transformation is not related to physical conversion but also involves statistical analysis and data to enhance manufacturing processes to ensure a thriving business. The advent of digitalization in manufacturing can help companies become more flexible, responsive, and cost-efficient. By integrating modern tools into production, digital transformation helps companies manage inventory and costs. It can also improve service to customers. By incorporating digital tools into manufacturing processes, companies can enhance the quality of products and reduce non-productive time. Digital tools help companies stay on top of the latest trends in the industry, and they improve productivity. It is important to remember that digital transformation is a process that takes years to complete. While the result may differ for each company, it will help to have a general idea of how to approach the process and plan accordingly. For example, the end goal should be “Point B” in the roadmap, while the next step is to fill in the gaps between where the company currently is and where it wants to be. Caution! A business that overlooks the importance of digital transformation is setting itself up for failure and providing their competitors an advantage in the market. In a survey of manufacturing companies, it was found that 36% accelerated their digital transformation. A further 35% slowed their digital transformation, and 47% remained untouched. Of the companies that have undertaken digital transformation, only 30% plan to increase their investment in this process by 2022. As per a Statista survey, spending on digital transformation and services worldwide has grown exponentially from 2017 to 2025 (in trillion US dollars). Implementation of Digital Transformation Implementation of digital transformation in your company might seem a bit uphill task. However, there are four key areas where you can focus on implementing digital transformation successfully. They are as follows: Boost your employees Educate, Encourage, and Empower your employees. These are the three words you should focus on when introducing new technologies to your employees. It can be challenging if they are reluctant to adopt it. You need to give them some time and space to innovate as much as possible. Even if it is one step at a time, it is still worth consideration. Interact with your Customers Customers have a higher expectation of service speed and an enhanced experience. Utilize data and statistical analysis for better engagement with customers. It helps companies cater to the needs of their customers by offering the best possible experience. Track their interactions, choices, and frequent search history to understand their mindset. Enable customization to let customers play around with products and decide what they need. Optimize the work processes Optimize your processes and human resources. The old-school way of working leaves many redundancies and sections where the time lag is so remarkable that it can affect your entire business. The optimizing system leaves you relieved that your systems are sufficiently tuned to operate the business smoothly. Transform the core of your business if necessary It refers to changing the core of your business to keep up with technological advances. You must adapt to the changing market or be left behind with increasingly irrelevant products/services. If that requires modernization and introducing new technologies, so be it. The Challenges with Digital Transformation Despite technological advances, traditional manufacturing companies face increasing competition from newcomers who successfully apply new technologies to their businesses. You must overcome certain obstacles in digital transformation to gain a competitive advantage. These include: Worker syndrome One of the biggest challenges in implementing digital transformation is culture. As automation becomes more prevalent, many workers look down on the benefits of digitalization. In fact, the challenges with digitalizing the manufacturing sector are directly related to the workers themselves. Employee resistance to change and employee pushback may be due to their inexperience with the technology or fear that automation will take away their jobs. Inadequate Information A lack of information is a significant problem for many businesses. They don’t have the digital expertise necessary to understand what’s available or how it can be used, especially the workers. Unfortunately, errors in manufacturing are universal. Workers may set up machines incorrectly, mishandle equipment, or send sensitive data to an unknown email attachment. Moreover, workers will be left with an unavoidable culture of ‘that’s not how we do things. Poor Strategy The lack of a strategy is a significant hindrance for many businesses on their way to completing the digital transformation—a poorly planned strategy results in failures. For instance, a lack of clear path, funding, and legacy systems are just a few of the most common strategic obstacles. Therefore, almost 50% of manufacturers enlist the help of consultants to undertake digital transformation projects. Prescient Technologies has been a consultant to some top names worldwide who wanted to embrace digital transformation. Let us help you in your
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The Increasing Prominence of Modularization in Mass Customization
Engineer-to-Order Modularization Industry 4.0 has driven the era of mass customization to inflated levels never seen before in manufacturing history. Accompanied by new-age technologies such as IoT, big data, 3D printing, and robotics, mass customization is executed on an unprecedented scale. Traditionally, the personalization of products was only available at a premium price. Ever since mass customization reached prominence, customers can order customized vehicles, cell phones, clothes and apparels, and even specific task- oriented machinery delivered on time. It has been possible due to the dramatic automation and modularity of workspaces that can be rapidly configured and then reconfigured to adapt to different specifications supplied by the customer. Mass customization trend is evident in both B2B and B2C sectors. Industries such as aviation, construction, glass, and ceramic manufacturing have adopted mass customization with a particular emphasis on 3D printing to a great extent. An exciting aspect of mass customization is lean customization, a just-in-time (JIT) inventory system, and digital tech to produce items with lesser costs. Lean customization allows consumers to select their preferred designs and colors at no extra cost to the company. Since lean customization involves a specific batchwise production process, it can be implemented in the well-known crafting specialty strategy known as Engineer-to-order. Engineer-to-Order Engineer-to-order means craftsmanship where production is tailored for specific customer requirements. It means the entire research and development, design, and build is suited for certain specifications, and it differs from customer to customer. Although such productions offer a great deal of personalized content to the customers, it comes with reasonable operational costs, making the product quite expensive. So, the prime goal is to reduce operating costs which will reflect on the product’s price. Incorporating lean customization into engineer-to-order addresses this issue, getting modular work processes. Modularization About 100 years ago, Henry Ford presented the first assembly line to the automotive industry. Since then, auto manufacturing has primarily been in a fixed and sequenced line, operated by pre-defined and rigid processes. Once an assembly line is defined for a specific model, it cannot be modified throughout the entire product’s lifecycle and commands over the intra-logistical methods of the production and supply chain. The auto manufacturers had to incur huge costs if they wanted to release a modified model since it involved creating an entirely different assembly line. This issue is not limited to car manufacturing but also apparel, chemical, and pharma industries. To address an agile and flexible production process, the industry is using the concept of modularization. Modularity essentially refers to the capability of a system to be reconfigured on a plug-n-play basis, thereby allowing it to respond to changes in customer requirements quickly and efficiently. Audi is one such company that has created independent workstations, each assigned a particular production function. Unfinished cars move autonomously from one workstation to the other, with the help of driverless transport systems (DTS), where connected robots and a few humans assemble a particular part of the car. Suppose one DTS reaches a station that is already occupied. In that case, it is programmed to head to another available station, thereby removing the delays part of the conventional assembly line. This modular assembly also allows for changes to be made on the go. The key advantages of modularization include: Modularization involves taking in requirements and specifications from customers and passing them off to the production floor directly without any significant engineering maneuver in between. Thus, it needs a rule-driven production that regulates how modularization is successfully achieved. To enforce a well- functioning and effective rules-driven production system, manufacturers can take these three steps: Modularization is the key to unlocking mass customization. By breaking down a product into smaller, more manageable parts, it becomes easier and faster to produce customized versions of that product. It also becomes more cost-effective, as each individual component can be produced in larger quantities. It is good news for consumers who want unique products without paying a premium price and for businesses who want to offer those unique products without breaking the bank.
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How Artificial Intelligence and 3D Printing can collaborate
Artificial Intelligence 3D Printing Machine Learning Applications of AI in 3D printing AI and 3D printing has been a hot tech for sometime and ever since their inception, these two domains has climbed steadfastly on the global market ladder. The 2019-20 global automation market size has displayed this rise. It is obvious that these two domain would cross paths sometime and strike up a beneficial collaboration. The intersection of AI and 3D printing has long been predicted. AI can analyze a 3D model and determine which parts will fail to form the part. 3D printers can also remove material from failed regions and use AI to create a different version. AI can even analyze a part’s geometry and identify a potential problem so an alternative way to create it can be found. The end result? A better-designed part with a high rate of success. Artificial Intelligence The merging of artificial intelligence and 3D printing is an evolution of manufacturing paradigms. Prosthetics design, for instance, is one of the most important applications of 3D printing. As technology advances, artificial intelligence and 3D printers can be used to control 3D printers and increase the number of compatible materials for the process. By combining these two technologies, manufacturers can create new and improved products and production processes. Artificial intelligence and 3D printing will eventually help humans create better prosthetics. The advancement of 3D printing has made it possible to create complex objects without the need for a human. Despite the complexity of the manufacturing process, AI can help to improve the process. The combination of AI and 3D printers will also create new applications. Here are some applications that will benefit from the convergence of these technologies. Once this technology becomes more widespread, it will revolutionize the manufacturing industry. It could even be used to create new prosthetic limbs that can be used for surgery. 3D Printing AI and 3D printing are often associated, but it can also be used to create better products and objects. By automating processes, AI can help eliminate human error and enhance 3D printing performance. The fusion of AI and 3D printing has a number of benefits for manufacturing and quality control. It also helps accelerate the rise of Industry 4.0 and the Industrial Internet of Things. But which use cases will AI have in manufacturing? What are some examples of where AI is already being applied to 3D printing? Machine learning, or AI, is a technology that can analyze a data stream and find hidden relationships. For instance, in the 3D printing process, artificial intelligence helps maintain the material properties of complex alloys, such as titanium, carbon, and other metals. The resulting models can be used for predictive maintenance. Machine learning can even help manufacturers improve spare parts and predict when to replace them. This is an exciting development for manufacturers and researchers alike. Machine Learning Bioprinting, also known as 3D bioprinting, is an emerging field in which machine learning is being used to improve the process of making organoids. This technique involves constructing a scaffold with a specific design to support cell growth and function. The complexity of the scaffold can have a big impact on the printed organ’s function. For this reason, scaffolds should be designed carefully and precisely to optimize the process. Using machine learning in 3-D bioprinting can help detect defects, such as incorrectly positioned cells, curved layers, and microstructure errors. It can also monitor the entire bioprinting process and identify problems before they arise. One such example is shown in Figure 4, which uses CNN to detect defects during the bioprinting process. In this example, images from high-quality cameras during the bioprinting process are input data for the CNN, which analyzes the images to determine whether they are defects. Applications of AI in 3D printing AI has a number of advantages when it comes to 3D printing, including the ability to analyze an object before starting the process, and to predict the quality of the part. The use of machine learning algorithms also improves the fixation process and reduces manufacturing waste. Some projects are even aiming for zero-waste additive manufacturing. AI can also be used to protect important data about the printing process, such as reducing the number of errors. A recent example of an application of machine learning in 3D printing is automated monitoring of 3D printed parts. By integrating image processing and camera data, supervised machine learning algorithms can detect defects during the printing process and help companies fix them without human intervention. The technology can also help companies cut the cost of reprinting parts if they have to fix a problem. Another cost-saving application of artificial intelligence in 3D printing is the guarantee of high- precision prints. A project developed by the University of Southern California has been designed to ensure that parts produced by 3D printing processes meet high-quality standards. The possibilities for AI and 3D printing to collaborate are endless. We’ve seen how they can work together to create a prosthetic hand, and we believe that as these technologies continue to develop, the potential value they can provide each other will only increase.
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Additive Manufacturing the rise of metals in 3D printing
Table of content Plastic as the basis for 3D printing Metal as the basis of 3D printing Additive manufacturing is one of the advanced techniques of Industry 4.0 that can manufacture industrial products faster and more precisely as compared to traditional manufacturing processes. Also known as 3D printing, it is a technique that works by turning a digital model of an object into a three-dimensional physical item by adding printable materials layer by layer on its digital design. It helps create complex geometrical patterns that are not possible with traditional manufacturing methods, designing and making lighter components, and controlling various material properties such as density and stiffness. 3D printing has gained popularity rapidly, involving minor prototype construction, fewer dies, and less post-processing. The aerospace and defense industry is experiencing large-scale use of 3D printing with French company Thales Group started a global center of expertise in additive manufacturing in Morocco in 2017. Boeing created its first 3D printed metal satellite antenna for the Israeli company Spacecom in 2019. Airbus used the technology to manufacture the titanium 3D printed bracket on an in series production A350 XWB commercial aircraft in 2017 and has since announced plans to develop 3D printed drones. Plastic as the basis for 3D printing Stereolithography (SLA): SLA is the first 3D printing technology ever used. It hardens a liquid resin using an ultraviolet beam, bonding each successive layer. Despite its antiquity, this technology is still widely used mainly due to a few advantages such as detail resolution, surface quality, and tight tolerances. It is used for UV-sensitive epoxy resins and ceramic-reinforced materials (NanoTool, BlueStone, CeraMax). This technique is widely used for coupling tests, dimensional verification, ergonomic studies, and wind tunnel aerodynamics tests due to its high detail resolution. Fused filament fabrication (FFF): In this process, melted thermoplastic material such as plastic, wax, or metal is sprayed from a nozzle to create many layers, each of which are bonded to the other. The bonding is done mainly by heat or adhesion. The most popular metals used here are nylon, high-density polyethylene, polycaprolactone, polycarbonate, and low melting point metals. Due to its affordability, FFF is a commonly used process for rapid prototyping parts with standard tolerances. Selective laser sintering (SLS): SLS involves hardening and bonding tiny seeds of plastic into layers in a three-dimensional structure using a laser. The powder is jet sprayed from multiple nozzles on the print area, and then the laser fuses or sinters the powder layer by layer. Based on the requirement, SLS printed objects are commonly made with plastic materials, such as nylon or any other powdered material. One of the main benefits of this technique is that, unlike many other 3D printing technologies, SLS doesn’t require much tooling once an object is printed.Unlike stereolithography, SLS doesn’t need additional supports to clasp a thing while it is being printed. Electron beam melting (EBM): Like SLS, EBM is a process that requires high energy high temperature, just that it uses an electron beam as its power source. In this, a tungsten filament in the electron beam gun is superheated to create a cloud of electrons that accelerate to approximately one-half the speed of light. A magnetic field focuses the beam to the desired diameter, while the second magnetic field directs the beam of electrons to the desired spot on the print bed. Currently, EBM is required mainly for producing refractory and reactive metals (titanium, niobium, zirconium, tantalum, etc.) and their alloys. EBM is great for melting and refining metals and alloys in water-cooled copper molds under a high vacuum. Laminated object manufacturing (LOM): Introduced by Cubic Technologies (formerly Helisys Inc.), LOM is a quick and comparatively cheaper method of 3D printing objects in various materials such as metals, plastics, or paper. It binds sheets in successive layers then cuts into the desired according to the 3D CAD model. It is a prototype-centric technique and is not used for production. Metal as the basis of 3D printing While 3D printing started by using mainly plastic as the base material, metal additive manufacturing technologies are currently the most significant growth area for additive manufacturing and include: Selective laser melting (SLM): A laser is used to melt successive layers of metallic powder until completely melted. The machine then adds additional layers of powder over the melted layer until the object is built. The aerospace and medical devices industries have witnessed the maximum use of this technology, as the manufacturing in those industries involves complex parts that can be simplified using this process. This technology was discovered in 1995 by the German research institute Fraunhofer Institute ITL. Direct Metal Laser Sintering (DMLS): Developed jointly by Rapid Product Innovations (RPI) and EOS GmbH, this technique is like SLM. The main difference is the degree to which the particles are melted. In DMLS, the particles are not completely melted. Also, the 3D printer parts are developed from excellent Aluminium or Titanium powder. Laser metal disposition (LMD): Laser Metal Disposition is also called directed energy deposition (DED). In this, a laser beam melts the metallic object and creates a pool into which the powder is fed. The powder then melts to form a deposit, and the required geometry is achieved layer by layer. The powder emitting laser and nozzle are controlled using a motion- centric system or robotic arm. This technology has been rapidly gaining traction in industries such as aerospace, tooling, transportation, and oil and gas. Electron beam melting (EBM): Originally patented and developed by the Swedish company Arcam, EBM differs from other techniques as it uses an electron beam as a power source instead of a laser to 3D print metal. The beam fully melts down the metal powder layer by layer in a high vacuum while retaining the original characteristics of the material. The technique can manufacture metal parts with 100% density and is also helpful for industries with complex components such as aerospace and medical implants.
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Combine Product Digital Twin and Product Configurator for Faster Product
By Swanand Javadekar A digital twin is a dynamic representation of an asset that allows us to understand the better working of the system and predict performance for better design directions. A product configurator is a dynamic representation of the CAD model that allows us to build an intelligent, practical model to enhance the speed of design and development. This paper conceives the concept and applies it to functional scenarios for better understanding and elaboration. Let us quickly elaborate on both the concepts and explore further for combined application: Product Configurator Product Configurator is a single solution that can, Essentially, it’s a solution that helps you get more customers and dramatically increases the productivity of your sales and design team. A product configurator is a design automation solution that works on parameter-driven design. We can create a complete model on the fly by entering a few key parameters. Our Product Configurator solution is based on proven and tested CAD neutral architecture. Hence we can work with the CAD system you use (NX, SolidEdge, SolidWorks, Creo (Pro/E), AutoCAD, Autodesk Inventor, and others). Digital Twin As mentioned earlier, a digital twin is a virtual representation of an actual world entity or a system to understand product behavior better. Generally, we can divide digital twin into three categories: Case Study: Industrial Engineering (Elevator) The product configurator and the digital twin have applications at various levels, typically in operations, commissioning, and installations. If we divide elevator methods and processes into three categories: Install, Operate, Maintain, we will elaborate areas where the standard approach will be helpful. Product configurator can be used to build a CAD model based on available configuration parameters such as allotted space, cage parameters, and internal and external dimensions. The cad model will be ready based upon various options, which can be easily used further for manufacturing drawings or product validation. Once your multiple models are available, the same can be used for further meshing and validation to pick the best-suited configuration. We can calculate the remaining useful life (RUL) and any what-if scenario. With confirmation from the product validation exercise, the final model can be used for further AR/VR exercise for product visualization purposes. Product configurator and digital twin combination will provide faster product development; the final product can also be used for further downstream applications such as AR/VR. Not only does the product manufacturer benefit by delivering a superior product, but other supporting systems such as building, and infrastructure management will benefit from the optimized maintenance cost and less downtime. Case Study: Industrial Engineering (Furniture) The furniture industry is an exciting example involving engineering with style and substance. The customer is demanding in terms of various options or variants, and the possibilities are endless. It’s where science meets the art, and probabilities are limitless. If we take the example of a simple chair, the flow chart is quite exhaustive: Type Base Features executive 5-star base high back conference 4-star base low back dining wood leg headrest auditorium sled base tablet soft stools stackable meeting swivel visitor adjustable plain sitting All the combinations come with the additional complexity of colors, mesh size, etc. In such a case where the manufacturer provides exhaustive options, and customers make customizable chairs, a combination of Product configurator and digital twin offers dynamic support to realize the dream. The CAD model of a chair combination is made faster while tested with the furniture industry-standard of weights. Any unique composite structure design or material changes can also be realized quickly. It allows the manufacturer to release the product faster to customer delight. Combining Product configurator and digital twin is the way forward as it allows manufacturers to manufacture faster to market methodology and offers customers to choose from a wide variety of options leading to customer delight.
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Smart Machines & Solutions for Smarter Performance
By Swanand Jawadekar Today, smart machines have become one of the integral parts of smart factories leading to the Industry 4.0 revolution. This paper details solutions developed for special purpose machines such as cartooning machines, tube filling machines and can be extended to similar types of SPM’s. These machines perform specialized manufacturing operations and are integral parts of agriculture, pharmaceutical or industrial factories. The Solution capitalizes on the readily generated engineering data in conjunction with loT (Internet of things) and AR (Augmented Reality) to make the machine smarter in a connected environment. It uses operating data from the equipment to predict various functional parameters such as production and performance analysis, energy analytics, delivering new insights towards Overall Equipment Effectiveness (OEE). Design and Development: Critical Foundation Today, the Digital twin has become an integral part of the manufacturing process. It can be characterized as a digital representation of the physical asset, which enables additional insight into machines’ performance. Besides supporting design strength analysis, it provides tools to examine the operating mechanism, loads and boundary condition, failure studies, alternate material. Carrying out a mechanism’s kinematic analysis involves calculating the velocity, location, and acceleration of any of its points or links for the prescribed time step. The study helps the user understand the mechanism’s behavior and make changes in geometry, material, and improve product performance. For any machine performance evaluation, mechanisms play a critical role. From material entry to final product manufacture, there are various mechanisms involved, consisting of combinations of conveyers, Cam, and rollers. Apart from analyzing critical mechanism parameters, Digital twin can be effectively used to identify influential data parameters affecting machine performance which can be further monitored using loT Techniques. The parameter identification will help the user effectively use sensors, location, and data acquisition and connect to the mobile portal. Once the critical parameter has been identified and equipped with sensors, they can measure the real-time mechanical or heat load which the machine experience in real life. Based upon received data, one can predict component failure, and the same can be replaced much before the break or worn out. Data Anytime / Anywhere Currently, most customers are looking towards intuitive products, easy to interact with, and high on performance parameters. Smart machines effectively use loT tools and parameters identified from Design simulations to provide a robust tracking mechanism. As determined by validation studies, critical machine design parameters can be further monitored to achieve better insight into machine performance. The performance tracker data can be accessed from a remote location and enhances the support system’s reach. IoT also helps the customer for a better post-sale experience and optimized environment. Following are some of the typical machine performance parameters which can be tracked live: Augmented Reality Augmented reality is gaining momentum in the marketplace and has shown incredible potential to support enterprise activities with different departments to perform their operations efficiently. It promotes a converged experience for the 3D AR content to Visualize, Instruct, simulate the working environment. The approach embeds desired parameters from the loT platform in the AR experience helps visualize a machine’s real-time information. AR studies can further be synched with various levels of an organization as illustrated below: In the Nutshell Design engineering has evolved dramatically. From draft board design to Computer-Aided Design and modeling to virtual reality, it has crossed global boundaries. With old proven CAD techniques and new Data, AR/VR (augmented and virtual reality) tools, we support international customers to build their design faster, better, and accessible / monitor from remote locations. These solutions extend flexibility to the customer and bring the global design team to work together towards standard global.
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Future of Product Design in the Era of Smart Connect!
By Swanand Javadekar Preface The automotive industry has been facing a daunted set of challenges with upcoming connected cars, autonomous driving, and electric vehicles. It is an opportunity to differentiate for the right minds by bringing the right mix of solutions to the customer and enlightening them with more intelligent products. The following paper highlights the association of technology trends to design connected products and build efficient ecosystems for execution. Some of the aspects discussed are Trends There are various ways technology is changing product outlook, following are some of the exciting trends influencing product design and development cycle: Smart Products: 4 promoting factors Today, Smart Products have become one of the integral parts of our life. It changes the way we use products and generates new business models. This paper details layout developed to build intelligent products and discusses the contribution and trends in each sector. The discussion is limited to product design and development and not extended to manufacturing 4.0. In a connected environment, smart products use the basic engineering data in conjunction with loT (Internet of things) / AR (Augmented Reality), embedded systems, and data analytics to provide better insight to the user and a machine manufacturer. It uses operating data from the equipment and uses a feedback loop effectively to predict various functional parameters related to product performance. Designing smart products As a designer who builds innovative products, he uses various advanced tools such as MBD (model- based engineering) and DEM (differential element method) to generate better insight into component behavior. Digital twin, which generates buzz across the engineering community, is a virtual replica of a product containing representative mechanical, electrical, electronic, and performance configuration information. The digital twin is not new, as the design community is already using various CAD, CAE, and CAM tools for the past few years. However, it has witnessed changes in the ability to collect, collate and analyze big data, work towards finding trends, anomalies and use the feedback loop back to design context to make it robust. Building digital twin also leads to effectively monitoring data, leading to building newer business models. Simulation is also one of the data-driven tools extensively used to analyze components, from simple durability to complex crash simulation. With higher computing power, the data handling capacity has been increased, as it can handle complete vehicle analysis compared to component level validation. Today, ROM (reduced-order method) based models have been used, which are machine learning solutions for reducing the size of a data set while preserving the essential parts of the information contained within that data. Such an approach now supports the user to analyze the components for rapid execution, reducing the total number of runs. There are various methods for which data analysis techniques are used: fault detection, predictive maintenance, statistical monitoring, real-time crash, and safety. Designing connected products: AR/VR Today AR/VR is playing a significant role in automotive product design and development. Typically, AR/VR can be extensively used for design and development, manufacturing, marketing, training, and servicing. More usage of these techniques is applied towards manufacturing and marketing, but the practice of product design is on the rise. Someone can effectively use these techniques used for design reviews and revision comparison. With the latest external devices such as hololens available in the market, the user can get an immersed view of the design for detailed assessment. Designing Embedded products: ADAS It’s exciting to note how these four verticals complement each other for product feature enhancement. Let’s take the example of embedded system / ADAS (advanced driver-assisted systems). We have seen that, typically, engineering simulation has been used for product development and digital twins, but the usage can be extended towards ADAS development. Some of the scenarios where validation tools can support to improve product performance understanding are semiconductor simulation (reliability analysis of Printed circuit board, energy consumption), sensor simulation (radar pattern simulation, placement of sensors compared to signal integrity), and driving scenario (software algorithm modeling simulation) Designing insightful products We know that Data analytics tools are effectively used for supply chain optimization, marketing mix analysis, user and dealer satisfaction, and customer behavior analysis. How can it be effectively used for a designer to view insight at an early stage? Today product designers are facing challenges towards converting data to actionable insights. The designer will work on three types of data, design data (based upon engineering calculations), test or proving data (standard vehicle test data), and real-life running data (received via various sensors loaded at designer vehicle test points). Multiple data analysis tools/algorithms will support to decode the data effectively and will support designer to take early decisions such as component failure prediction, feature management (leads to customization of platforms). Getting Act Together As mentioned in the above column, various technologies work seamlessly to build a better and more innovative product. Let’s discuss a few examples of how companies use a combination of technologies to build a newer customer experience. Design proposal selection Today Tier1 suppliers are interacting with OEM to select their various design proposals. With AR/hololens, the supplier can offer a better immersive experience to the customer. It also helps end customers select design proposals much swiftly, saving time and money. For example, automotive interior tier 1 suppliers can envision and demonstrate “Instrument panel” fitments within the car environment to OEM’s. With changes in color scheme, shading, feature recognition, the end customer can envisage effectively for better selection. Light-weighting In summary Automotive product design has expanded beyond CAD, and advanced tools have been implemented in the early stage of the design cycle. It assures various benefits to designers such as better understanding of product behavior, customer-centric innovative design, and shortens design cycle, saving time and money.
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