IEN: What are the major concerns facing this sector in the next few years?

Taute: Time to market: Continually, we are asked about making our technology faster because time to market is a key factor for many in this industry. Mold makers are increasingly concerned about the turnaround time to get a mold. Injection molders are increasingly concerned about getting more production from the tool, with less overhead.

Profitability: Because of the increasing transfer of work to Asia and other foreign countries, many domestic mold makers are concerned about maintaining profitability given that these suppliers are able to turn molds around quickly and less expensively.

Availability of skilled labor: Europe is experiencing an aging workforce, which leaves traditional manufacturing lacking. In the U.S., one could argue that this same factor could be a concern. With fewer future workers engaging in apprenticeship-type programs, there will be fewer people who know many of the key elements in manufacturing.

IEN: What innovations are in store for users?

Taute: User-friendly interfaces: Because of the lack of craftsmanship, new technologies will need to be user-friendly. The one-button approach, with total closed-loop processes is a key consideration.

Innovative methods: In rapid manufacturing, prototyping and tooling technology will be driven to complete complicated tasks never before achieved using conventional methods. Already we have seen with LENS the ability to create multiple material structures in gradient or embedded fashions. We have also developed a way to create conformal cooling channels that will enable mold designers to integrate the channels in truly unique, 3-dimensional fashion. Both of these methods will increase productivity for injection molders by decreasing cycle-time.

IEN: How are software, materials, and equipment being improved?

Taute: Software: In the LENS technology, for instance, Optomec has made advancements in data capture of process parameters. In addition, the future holds an online "recipe book" of desired material properties. This software would enable the operator to key in the materials, the desired results, then walk away to return later to a finished metal part.

Materials: The LENS process has the ability to create unique materials. These include gradient structures and the creation of unique alloys. These materials are fully dense and stronger than conventionally wrought or cast metals.

Equipment: Once the equipment is set to start a project, there is no intervention from the operator. The operator can come back to the equipment to find a "perfect" part made to the specification indicated.

IEN: Are we entering a new era of e-manufacturing?

Taute: Definitely. In lieu of keeping time to market at a desirable level, there will have to be methods by which file transfers are completed in timely fashions. In addition, the equipment that makes these parts would be remotely operated and controlled with little human intervention.

IEN: How will the drive toward lean manufacturing impact this sector?

Taute: As mentioned above, e-manufacturing and the ability to reduce time-to-market are key factors in helping this sector to move to more lean operation. The LENS® process has the ability to increase productivity by reducing production times, without having to increase capital costs and overhead, with very little human intervention.