The multi-industry program provides a forum for small- and medium-size companies in Ohio who hail from different but complimentary industries and sectors — public/private, customer/vendor, different industries. This function is based on the belief that the parts are greater than the whole. What you represent is the ideal solution for another entity. Both parties are unknown to each other but stand to benefit from symbiosis. CDME is the agent, the host, the moderator.
CDME's multi-industry program unites non-competitive companies in an innovative space to collaborate on product development and processes. This unified approach is supported by a talented staff of professionals and students who are dedicated to engineering, industrial design, graphic design, marketing, finance, and research. Many members of the staff have extensive history working in the industry and bring valuable professional experience to these programs. In addition, CDME has immediate access to faculty affiliates with OSU's College of Engineering.
Current multi-industry programs
CDME is proposing to build and test an engine based on the capabilities afforded by additive manufacturing, including all types of AM materials. This project is about pushing the limits of our knowledge, more so than building an engine. The model is based on the redesign of an engine — including the design, build and test cycles — in an 18-month period and using significantly less parts. The benefits include a more efficient manufacturing process, the use of improved materials and quicker time to market.
Printing your own tools is here and now with the advancement of 3D printing. The importance of thermal conductivity, electrical resistivity and compression strength are essential to design stamping, forming, casting, and injection molding tools, but these material property values are not currently included in additive manufacturing literature. There is a need for an agile tooling database where printers can reference tested standards for thermal conductivity, electrical resistivity and compression strength.
CDME is proposing test prints to allow for validation of published data and for the collection of additional data relevant to toolmaking. A line-up of initial collaborators has been drawn, and we are wanting additional sponsors who can help us identify materials or material types to be tested. Ultimately, this collaboration will yield a database that includes vital material properties that can be applied to agile tooling. The database will remove the guesswork. Agile tooling becomes even more efficient.
Researchers from OSU's CDME, the Material Science Engineering department and the Integrated Systems Engineering department has developed a concept to reduce pre-production manufacturing cost and facilitate quicker time to market, while staying applicable to smaller quantity runs by leveraging a new twist on hybrid dies.
In this new concept, the die sets would not be a match set as is typically the case. Rather the lower die would be manufactured using a low-cost, easy-to-machine or print material. The upper dies would be modular design commensurate with metallic “Legos”. Trials have already been conducted and have proven the feasability of this concept. CDME is launching a multi-sponsor, multi-industry project focused on evaluating and documenting the performance of 3D-printed materials for use in mold and die applications.
The advent of new materials joining the manufacturing marketplace is still growing at a swift pace. The demand for lighter, more durable and cost-effecient materials in manufacturing, especially in automobiles, is magnetic. The challenge in manufacturing with dissimilar materials, especially new metals, is the joining architecture. Dissimilar materials have to maintain a level of strength, adhesive, corrosion, and performance when joined. This project seeks to understand material joining technologies and how they will affect long-term performance. CDME is looking for sponsors to help us investigate these joining combinations and to test the boundaries of dissimilar materials joints.
VFAW is a solid-state welding process that can be used to join similar and dissimilar sheet metal materials with a strong interface between mating surfaces and the absence of a heat-affected zone. Additionally, the original mechanical properties of the workpiece materials are retained throughout VFAW. This technique provides a new and useful means for creation of lightweight and multi-material vehicle structures, featuring high strength steel and aluminum alloys.
VFAW is being adapted for use with a fully automated robot welding system. This process is an excellent candidate for the high-volume production manufacturers. CDME and its partners are working to adapt VFAW to a robotic configuration, but a number of technical challenges must be addressed through proper design implementation, including:
- proper assembly fixturing to existing equipment
- implementation of well-insulated, high-voltage terminal circuitry
- durability of housing assembly structure for repeated use
- automated loading and unloading of foils
- solutions for maintaining clean, undamaged working surfaces during trials
If your company is intersted in participating in any step of adapting VFAW to an automated robotic welding system, please contact us!