114.7.1 - Total Manufacturing

Intro to AUT FAB

What is "Automated Fabrication"?

- Automated Fabrication is the use of computer-controlled systems, robotics, and specialized machinery to perform manufacturing and assembly tasks with minimal direct human intervention.
- In practice, automated fabrication can include a wide variety of technologies—robotic welding cells, automated cutting and bending systems, CNC-controlled sheet metal punch presses, robotic pick-and-place systems, and fully integrated production lines.
  - These systems can work independently or be connected together through Industry 4.0 principles, allowing machines to communicate, share data, and adapt to production demands in real time.
- The advantages of automated fabrication include higher throughput, improved product consistency, reduced labor requirements for repetitive tasks, and enhanced worker safety by removing people from hazardous operations.
  - However, the success of such systems depends heavily on skilled technicians and engineers to program, maintain, and continuously improve them.
- Generally speaking, Automated Fabrication processes can be divided into three key categories:
  - Cutting: Automated cutting processes use computer-controlled equipment to separate or shape raw materials into desired dimensions or profiles. This includes technologies such as CNC laser cutting, plasma cutting, waterjet cutting, automated sawing, and CNC punching. Automated cutting ensures precise, repeatable edges and shapes, often with minimal post-processing, and can handle materials ranging from thin sheet metal to thick plate, tubing, and composite panels.
  - Forming: Automated forming processes shape or bend material without removing significant amounts of it. Common examples include CNC press brake bending, automated tube bending, roll forming, stamping, and hydroforming. By controlling force, speed, and tool positioning digitally, these systems can produce highly consistent parts while reducing operator fatigue and minimizing material waste.
  - Welding: Automated welding uses robotic arms, CNC-controlled fixtures, or dedicated welding cells to join materials—often metals—through processes such as MIG, TIG, spot welding, and laser welding. Automation improves weld consistency, increases throughput, and reduces operator exposure to heat, fumes, and UV light. Automated welding is widely used in industries like automotive, aerospace, shipbuilding, and heavy equipment manufacturing.

Plasma Safety

CNC plasma cutting is a powerful technology that can be dangerous if proper safety measures are not taken. Here are some safety considerations for CNC plasma cutting:
- Eye injury: Direct exposure to the plasma arc can cause serious eye injuries, particularly "arc eye" of flash burn of the retinas. It is essential to wear appropriate plasma cutting goggles or a helmet with a face shield when working with a plasma cutter.
- Burns: Both the intense heat and Ultraviolet (UV) radiation generated by the plasma arc can cause burns. Proper clothing that blocks UV light and protects from heat must be worn to prevent burns.
- Fire: Plasma cutting can ignite flammable materials, and the intense heat generated by the plasma arc can cause a fire. Proper housekeeping, ventilation, and material handling procedures must be in place to prevent fires.
- Smoke and fume: The plasma cutting process generates smoke and fumes, which can be harmful if inhaled. Proper ventilation and air filtration systems must be in place to remove smoke and fumes.
- Noise: The plasma cutting process generates high levels of noise, which can be harmful to hearing. Proper hearing protection must be worn when working with a plasma cutter.
- Electrical hazards: The plasma cutter is an electrical device and can pose an electrical shock hazard. Proper grounding and electrical safety procedures must be in place to prevent electrical shock.
- Material handling: Material must be handled carefully to prevent injury. The material should be secured properly before cutting, to avoid any slips or falls.
To prevent injuries, it is important to follow the manufacturer's instructions and guidelines for the plasma cutter, as well as to provide proper training for operators. Additionally, it's essential to have emergency stop buttons and fire extinguishers nearby and to be familiar with the emergency procedures. It's also important to conduct regular safety inspections and maintenance to ensure that the machine is in good working condition.

Waterjet Safety

Thermal/Arc Welding Safety

Laser Cutting/Welding Safety

CNC lasers are a powerful technology that can be dangerous if proper safety measures are not taken. Here are some safety considerations for CNC laser cutting/welding:
- Eye injury: Direct exposure to the laser beam can cause serious eye injuries, including blindness. It is essential to wear appropriate laser safety glasses or goggles when working with a laser cutter.
- Fire: Lasers can ignite flammable materials, and the intense heat generated by the laser can cause a fire. Proper housekeeping, ventilation, and material handling procedures must be in place to prevent fires.
- Smoke and fume: The laser cutting process generates smoke and fumes, which can be harmful if inhaled. Proper ventilation and air filtration systems must be in place to remove smoke and fumes.
- Noise: The laser cutting process generates high levels of noise, which can be harmful to hearing. Proper hearing protection must be worn when working with a laser cutter.
- Electrical hazards: The laser cutter is an electrical device and can pose an electrical shock hazard. Proper grounding and electrical safety procedures must be in place to prevent electrical shock.
- Material handling: Material must be handled carefully to prevent injury. The material should be secured properly before cutting, to avoid any slips or falls.
To prevent injuries, it is important to follow the manufacturer's instructions and guidelines for the laser cutter, as well as to provide proper training for operators. Additionally, it's essential to have emergency stop buttons and fire extinguishers nearby and to be familiar with the emergency procedures. It's also important to conduct regular safety inspections and maintenance to ensure that the machine is in good working condition.

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