DEARBORN, MI – Honoring both innovation and manufacturing, the Society of Manufacturing Engineers (SME) announced the 2011 list of “Innovations That Could Change the Way You Manufacture.”
This annual list of innovations showcases new and emerging technologies that are making a difference in manufacturing. This is not the usual list of emerging technologies. These are innovations that can be used today or within a few months and have already shown some successful implementation.
Among this year’s innovations is graphene, which is not only the strongest material ever developed, but this one-atom-thick sheet of carbon is lightweight and electrically conductive. Fifty times stronger than steel, graphene is being used for extremely sensitive sensors, super-fast electronic switches, aircraft braking systems and touch screens.
Programmable magnets open the door to self-assembling. The ability to manipulate magnetic fields lends itself to many applications from precision switches to snowboard bindings to spinal implants. Using heat to erase a magnetic field, the material can be reprogrammed to have multiple north and south poles of differing strengths.
Not all innovations on this list are technical. The committee also recognized the Build to Demand (BTD) process as something that can change the way things are manufactured. BTD, an alternative to the Toyota Production System (TPS), works well for suppliers that experience variable demand and are seeking to increase customer service rates while reducing inventories and production costs. Limited or no capital investment is required to implement BTD in most companies.
Microstructured molding tools will impact manufacturers of products that could benefit from enhanced surface capabilities. Created as square or custom inserts for injection or compression molds, the innovation adds several capabilities to any molded product. This approach reduces microstructure manufacturing cost by 83 percent to 98 percent.
Programming light with quantum dots is an innovation that promises not only to change the way things are manufactured but also change the way we light our homes and offices. Quantum dots are nanoparticles of a semiconductor material that range from two to 10 nanometers in diameter. The ability to control the size of a quantum dot enables a manufacturer to determine the color of light emitted. Quantum dots are currently providing brighter images, lower power consumption and improved color purity for electroluminescent displays.
Controlled through a Web-based application, a remote-presence robot allows a telecommuting worker to remotely attend meetings, drop into the offices of colleagues and otherwise collaborate with people in another office. With cameras in the eyes to capture video, speakers and microphones to relay sound and a laser pointer “finger,” the user can see what the robot sees and direct it around by using a computer’s arrow keys. Companies such as Procter & Gamble are using these remote-presence robots to increase the efficiencies of teams working across the world.
Ten times stickier than Velcro® and reusable gecko-inspired glues, Super Velcro is an extremely strong adhesive that comes apart when heated. Using shape-memory polymers, General Motors researchers have created a product that allows a strong but alterable bond that replaces liquid adhesives requiring lengthy oven curing, which consumes a lot of energy, or foam tapes that do not provide high adhesion strength. Super Velcro is currently being used for interior and exterior automotive trims with potential applications for furniture, toys and buildings.
In reviewing submissions for the “Innovations That Could Change the Way You Manufacture,” the committee also highlights an “Innovation Watch List.” These technologies are showing great promise but, as yet, are unproven in the manufacturing setting. This year’s list includes: continuous-flow microreactors, dip-pen nanolithography, green cement, large-format ceramic batteries, laser heating in a diamond anvil cell, metamaterials, self-assembling vehicles, and synthetic cells.