EWI associates to meet with attendees at DMC 2017

DMC imageAs in past years, EWI will be well represented at the upcoming Defense Manufacturing Conference in Tampa, FL,  December 4-7. Several  associates will present technical research during the conference, and our staff will also be on hand to meet with colleagues, customers, and companies interested in using EWI’s services to address defense manufacturing challenges. If you plan to  attend DMC 2017, we invite you to stop by Booth 602 to discuss objectives, issues, and options for optimizing your  production processes.

Please plan to attend our presentations:

If you would like to schedule an appointment to meet with an EWI associate during DMC 2017, click here now.

For more information, contact Mark Schimming at [email protected].

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New Article — Can Metal Additive Manufacturing Compete with Casting?

AM parts 2Casting is one of the oldest and most popular manufacturing processes for metals, but could eventually be displaced by additive manufacturing (AM).  Costs for AM are continuing to decrease while material performance and the number of available materials continue to increase.  For small production runs with long lead times, it is possible additive manufacturing is preferred solution for complex geometries.

In a new article, Can Metal Additive Manufacturing Compete with Casting?EWI engineers Ron Aman and Ryan Hurley discuss the possibilities of shifting from casting to AM and provide examples using powder bed fusion technologies. To read the article, click here.

The authors can be reached at [email protected] or [email protected].

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AtriCure is New EWI Member


EWI welcomes AtriCure, Inc., as a new member company. Based in Mason, OH, the company provides innovative technologies for the treatment of atrial fibrillation and related conditions. AtriCure invests in clinical science and technology to develop standards of care that support long-term outcomes. To learn more visit www.atricure.com.

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Metal Powder Recycling and Reconditioning in Additive Manufacturing — New Paper

With the advent of metal powder-based additive manufacturing (AM) and its acceptance for critical applications, it has become important to understand the behavior of raw materials using different AM techniques. Each AM process has its own requirements for material properties in terms of chemistry, size distribution, porosity, flow-ability, morphology and apparent density, all of  which can affect the properties of the final part. Recycling expensive specialty powders can make the AM process more affordable. The limits of reusing powders, however, must be understood so that quality specifications can be maintained.

Recyclability builds

Recyclability builds

A new paper by Rutuja Samant and Brendan Lewis, Metal Powder Recycling and Reconditioning in Additive Manufacturing, examines both the challenge and potential of metal powder reuse, and the need to develop qualified methods to recondition powders and re-qualify them for production.

To download the paper, click here.

To contact the authors, email [email protected].

To learn more about EWI’s work in AM, visit ewi.org/technologies/additive-manufacturing.

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WNY Economic Development Expert Joins EWI to Support New Initiative at Buffalo Manufacturing Works

Buffalo, NY – EWI announced that Elizabeth Callahan has joined its team at Buffalo Manufacturing Works. Callahan has been hired as Senior Program Director to launch a new program that will guide small and medium sized manufacturers through the identification, adoption, and deployment of technology and innovation.LizCallahanHeadshot2017

The new program, funded through Buffalo Billion II, will work directly with this cohort of manufacturers to help them through the process of learning about, preparing for, and identifying mission critical technology. Once that step is complete, the team will prioritize the deployment of that technology. The program will be launched later this year.

Prior to joining Buffalo Manufacturing Works, Callahan was the workforce development manager at the Buffalo Niagara Partnership. She has extensive experience in bringing together cross-sector partners to address critical manufacturer needs in our region. Callahan is a graduate of Purchase College, State University of New York.

“As Buffalo Manufacturing Works continues to expand our service offerings to help manufacturers grow and compete, we are excited to have Liz on board to launch this new program, ” said Michael Ulbrich, President of Buffalo Manufacturing Works. “Liz has spent years on the ground working directly with the Western New York business community and will be a great asset as we look to help more manufacturers make transformative improvements to benefit our entire region.”

Buffalo Manufacturing Works, an advanced manufacturing center of excellence operated by EWI, is part of Governor Andrew M. Cuomo’s Buffalo Billion initiative. Since opening its doors in April 2015, it has invested $18 million on state-of-the-art equipment and has engaged with clients in a wide variety of industries on more than 100 projects.


About EWI

EWI is the leading engineering and technology organization in North America dedicated to developing, testing, and implementing advanced manufacturing technologies for industry. Since 1984, EWI has offered applied research, manufacturing support, and strategic services to leaders in the aerospace, automotive, consumer electronic, medical, energy, government and defense, and heavy manufacturing sectors. By matching our expertise to the needs of forward-thinking manufacturers, our technology team serves as a valuable extension of our clients’ innovation and R&D teams to provide premium, game-changing solutions that deliver a competitive advantage in the global marketplace. To learn more, visit www.ewi.org, email [email protected], or call 614.688.5000.

About Buffalo Manufacturing Works

Buffalo Manufacturing Works, operated by EWI, helps innovation-driven organizations across North America excel by partnering with their internal manufacturing, engineering and R&D teams to deliver better products, grow, and compete. Located on the Buffalo Niagara Medical Campus in downtown Buffalo, the facility houses state-of-the-art equipment to facilitate applied R&D projects with members, as well as a team specializing in three primary technology focus areas: Advanced Automation, Additive Manufacturing and Metrology & Inspection. For more information, visit www.buffalomanufacturingworks.com.

About the Buffalo Billion

In an extraordinary recognition of Western New York’s potential, Governor Andrew M. Cuomo has committed an historic $1.5 billion investment in the Buffalo area economy to create thousands of jobs and spur billions in new investment and economic activity over the next several years. This $1.5 billion commitment to economic excellence is setting a new growth trajectory for jobs and the regional economy. We are creating a region that is admired worldwide, that attracts more people to live, learn, work and visit; where entrepreneurs and businesses want to invest their time and capital; and where all our institutions reflect a transformative culture of inclusion, continuous improvement, adaptation and excellence. To learn more about the Buffalo Billion, visit www.buffalobillion.ny.gov.

An Approach to Determine Minimum Amplitude Required for Ultrasonic Welding — New Paper

One of the most important variables for ultrasonic welding is amplitude.  While recommended amplitude guidelines are available for many generic materials based on accumulated industry experience, use of specialized and newly developed materials is rapidly increasing.  To that end, it is desired to have a method for experimentally determining the minimum amplitude required for a material.

Blog photo for post

EWI Applications Engineer Miranda Marcus has written a new paper, “An Approach to Determine Minimum Amplitude Required for Ultrasonic Welding,” to introduce a new, experimental method for determining minimum required amplitude. To download the paper, click here.

Miranda Marcus can be contacted at [email protected].

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EWI Welcomes New Member NWMO

NWMO 1We are pleased to introduce The Nuclear Waste Management Organization (NWMO) as a new EWI member. The Canadian organization is responsible for designing and implementing Canada’s plan for the safe, long-term management of used nuclear fuel. NWMO has provided technical expertise in support of Ontario Power Generation’s (OPG) efforts to obtain regulatory approvals for a proposed deep geologic repository (DGR). The organization’s vision is the long-term management of Canada’s nuclear waste in a manner that safeguards people and respects the environment, now and in the future.

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EWI Validates New NanoSteel Alloy for Resistance Spot Welding

Dissimilar weld joint between NXG 1200 and DP 980

Dissimilar weld joint between NXG 1200 and DP 980

NanoSteel, which develops advanced high-strength steels (AHSS) for manufacturing, has a new alloy, NXG™ 1200, designed to address the need for weight reduction and safety enhancement in the automotive market. Recently, EWI helped NanoSteel evaluate and validate the weldability of this new sheet steel both to itself and to other commonly used sheet steels.

EWI Senior Engineer Dave Workman has written “Resistance Spot Welding of NanoSteel NXG™ 1200 to Other Materials,” which highlights EWI’s evaluation of this new material and it’s successful validation. To read the full story, click here.

To learn more about EWI’s testing and evaluation services, contact [email protected].

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Ultrasonic-Assisted Drilling of 4340 Alloy Steel — New Article

Tough and resistant to fatigue, 4340 is a high-strength alloy steel that is widely used in the automobile and aerospace industries. Due to its properties, drilling 4340 alloy steel, especially at high material removal rates, has challenges that include heavy thrust force and torque which directly affect tool life, surface roughness, and dimensional accuracy of drilled holes. Therefore, to improve productivity of the drilling process using faster feed rates, these challenges must be addressed.

EWI UAD module

EWI UAD module

 With deep expertise and capabilities in high-power ultrasonics, EWI has developed an industrially hardened, ultrasonic-assisted drilling (UAD) system which applies high-frequency (20 kHz) vibrations at amplitudes of 2-20 µm to the drill tip in the feed direction. This system, which is fully compatible with CNC systems, is able to work with a drill at a shank diameter of up to 20 mm for a variety of materials from aluminum to Inconel and composites.

Studies conducted by EWI’s Amin Moghaddas, Matt Short, and Karl Graff  have demonstrated notable improvements in productivity using the EWI UAD system on 4340 alloy steel. The findings are reported in a new article, Ultrasonic-Assisted Drilling of 4340 Alloy Steel.

To download the article, click here.

To learn more about EWI’s high-power ultrasonic capabilities, contact Matt Short at [email protected].

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