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Explore the advancements in additive manufacturing of lightweight alloys, focusing on challenges and solutions for materials like magnesium and aluminum. This study highlights new alloy designs and process optimizations to overcome issues like hot cracking and thermal management.

Additive manufacturing (AM) represents a new paradigm for manufacturing, engineering of complex parts and design of novel materials that is having a profound impact on development and the economy. The design freedom offered by this category of manufacturing processes has and will have important implications for various industries, including tooling, automotive, aerospace and medical. AM applications have evolved from rapid prototyping to the production of end-use products. Currently, AM can be particularly advantageous for very small customised series, personalised parts or in cases where AM-based redesigns or a novel design offer significant functional benefits during the utilisation phase of the product (e.g. lightweight designs and remanufacturing of parts). In addition, AM has great potential in the development of new alloys, functionally graded materials (FGM) and metamaterials. In this context, the lecture will introduce the basic concepts of AM and the different processes used in AM. This is followed by a brief overview of the history and classification of AM processes with some additional information on the laser beam powder bed fusion and the directed energy deposition process of powder or wire, which are most commonly used in industry for AM of metal components. A comparison between AM and conventional manufacturing, i.e. formative and subtractive manufacturing, in terms of material consumption and waste, cost per part in relation to part quantity and complexity is presented. Prior to the examples of AM applications in FGM manufacturing, examples of successful industrial applications of AM in lightweight construction using generative design, part consolidation and improvement of functionality will be presented. The presentation concludes with an outlook on the future prospects and challenges of AM.

At the heart of modern manufacturing, SprutCAM is championing "The Nature of Manufacturing" by pioneering the integration of robotics into the structure of industrial operations. This innovative leap forward transcends the conventional and ushers in a new age of flexibility and expansive range of operations. In the article delves into the essence of SprutCAM\'s groundbreaking approach, highlighting its application to milling, welding, 3D printing, polishing, cutting, machine tending and painting. While robots may not match the precision of traditional CNC machines, their unparalleled flexibility and superior reach open up a realm of possibilities previously unimagined. Discover how SprutCAM Robot takes advantage of these benefits to provide solutions that redefine the manufacturing process, making it more adaptable and more comprehensive than ever before. With SprutCAM, industries are witnessing the evolution of manufacturing, where adaptability and expansion of capabilities are at the forefront of innovation. In the article you will discover how SprutCAM Robot is not only adapting to, but actively reshaping "The Nature of Manufacturing", proving that the future of manufacturing lies in the using of industrial robots in wide specter of applications

Increasing customer demands for lower prices and shorter delivery times are forcing companies to increasingly optimize machining processes on CNC machines. These processes also include the production of boreholes of smaller diameters up to a depth of 30D. When choosing the most suitable tool for the application, we must take into account the properties of the material being processed, the depth of the hole, the capabilities of the machine, the method of clamping the tool, and the properties of the coolant. When using classic drills, the process of making holes is relatively long and very time-consuming. In most cases, there are problems with the quality of the produced bore, flatness, and broken tools. The very geometry of the drill sometimes does not allow for quality cooling through the center, and the flow of coolant through the spiral is not intense enough. As a result, a poor-quality supply of coolant to the cutting edge occurs. Poor quality cooling of the cutting edge causes faster wear of the tool and thus also a shorter service life of the tool itself. In order to reduce the temperature at the cutting edge, we have to drill holes with interruptions (moving the drill while drilling), which increases the production time. Due to the increasing demands for high-production tools and ecological awareness, demands for the highest possible precision of the produced hole and the highest possible quality of the produced bore force manufacturers of cutting tools to continuous development. The Japanese manufacturer of cutting tools OSG has developed ADO MICRO drills, which, with the correct choice of clamping and drilling technology, enable fast and more stable production of holes and the achievement of better hole tolerances, as well as shortening subsequent procedures. They can be used without problems on materials such as mild steels, tool steels, special alloyed steels, cast irons, heat-resistant alloys, INOX 303, INOX 316L, aluminum, titanium alloys...

Maja Vidmar, Olma d.o.o.
Aleš Hrobat, Olma d.o.o.

Among the properties of oil, air release and foaming tendency are very important. This is mainly because oil fills are getting smaller and the associated circulation times are getting shorter. The oil has less and less time to release air in the tank before it is recirculated. When we use additives to reduce the tendency of the oil to foam, we usually also decrease the rate at which the air is released from the oil. It is therefore a challenge for lubricant manufacturers to harmonise these two properties.

This paper will present measurements of both foaming and air release from the oil. Requirements for fresh hydraulic oils will be given as a point of reference. The influence of different types and viscosity grades of fresh mineral hydraulic oils will be shown. The results of the measurements on different types of base oils will be presented.

Anet Rožič, Hella Saturnus Slovenija d.o.o.

With the advent of electric vehicles, new car components have emerged that require additional surface protection. Surface protection already used in the interior of the car were developed for use on external components. That resulting in alternative surface protection technologie for car body lighting equipment. Fewer production processes are required to produce a product, and these have acquired better properties.

In the company, where they are specialized in the production of motor protection switches, was before manual assembly production and control of these switches. Due to the increased scope of work and repeatability of composition and control, they decided to create an automated device that would reach the capacity of two existing manual devices. Before automation, they had 2 manual devices with a total of 24 nests. The automated device has 16 nests and reaches the same or an even bigger capacity of switches produced. The emphasis is on the repeatability of the composition and the reliability of the control.
In presentation you can find the development of a device for assembling and controlling switches, which is divided into four functional and three basic units. Such automation is an indispensable part of economical and human-friendly technology in industrial processes. The request for the production of such a device came from the customer, because manual work is time-consuming and unfriendly to humans, so we developed an automated device, where monotonous work is performed by a robot and other automated stations, while at the same time we provide larger series of products with smooth work without interruptions. Large series are now made in a much shorter time. Presentation describes the process of designing such an automated device.

Jan Tavčar, Domel

Domel tool shop manufactures tools for overmoulding with thermoplastics, moulding with duroplasts and die cutting tools for stamping electrical steel laminations. Some of the most important processes used in tool making are HSC milling, die-sink EDM and graphite electrode milling.
Due to the desire to make the best possible use of the equipment, we decided to automate these processes. Otherwise, we started with the automation of sink EDM processes using a pallet system and the production of graphite electrodes already in 2001, but the equipment was no longer at the appropriate technical level.
We decided to build a new cell to automate the process of producing moulds with dimensions up to 400 mm x 400 mm and a maximum weight of 150 kg. The cell contains two sink EDM machines, an HSC milling machine for milling graphite electrodes and steel, a coordinate measuring machine and a washing device for cleaning the workpieces after the completed treatments and before the process of measuring.
When planning the cell layout, we started from our needs and previous experience in the field of automation and the requirement to increase productivity. In any case, we also wanted to automate the process of measuring the workpieces, as well as the analysis of the measurement results.
Based on our request, we obtained offers, and finally decided to entrust the implementation to the company Erowa, which is an independent provider and can include machines from other manufacturers.
In the following, together with the company Erowa, we determined the layout of the cell and precisely defined the technological processes.

Erih Arko, Yaskawa Ristro d.o.o.

In the modern world, robotic debugging proves to be an extremely important and innovative technology with many key advantages. One of the most important aspects is the guaranteed humanization of the workplace. The task of deburring is taken over by the robot, which reduces the physical load on the worker and allows them to be redirected towards more creative and intellectually demanding tasks. The quality of deburring performed improves. Robots perform the work precisely, consistently and without the influences that the human factor can bring.

In Gorenje IPC d.o.o. we manufacture bottom sumps for new dishwashers of the DW50/60 series.
In this bottom sump, a pump is later installed for the dirty water that is the result of washing the dishes. Bottom sump consists of three main components, which are welded together by a melting process using heating plates. The modification of welding was carried out due to the capacity increase at the finalist, i.e. due to a higher production plan. If we wanted to ensure a sufficient quantity of pieces per shift on the existing, rather old and manually operated device, two workers had to work on the existing machine per shift. The maximum possible number of manufactured pieces per shift was 650, which was not enough for the daily need of 2,200 pieces ordered by the finalist.
We set ourselves the goal of automating the existing process, based on manual insertion at all three workstation in the process (Welding 1, Welding 2, Testing) and using the new automated cell to produce 780 pieces per shift with one worker. The total saving is therefore an increase in capacity and a reduction of workers from two to one. All under condition, that the welding technology remains the same.
The result of the modernization is that we produce up to 830 pieces per shift with one worker. Solution was provided by Flexido d.o.o.

Dušan Božič, Inden d.o.o.
Andraž Žertek, Inden d.o.o.
Peter Korenčan, Inden d.o.o.

Digitalization of production processes brings numerous benefits, such as increased efficiency, lower costs, and greater flexibility. However, its implementation is also associated with risks, as uncontrolled use of digital tools can lead to various challenges. The article thoroughly explores some of the key pitfalls of digitalization that can significantly impact quality assurance in manufacturing. Through research, which involved designing and distributing a survey questionnaire to international companies, we gained valuable insight into their perception of the risks associated with digitalization and the strategies they use to manage them. The research results reveal that deliberate and targeted use of digital technologies, along with continuous education and training of employees, is crucial to avoiding all the pitfalls of digitalization and ensuring high product quality. The analysis provides a detailed insight into the key aspects to consider when implementing digital technologies in manufacturing. It highlights the importance of adapting current processes and continuously monitoring and improving product quality. The survey results should serve as a valuable source of information and guidelines for industrial experts in dealing with digitalization and quality assurance in production.

Metal Binder Jetting (MBJ) 3D printing technology evolved from Metal Injection Moulding (MIM) technology. Both technologies allow us to produce smaller metal parts of complex shapes. This is a powder metallurgy. The difference between those technologies is how we obtain the so-called green part, which will be presented in this contribution in more details.

Luka Čas, Univerza v Mariboru, Fakulteta za strojništvo
Bojan Ačko, Univerza v Mariboru, Fakulteta za strojništvo

Growing demands of customers and needs of companies to improve competitiveness and achieve greater profits are one of the driving forces for encouraging the economy to constantly improve the quality of production processes. An important role in ensuring this, play reliable and accurate measurements, which are carried out both during the production process itself and during the control process. Due to the fact that with the development of modern precision machining technologies, the requirements for the accuracy of certain parts can reach the sub-micrometre level, the need for high-quality sensors and measuring instruments is increasing. Taking into account the fact that sensors as a measurement basis directly reflect changes in the measured components, the sensor signal represents one of the main sources of a measurement error. For this purpose, in order to achieve traceable measurements that are linked to the SI unit (meter), it is necessary to calibrate the sensors with measurement standards with measurement uncertainty at least five to ten times lower than the permissible error of the sensor under calibration. In the Laboratory for production Measurements at the University of Maribor, which is the holder of the national standard for length, we ensure traceability of length measurements at the highest level in the country. The content of development and research work is based on the results of analysing metrology needs in industry, research and other branches. The paper presents the most precise calibration methods and procedures that are being developed in the laboratory for fulfilling the needs of Slovenian industry and accredited calibration laboratories. Special emphasis is placed on the latest method of calibrating precision displacement sensors, which is currently being developed in the laboratory.

In Siliko, as a development partner of premium European car manufacturers, we have acquired and implemented a demanding project of development, testing and production of Fuel Filler and Changing Pot Systems for ICE, PHEV and BEV Vehicles of the new BMW 7 Series.
The fact that we were developing for the \"flagship\" vehicle of a premium manufacturer added an additional challenge to the already technologically demanding product.
The quality requirements of the final assemblies, from the customer\'s side, are extremely high. Higher than in similar previous projects, which means a lot of input from the entire development team, i.e. the teams of development engineers, test laboratory, quality department, measurement department, team of technologists and, of course all other members of the project team.
Basic functional requirements, such as adequate stiffness, dimensional stability, prescribed forces and opening times, resistance to chemicals and aging, were joined in the aforementioned project by even stricter requirements for visual appearance (flatness, surface structure, etc.).
Numerical simulations and precise and high-quality production of tools and preparations were also crucial for successful finalization of the project.
As part of the project, we carried out our own development and production of products (a total of 8), internally developed and produced production means (tools, assembly preparation, grinding preparation) and developed new processes (injection compression molding, automatic grinding, semi-automatic assembly with final control, automatic surface control) and successfully integrated them into series production.

Aljaž Javernik, Univerza v Mariboru, Fakulteta za strojništvo
Klemen Kovič, Univerza v Mariboru, Fakulteta za strojništvo
Iztok Palčič, Univerza v Mariboru, Fakulteta za strojništvo
Borut Buchmeister, Univerza v Mariboru, Fakulteta za strojništvo

The article introduces the use of digital twins for the purpose of optimizing production systems. It focuses on the comparison between the results of simulation modeling of the digital twin and the data obtained in a real-world production system. The digital twin is created in the Simio software environment, which is based on the use of a data-driven simulation model. Running the digital twin in real time enables the analysis of production parameters (number of finished products, average flow time, capacity utilization and product quality). The results illustrate the financial feasibility and analytical capabilities of digital twins for optimizing production systems. Real-time operation enables continuous evaluation and tracking of production parameters. The study emphasizes the importance of accurate selection of input data, which in the vast majority of cases is the biggest limitation in achieving useful results in the real world. The results encourage the integration of digital twins into production systems in Slovenian industry.

Tomislav Hercigonja, Topomatika d.o.o.
Nenad Drvar, Topomatika d.o.o.
Josip Kos, Topomatika d.o.o.
Matic Vogrin, MARSI Group d.o.o.
Mario Šinko, MARSI Group d.o.o.

Advancements in the field of computerized tomography have revolutionized the way we approach the analysis and understanding of complex technical assemblies. The conventional method of assembly analysis involves cutting or disassembling the assembly and analyzing each individual component, resulting in the destruction of the sample. This creates material damage and, more importantly, leads to a misinterpretation of results. By introducing CT technology into research and industrial applications, doors are opened to more precise and non-destructive analysis, design optimization, defect identification, and improvement of assembly quality and efficiency.
This paper presents the results of 3D measurements obtained with the ZEISS METROTOM industrial CT system and data processing with the ZEISS INSPECT X-Ray software package for comprehensive analysis of 3D data.

Filling the electrical drive with epoxy resin
Objectives:
- weight reduction
-reduction of vibration and noise
-reduction in size while increasing the performance of the electrical drive
-resistance to temperature shocks and increase in operating temperature
- operation at higher voltage loads
This paper presents a practical solution for potting an electric actuator with potting compound. This process reduced vibration and noise, which is one of the key characteristics of E-drives.

Tim Herbertson, Erowa AG

EROWA\'s Job Management System (JMS) seamlessly integrates with their Flexible Automation Concept to revolutionize manufacturing efficiency. JMS acts as the central nervous system, coordinating the entire production process. It enables real-time monitoring, scheduling, and optimization of machining tasks across multiple machines and workstations.

At the core of JMS lies its ability to manage job queues intelligently. It prioritizes tasks based on factors like deadlines, machine availability, and part complexity. This dynamic scheduling ensures optimal resource utilization and minimizes idle time, leading to enhanced productivity.

JMS also facilitates seamless communication between CNC machines, robotic systems, and ERP/MES software. It automates data exchange, eliminating manual input errors and reducing administrative overhead. This connectivity enables lights-out manufacturing, allowing operations to continue 24/7 without human intervention.

Furthermore, JMS enhances production flexibility by enabling on-the-fly job modifications. It accommodates rush orders, last-minute design changes, and production rerouting with ease. This agility is crucial in dynamic manufacturing environments where adaptability is paramount. Due to the mentioned benefits, this kind of system can be fully utilized in production facilities with small and combined batches as well as batch size 0 facilities. Examples of such industries are: tool shops, die shops, job shops, machine building facilities, precision manufacturing...

In combination with EROWA\'s Flexible Automation Concept, JMS maximizes the benefits of standardized workholding and automated palletization. It orchestrates rapid tool and pallet changes, seamlessly integrating with CNC machining centers. This streamlined workflow minimizes setup times, accelerates changeovers, and optimizes overall equipment effectiveness (OEE).

Overall, EROWA\'s JMS system empowers manufacturers to achieve unparalleled efficiency, flexibility, and agility in their production processes. By harnessing the synergy between intelligent job management and flexible automation, businesses can stay competitive in today\'s fast-paced manufacturing landscape.

Vinko Drev, LTH Castings d.o.o.

The company LTH Castings d.o.o. has been steadily expanding for some time and investments in the field of automation are inevitable despite its high level, as the demand for our products increases every year. In the last three years in our Ljubljana plant, where we have our Process Automation department, in addition to several smaller automation projects, we have set up and launched the currently largest fully automated line in our company. It is a line that runs through three spaces and covers processes of machining, washing, assembly, dimensional control, leak testing and engraving. Due to the complexity of the line, it is divided into two parts: processing with washing and a clean room, where clean processes (assembly, leak tests, etc.) and manual
product packaging take place. In the first part of the line, there are 4 robotic cells with 8 machining machines, and a pallet line for product distribution from the robotic cell, through washing, to the clean room. In the clean room, products are transferred to another pallet line, where three standalone machines with integrated robots are located, along with 5 robotic cells for machine loading, and 8 workstations for visual product inspection and packaging. Currently, we can produce 15 different types of products on the entire line, while simultaneously handling 8 different products. We have entirely manufactured the line within the company\'s Process Automation department, utilizing many innovations not present in previous lines. The entire line and its processes will be presented in detail in the article.

A journey of Additive Drives from prototyping to production of customized, high-efficiency electric motors using 3D printing is presented. We discuss the transition from manual to scalable processes, achieving series production across industries, and the development of technologies with nearly 20 patents. Looking forward, it focuses on the scaling of production through advanced automation and continuous innovation in additive manufacturing, catering to a diverse array of motor types and sizes.

In 2016, Japan announced a strategy called Society 5.0 (Society 5.0), which is equivalent to the EU's Industry 4.0 from 2011. They put the technology of digital twins as the basic generator of development. Since then, the whole of Japan has been developed as a digital twin made up of many digital twins. The Japanese added an environmental upgrade to the Society 5.0 strategy in March 2021, but they did not change the number of the revolution, because it did not happen. Eight months later, the EU Commission published a strategy, and in January 2022 a development vision entitled Industry 5.0, which is also an environmental upgrade of Industry 4.0 and is not a technological revolution, but a political construct. Indeed, the EU is still living in the age of Industry 4.0 and will be for quite some time. Since 2016, Japan has put human well-being at the center of all development in its strategy, and it has also put people at the center of EU Industry 5.0 six years later. When rewriting Japan's strategy, EU strategists omitted the development of digital twins in Industry 5.0 and envisioned the manual production of highly individualized products instead, thus directing EU development backwards. The development of technology overtakes the development of society by ten years or more and literally drags the development of society forward. The most developed society is the result of the most developed technology and nowadays these are digital twins. Slovenian development lags behind three revolutions, so we have no choice but to implement industrial revolutions 3.0, 4.0 and 5.0 at the same time and integrated into a whole, under the name Human-centered industry 60 as a generator of a super innovation society.

Andrej Lebar, UL, Fakulteta za strojništvo, Zdravstvena fakulteta
Izidor Sabotin, UL, Fakulteta za strojništvo
Pavel Drešar, UL, Fakulteta za strojništvo
Joško Valentinčič, UL, Fakulteta za strojništvo

In abrasive water jet cutting (AVC) technology, a mineral abrasive is used for cutting, which is accelerated to the workpiece by a water jet at speeds over 600 m/s depending on the working pressure. One of the main advantages of AVC over related processes is that it does not cause a heat-affected zone. In Slovenia, AVC cutting technology has been present since 1990, which is only 10 years after its first industrial use. Despite obvious advantages, the use of the process in industries where the introduction of inclusions into the workpiece, such as the food and seal industries, is not acceptable. In ice abrasive water jet cutting (LAVC), the mineral abrasive is replaced with ice grains of water at very low temperatures (below -100°C), as ice only has the appropriate mechanical properties necessary for effective material removal at these temperatures. The advantage of using ice is the cleanliness of the machining process while maintaining high cutting efficiency. With previous research, we have confirmed the survival of ice grains in extreme conditions that prevail in the cutting head, and with the help of numerical analysis, we have analyzed the temperature conditions inside. We also experimentally checked the potential erosive efficiency of ice grains on workpieces made of aluminum and glass, which show erosiveness that is comparable and in some cases even higher than that of mineral abrasive. Based on the results and publications so far, we have caught the attention of the industry both in the EU and in Asia, which are already showing a need for this technology. This opens up new possibilities for Slovenian machine building industry.

Marko Jerman, Fakulteta za strojništvo, Univerza v Ljubljani
Jithinraj Edaklavan Koroth, Fakulteta za strojništvo, Univerza v Ljubljani
Andrej Lebar, Fakulteta za strojništvo, Univerza v Ljubljani
Pavel Drešar, Fakulteta za strojništvo, Univerza v Ljubljani
Izidor Sabotin, Fakulteta za strojništvo, Univerza v Ljubljani

Plasma Electrolytic Polishing (PeP) is a suitable technology for improving the surface integrity of metal parts. PeP, a form of anodic dissolution, achieves surface polishing through chemical and plasma reactions. The resulting synergy produces a high-gloss surface. The standard PeP setup involves anodically polarized workpiece in an aqueous electrolyte with a simple disc-shaped cathode placed in the vat. PeP uses a water-based electrolyte with a low concentration of neutral salts, which are environmentally friendly and low-cost.
PeP is applied in industry sectors where achieving an exceptionally refined surface finish is crucial such as tool making and medical implants industry. It is foreseen as a highly promising post-processing technique for additively manufactured metal parts. Main advantages of PeP technology are: simultaneous polishing over the whole surface of complex shaped parts, short processing times, achievable high gloss surface, increasing fatigue strength and corrosion resistance, surface sterilization and eco-friendliness.
Here we present some industrial case studies of PeP usage. The specimens were polished on a newly acquired PeP machine at the Faculty of Mechanical Engineering, University of Ljubljana. The presented work was performed within the scope of Horizon Europe project titled Strengthening the Excellence of Additive Manufacturing Capabilities (SEAMAC) coordinated by Assoc. prof. dr. Joško Valentinčič (Laboratory for alternative technologies).

In the manufacturing industry, where efficiency and energy conservation are key priorities, pL LEHMANN rotary tables offer a compelling alternative to traditional machining methods. This article examines the benefits of integrating a 3-axis vertical machining center with 1- and 2-axis pL LEHMANN rotary tables, compared to using a standard 4- and 5-axis machining center. The focus is on the systems increased flexibility, improved setup changeover speed and reduced energy consumption.
Another key feature of pL LEHMANN innovative approach is the Roto-Fix clamping system, which underlines pL LEHMANN commitment to precision and reliability. It's not just about the rotary tables; pL LEHMANN aims to provide solutions that meet the wider needs of modern manufacturing processes.
KROKK d.o.o. plays a key role in bringing this solution to the market by offering not only the Lehmann tables, but a comprehensive package that includes bespoke fixtures and professional installation. This ensures that customers receive a fully optimized solution that integrates effortlessly into their production lines, increasing efficiency and reducing energy costs.

We present a revolutionary platform for the visualization of industrial systems, which stands out for its modernity, adaptability and universality. It is an innovative solution that goes beyond traditional approaches.
Its main advantage is complete adaptability and the ability to connect to various control systems of leading manufacturers. The integrated drivers enable a wide variety of connection options and smooth data flow, also via the OPC UA or MQTT protocols.
The platform works independently of the operating system, which allows it to be used on a variety of devices, including mobile devices. The free development environment makes it easy to create applications, while the more advanced version offers additional functionalities such as group project development and versioning via the GitHub platform.
It includes all the necessary elements for efficient management of production processes, such as an alarm system, data storage and recipe management. The possibility of customization with the help of C# scripts allows flexibility already in the development phase or in the application execution phase.
Licensing is based on functionalities, which allows flexibility according to the needs of the organization. With this platform, you not only change production processes, but open new doors for the development and growth of your company.
We will also present you some possible ways of using the new digital platform in practice.

Petr Atanasčev, Konica Minolta Europe

Get the insight into many AI based machine vision projects delivered by Konica Minolta to inspire yourself! We will show you many use cases and verticals where the visual quality inspection software can be used.

In general, there will be mentioned use cases related to:
- Defect detection – where we analyse products or surface if they are not scratched or if they have no other type of defect
- Assembly Quality Inspection – where we check if the product is assembled of all components in proper way
- Object detection, classification and counting – where we help to count the products (e.g. for packaging) and sort them automatically

All use cases will be introduced as customer problem which they needed to solve and what benefits they got by implementing Konica Minolta’s solution.

Rok Završnik, Turnaplast d.o.o.
Jure Perme, Tutnaplast d.o.o.
Silvester Bolka, Fakulteta za tehnologijo polimerov
Tamara Rozman, Fakulteta za tehnologijo polimerov
Teja Pešl, Fakulteta za tehnologijo polimerov

In this paper, we will present the use of mechanically recycled wings of wind power plants and carbon fibers in combination with recycled polyamide 6 reinforced with glass fibers for very demanding applications. At the Faculty of Polymer Technology, we used industrial waste from the company Turnaplast to prepare a thermoplastic composite, to which we added ground waste from the wings of wind power plants and ground carbon fiber waste from the automotive industry. In order to achieve the required properties of the prepared composite, we used different combinations of added waste fibers and different combinations of compatibilizers, which ensured good interfacial interactions between the waste fibers and the polyamide matrix. We measured the mechanical and thermal properties of the highly filled composite, which were improved during the recipe optimization phases in order to achieve the required properties of the final product.
The implementation is a good example of cooperation between industry and a research institution in the field of circular economy. We have shown that, with our own knowledge, we can make thermoplastic composites for the most demanding applications on existing equipment.

Merel has been establishing itself as a key player in the market for more than three decades, specializing in the sale and servicing of measuring equipment essential for chemical analysis. In the modern industry, where the quality of products is directly linked to the precision and reliability of measurements, Merel stands at the forefront by providing top-notch solutions.

Our mission goes beyond merely supplying equipment; with professionalism and dedication, we tackle the measurement challenges faced by advanced companies. The chemical composition of materials and their associated product properties are key parameters that our technology is capable of analyzing accurately.

During the presentation, we will reveal how we face real measurement challenges. Through practical examples, you will learn how close collaboration with manufacturers and customers leads to innovative solutions. Our extensive knowledge and years of experience enable us to use measuring equipment in unique ways.

We will focus on specific examples, such as the analysis of metal samples with a high content of halogens in advanced recycling, determining the thickness of passivation layers in the automotive industry, and analyzing raw materials that are crucial for the production of building materials and consumer products.

The company\'s advanced solutions for metal finishing using plasma polishing and JetPeP technologies are presented. It highlights their environmentally friendly and efficient process that combines cleaning, deburring, and polishing in a single step. The focus is on the unique capabilities of JetPeP for selective and precise finishing, ideal for large workpieces and enhancing weld seams. The company leverages a robust patent portfolio and custom machine development for diverse industrial applications.

MoldJet Technology introduces Additive Manufacturing 2.1, the next level in 3D printing. Developed by Tritone Technologies, this advanced system enhances production efficiency and quality, setting new standards in the AM industry.

Egidij Hudrap , SIJ Ravne Systems d.o.o.

For this year\'s industrial forum, we are preparing a summary on a joint project between BOSIO d.o.o. and SIJ Ravne Systems d.o.o., where a new hardening line for thermal treatment of industrial knives will be presented. Ravne Systems has been manufacturing industrial knives for over 50 years. The key line for heat treatment of knives for cutting and peeling of veneer was already old and energy insufficient. Problems with the straightness of the knives during the heat treatment itself were reflected in complaints from their customers. Therefore, they urgently had to make new hardening line. They chose the company Bosio d.o.o. as a partner for the project. By combining their many years of experience in heat treatment of industrial knives and the expertise of Bosio colleagues, they jointly constructed a modern computer-controlled hardening line. The purpose of the project was to improve the quality of industrial knives, increase the hardening capacity and reduce energy consumption. Bosio\'s scope of work included the production, supply, assembly and commissioning of a preheating furnace (850°C), a manipulator and a hardening furnace (1100°C). Both furnaces are electrically heated with a horizontal arrangement of heaters. The heaters are inserted into the radiant tubes. In the hardening furnace, the biggest challenge was to choose the type of hearth, because an industrial knife, which is heat treated at a temperature of 1100°C, must have an appropriate straightness of the hearth, as the quality of the final product depends on it. Together, they chose the solution that the hearth in the furnace will be made of RSiC plates, which is offering appropriate straightness of the hearth at 1100°C. They also added an innovative solution for re-levelling the hearth if necessary.

Silvester Bolka, Fakulteta za tehnologijo polimerov
Marko Verčkovnik, Fakulteta za tehnologijo polimerov

In this paper, we will present the evolution of mould for injection molding printed with the selective laser sintering technology of polyamide 12. At the Faculty of Polymer Technology, we use 3D printed mould inserts with SLS technology for injection molding of prototypes and demonstrators. The main advantage of this type of mould insert production is the short production time and virtually no finishing required, which is often a necessary step for metal tool inserts. Like other mould insert manufacturing technologies, SLS technology also has its weaknesses. The main disadvantage is the large proportion of material that remains after SLS printing. At FTPO, we solved this problem by using exclusively recycled PA12 material for SLS printing. The following disadvantages are that mould inserts for injection molding made with SLS technology requires very long cooling times, the mould insert has a large abrasion mainly in the area of the injection and we are limited by the temperature stability of such a mould insert. We decided to gradually eliminate the weakness. At the beginning we first solved the problem of long cooling time by using a metal insert on the lower side of the mould insert. The next step was the use of a mould insert in the area of the runner, with which we drastically extended the life of the mould insert. In order to increase the temperature stability, we are currently conducting tests with a composite material that we are developing together with a supplier of recycled PA12 material.

Explore the principles of additive manufacturing (AM) for metallic materials, focusing on the selection of materials and processes that enhance both functional and aesthetic properties. This overview includes technologies like SLM, EBM, and BJP, detailing their applications in creating efficient, cost-effective components.

Milan Pecl, M Pecl d.o.o.

Plastic injection molding is a complex process in which many factors have to be considered. One of those key factors that takes the longest time is cooling, where not only the long time has to be considered, but also the precise quantity of cooling medium that runs through the cooling channels. Because of ever increasing level of molded part complexity, it is a must to control the cooling medium. Good control of water and cooling medium are therefore key to control the quality of molded parts.

Jörn SENGELAUB, CONTURA-MTC GmbH
Christian Preuß-König, CONTURA-MTC GmbH

Injection moulded plastic products often exhibit aesthetic defects, including weld lines and sink marks. This article discusses these common issues and explores the potential of eliminating them through the implementation of conformal cooling. By integrating conformal channels and heat transfer elements along the contour of the moulded part and employing the variothermal process, stable and sustainable production processes have been achieved. This technology not only facilitates high-gloss surfaces but also allows precise control over matte or textured surfaces, eliminating the need for additional procedures like painting and thereby reducing the component's carbon footprint.

Jernej Hernavs, Univerza v Mariboru, Fakulteta za strojništvo
Lucijano Berus, Univerza v Mariboru, Fakulteta za strojništvo
David Potočnik, Univerza v Mariboru, Fakulteta za strojništvo
Kristijan Šket, Univerza v Mariboru, Fakulteta za strojništvo
Simon Klančnik, Univerza v Mariboru, Fakulteta za strojništvo
Mirko Ficko, Univerza v Mariboru, Fakulteta za strojništvo

In the steel industry, the need for improved mechanical properties often means that heat treatment (quenching) is required, which can lead to undesirable changes in shape due to structural changes in the material. Due to the high hardness of the materials, often exceeding 60 HRC, conventional shape straightening processes such as bending and rolling are not feasible due to the risk of material failure. Our research focused on predicting the final shape of hardened metal workpieces after the controlled insertion of notch punches. We introduced an experimental procedure in which the 3D shape of the workpiece was accurately captured with a 3D scanner after each impact. The experimental data was collected in a large database to train multi-level regression models with deep neural networks. We developed an innovative architecture that combines two different types of data in the model - the shape of the workpiece and the planned blows - to accurately predict the shape change.

Jure Korbar, Fakulteta za strojništvo, Univerza v Ljubljani
Luka Bertoncelj, Iskra ISD d.o.o.
Rok Kočevar, Iskra ISD d.o.o.
Gregor Čepon, Fakulteta za strojništvo, Univerza v Ljubljani

Reliable prediction of tool wear plays a crucial role in improving the efficiency of manufacturing processes. In the context of the turning process, an accurate assessment of the current wear on cutting inserts is an important aspect of ensuring the high quality of the final product and optimal tool utilization. For this purpose, in the LADISK laboratory, in collaboration with the company Iskra ISD, has developed a system for automatic detection of cutting edge wear.
The system is based on a machine learning methodology that allows for the analysis and recognition of specific vibration patterns associated with the degree of wear on the cutting inserts. With the help of developed algorithms, the system can precisely determine the current state of the tool, enabling the planning of optimal tool change intervals. It takes into account actual measurements and the dynamics of vibration patterns, which improves the reliability of predictions compared to existing methods that rely solely on time intervals for tool change.
The use of machine learning allows the system to be adaptable to different production environments, increasing its universality. This achieves several objectives at the same time: ensuring higher quality of products, reducing maintenance costs, and increasing productivity.

Danijel Kukovič, Unior d.d.
Branko Bračko, Unior d.d.

Climate change resulting from anthropogenic activities has been identified as one of the greatest challenges facing the world and will continue to affect businesses and citizens for decades to come. With the European climate rules, the European Union undertakes to become carbon neutral by 2050, with an intermediate goal of reducing emissions by 55% by 2030 compared to 1990. The demands of various customers, especially from the automotive industry, are even more ambitious than the commitments of the European of the Union. The paper presents requirements from the automotive industry. Next, a proposed list of activities to achieve the set goals is presented. Each proposed activity is also evaluated. These results can be used in sustainable communication with customers and achieving their requirements in the field of sustainable development.

Possible use cases of cobots in quality control applications and one practical example.

The article presents the use of 3D printed (SLA) inserts in a mould for injection moulding. There are presented advantages of using 3D-printed inserts and their limitations. The hybrid manufacturing process enables the rapid production of injection moulds to produce small batches of thermoplastic parts. The article presents the use of injection moulding simulations for process and product optimization, mechanical simulation to determine the limitations of 3D-printed inserts, and optical 3D-scanning for product validation and insert manufacturing optimization.

Grega BOH, BTS Company d.o.o.

Increasing competition and customer demands encourage continuous development and the search for solutions in the field of shortening product manufacturing times and sample series. With the right choice of manufacturing technology and the right choice of cutting tool, we achieve very high-quality processing and a very favorable ratio between the quality of processing and the price of the tool. This is influenced by various factors, the impact of which we must know and take into account for each individual case of processing separately. We often encounter, for example, the problem of a lack of tool storage capacity in the machine, a large number of tool changes during processing, which represent additional processing time and consequently increase the price of the product and reduce competitiveness. The solution is to use a dedicated tool with which one tool can be used to perform several operations at the same time. With this, we achieve a smaller number of tools needed to manufacture the product, a smaller number of tool changes and, as a result, a significantly lower production price and greater competitiveness. In many cases, we also need a dedicated carbide and HSS tool. The use of grinding with the MAC system in the production of samples and initial batches where a lot of quick and precise finishing of the cutting tool is required, as well as in the restoration of only this, represents an ideal solution and greatly reduces the costs of processing the cutting tool. By using high-quality dedicated tools, finishing with the help of the MAC system, we can achieve very high-quality processing, shorter processing times, which also mean less energy consumption, and as a result, we also reduce the impact of processing on the machine spindle and thus significantly extend the life of the machine spindle.

Matjaž Novina, Nopromat d.o.o.

Why milling with a robot? Because in this way you will save time because it´s easy. In any case, the quality of your products will not suffer, because milling with a robot is very reliable. Not only time, but you will also save money because the price of a cell for milling with a robot is much lower than the classic ones, plus you use less of your valuable space and are more flexible during today\'s too fast changes.

Marko Šimic, UL, Fakulteta za strojništvo
Niko Herakovič, UL, Fakulteta za strojništvo

This year\'s IRT Industrial Forum will highlight the key topic of sustainable transformation of companies. Given the growing importance of sustainable development, discussions at the forum will also cover the approach to carbon footprint reduction, the circular economy, corporate social responsibility and other key aspects of the sustainable economy.
Sustainability in the manufacturing environment refers to practices that enable the production of goods or services in a way that minimizes negative impacts on the environment, protects natural resources and supports long-term sustainability. This can include using renewable energy sources, recycling waste, reducing water consumption, optimizing processes to reduce greenhouse gas emissions and ensuring safe and healthy working conditions for employees.
In addition to environmental sustainability, it is also important that production ensures social sustainability, which means respect for workers\' rights, including fair wages, safe working conditions and equal opportunities. Sustainability in the production environment therefore encompasses both environmental and social aspects and is key to the long-term success of companies and the well-being of communities and the environment.

Boštjan Žagar , CAP d.o.o.
Silvester Bolka, Fakulteta za tehnologijo polimerov
Teja Pešl, Fakulteta za tehnologijo polimerov
Tamara Rozman, Fakulteta za tehnologijo polimerov

In this paper, we will present the use of industrial polyester felt waste in the company CAP in combination with a thermoplastic matrix. From the idea to the final solution, the company CAP and the Faculty of Polymer Technology from Slovenj Gradac worked together. We used recycled thermoplastic matrices with a lower melting point than the melting point of polyester felt. We chose this approach to obtain a thermoplastic composite, where the fibers of the polyester felt acted as a reinforcement for the thermoplastic matrix. The thermoplastic matrices were recycled polypropylene and recycled thermoplastic elastomer. In order to achieve good interphase interactions between thermoplastic matrices and polyester felt fibers, 2% compatibilizer was added. With this, we achieved a reinforcing effect of the fibers in the thermoplastic matrices and at the same time a homogeneous distribution of the fibers of the polyester felt in the thermoplastic matrices. The composites prepared in this way are environmentally friendly due to the use of recyclates, but at the same time they are also friendly to processing machines and tools due to much lower abrasion than, for example, glass or carbon fiber.

Jelena Širjan, student
Mario Brozović, student

Topology optimization (TO) is one of the most powerful tools when designing products intended for additive manufacturing (AM) because, for example, it enables weight reduction while simultaneously maintaining or even increasing the performance of additively manufactured products. This saves resources, primarily used material, and depending on the application, energy savings, which is most obvious in the field of transport, better ergonomics, customisation to users, etc. Although topology optimization has been known for a while, only with the development of additive technologies, the preconditions were created to exploit the full potential of TO, because the results of TO are very often complex geometries of products that are very difficult or even impossible to make with traditional production technologies. The TO procedure implies the implementation of a computer simulation of the behaviour of the future product under given boundary conditions and with the set optimization criteria (e.g. minimization of mass and maximization of stiffness). Today, several commercial computer programs can be used for this purpose. The paper will present the basics of topology optimization as well as application examples with the indicated advantages.

With the advent of electric vehicles, trends in the design of car body parts are changing. The tendency towards individualization brings to the market new design and functional solutions for semi-finished parts and assemblies, which also bring new opportunities to suppliers of car body parts and sub-assemblies.
The higher complexity of products also brings new opportunities to manufacturers of car body parts made of polymer materials.
The article will present an illuminated front panel for electric vehicle with two key features: the possibility of car body colour harmonization and built-in additional functions.

Petr Atanasčev, Konica Minolta Europe

Konica Minolta develops and implements its own AI platform for visual quality inspection which is combined with machine vision cameras. In the first part of our presentation, we will make a short review why the visual quality inspection is so important and how it can help to increase efficiency of your production. Then we will focus on common issues which are related to implementation of such technology inside current production lines, possibilities of current AI based solutions, its limitations and what effects the hardware scene setup in general. During the presentation, you will get the knowledge what is needed for successfull implementation. In the end, we will show you why regular CCTV camera is not suitable for such machine vision projects and we will also show special hyperspectral cameras which „make invisible visible“.