A Revolution in Mass Customisation

In 1760, machine and power tools, as well as large-scale industrial manufacturing, began, ushering in enormous social and economic upheavals. For the first seventy years of our century, the United States dominated global industry. The phrase "Made in Japan" was considered a punchline in 1960. Those exact words had established manufacturing parlance by 1980. The industrial sector in the United States was in a severe slump in 1985. Items were overpriced, of low quality, and lacked sufficient innovation.
When it comes to manufacturing, the United States is once again at the top of the list (World Competitiveness Report, 1996).
Personalisation on a massive scale
The manufacturing revolution that began in the United States in 1985 is largely responsible for its current position as the top economy. The unparalleled inventiveness of the American people is the bedrock upon which this subtle revolution rests. The United States of America is based, in part, on its innovative spirit. When it comes to innovation, American manufacturers are unrivalled. An organisation may build a solid foundation with the correct mix of people and technology. Thanks to these technological advancements, a brand new phenomena is emerging: mass customisation. This allows for the personalisation of products down to the individual level, with production speeds comparable to those of mass-produced goods. The Industrial Age's mass-production approach is giving way to the Information Age's mass customisation.
Simultaneous manufacturing is the end result. What this means is that production can begin here simultaneously with the consumer placing the order. It may sound like something out of a fairy tale, but soon enough, shoppers will be able to take their measurements in the fitting room, select the fabric and pattern they desire, and have their order made before they even leave the store. That customer is absolutely empowering!
Lasers have been the subject of several articles in recent years. Each contributor focusses on their own area of expertise while listing applications. On the other hand, EdgeWISE Tools hopes that this article will inspire you to think about the many things that can be made with a laser. Unleash your creativity. The unknown isn't scary. Those with a sixth sense are most likely to achieve phenomenal success. Live each day to the fullest—"Carpe Diem"!
What are the benefits of using a laser?
The first thermal contact cutting tools for roll feed plotters were created in 1985. In the sign industry, the "Hot Tip" was the initial large format cutting system. It was on this method that the majority of plotter manufacturers based their products. The cutting hardware has evolved, and a lot of progress has been made. We have witnessed the advancement of technology to its current state.
The majority of the older production methods relied on contact cutting instruments, which cut by making physical contact with the material. Regular sharpening or replacement of the cutting tools is required, and quality declines with wear and tear. Because manufacturers can now sell one or more consumable tools using this outdated manner, it has become an additional source of cash for them. A more cost-effective alternative to contact manufacturing has recently been developed.
Switching from contact to non-contact cutting tools will be the next big step in production cutting technology. Using laser technology for mass customisation is the next obvious step. One factor that has slowed the advancement of the Roll Feed Laser (RFL) is the hefty price tag. Technology advances at a rate equal to one day every year. But now that laser technology has grown more inexpensive, it may be used for production at a lower cost than before.
Roll-Feedable Laser
Initial preparations for the Roll Feed Laser system (RFL) started in 1988. A new product was not the only outcome of this research. It gave rise to novel industrial ideas and processes. Lasers are making mass customisation a reality. According to EdgeWISE Tools, this is all part of the laser manufacturing revolution. The scale of the laser manufacturing revolution is growing faster than anybody could have predicted. The number of untapped markets and sectors is in the hundreds, if not thousands.
So, are you able to make a change?
Some people just don't have the insight or vision to adapt to the times, as we can see from past events. A big format computerised cutting system was ridiculed by industry in 1986, ten years ago, when it was proposed as the primary instrument for the trade. Back then, people were very resistant to change. A low-wattage Roll Feed Laser system would have been laughed at and not made by most plotter manufacturers seven years ago. Observe the current situation, Application diversity and the number of low wattage CO2, Nd:YAG, and Diode laser systems have skyrocketed since 1990. Annual growth in the CO2 laser industry has averaged 60%. The advantages of a CO2 laser in comparison to more conventional manufacturing equipment are becoming more apparent. Affordably powered RFL devices are gradually supplanting expensive machinery such as routers, hot knives, mechanical engravers, and dies. There are various uses where low wattage lasers used for marking are making ink jet printers obsolete.
I don't understand.
I can't think of any other industry where one investment in machinery could provide such a diverse array of goods. Materials such as metals, wood, textiles, rubber, and plastic can all be used in product manufacturing. You can cut almost any design with this laser because the kerf is so thin and the computer controls it. Making a single cut is as simple as making a million cuts. You could spend $50,000 to $500,000 for an offset printing press, which is comparable to typical manufacturing equipment. There is a material restriction on the use of this printer. Almost everyone working in manufacturing—silkscreeners, sign makers, engravers, etc.—will invest in specialised machinery to carry out their work. A machinist could be the sole one who buys a piece of machinery that can handle a limited range of materials. The limited types of shapes that the machinist can mould are a clear indication of his limitations. Roll Feed Lasers allow for a variety of materials and designs that even machining tools can't handle.
New or expanding businesses often find it challenging to acquire necessary capital equipment. One of the biggest challenges for a startup or expanding company is raising capital. Capital investment is the one major issue that is getting difficult to justify to start-ups or companies looking to reinvest. When there is a multipurpose alternative, it is more cost effective to use a piece of capital equipment that can do more than one thing. The money needed to make a unique product is quickly dwindling due to the enormous cost of doing so. The use of lasers in production is a relatively recent innovation. A procedure that, if broken, can cause the business owner to lose customers and revenue. The vast majority of us have personal knowledge of someone who has been affected by this. Even a great company can fail due to a lack of willingness to change. When it comes to product variety and design freedom, EdgeWISE Tools has not found a procedure that compares to the RFL. Nowhere else can you use the same tool to manipulate paper, plastic, wood, and anything in between. Now the only thing standing between the product and its production is the owner's or operator's inventiveness.
Reduced spoiling is possible since the material being created does not come into touch with or undergo any force when using a laser. Companies can boost their yield by using lasers. Rates of 95% to 99% yield have been found in several surveys. Having run a graphic arts factory in the '80s, I can say with confidence that the yield rate ranged from 75% to 80%, with the best days seeing 80% to 85%. One reason for the greater yield rates is the absence of material interaction. The use of a laser makes the process far more repeatable than other approaches because it is automated. Every step of the process is repeatable and unchangeable once it has begun.
Get ready for what's to come!
Just picture the industrial revolution without mass customisation, and then picture it with it. The jeans business is a good illustration of mass customisation. Getting a pair of tailor-made pants was something only the well-off could manage. The majority of shoppers are limited to purchasing pants in sizes determined by production costs rather than their actual body types. The American people deserve a high-quality product from manufacturers once again, especially now that mass-customization technology is accessible. Industries like denim and roll feed laser are at the forefront of the movement to bring mass-customized products to the masses.
Thanks to mass production, the industrial revolution lowered product prices. With this method of mass production, thousands of pieces may be made using just one setup. The break-even threshold is controlled by the cost of tooling, which is one of the biggest expenses. Customisation was sacrificed throughout the industrial revolution in order to keep manufacturing costs low. But now you can opt to upgrade to something with more processing power, easier software, low wattage laser technology, and little to no setup time required. Think about the efficiency, cost-effectiveness, and quality of the final product when you think about investing in roll feed laser technology.
Originally published in 1996 by Patrick J. Momany, founder of EdgeWISE Tools, Inc. (www.ewt-inc.com).
Laser systems engineer Marty Kalberer edited the document.
Oh my goodness!

Location:

Share :