{"686876":{"#nid":"686876","#data":{"type":"news","title":"Manufacturing Consortium Helps Industry Close the Finish Gap","body":[{"value":"\u003Cdiv\u003E\u003Cp\u003EFrom fighter jets to medical devices, today\u2019s most advanced machines depend on parts as intricate as their missions. These components aren\u2019t just geometrically complex \u2014 they\u2019re made from specialized metals engineered to withstand extreme heat, friction, and wear. But that strength comes with a challenge. How do you shape metals tough enough to survive the heat of a jet engine?\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EOne solution is to start with a more moldable form of these super-metals: powder. In a specialized form of additive manufacturing (like 3D printing), manufacturers start with fine metal powders and fuse them, layer by layer, using focused energy. Known as powder bed fusion (PBF), this method enables highly complex shapes and reduces the amount of finishing work needed. Still, when a micron of extra material can make or break the final product, even near-perfect parts require precise finishing touches.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cThe introduction of new, exotic materials produced through additive manufacturing has brought unique challenges, especially for applications in space and missile systems,\u201d says David Antonuccio, business development director at \u003Ca href=\u0022https:\/\/www.halocarbon.com\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EHalocarbon\u003C\/a\u003E, a Georgia-based company producing advanced chemical solutions used in manufacturing and other fields. \u201cWhile these materials offer distinct properties, they are notoriously difficult to machine.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThat\u2019s where the \u003Ca href=\u0022https:\/\/manufacturing.gatech.edu\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EGeorgia Tech Manufacturing Institute\u003C\/a\u003E (GTMI) comes in. Through its Manufacturing 4.0 Consortium, GTMI connects industry manufacturers like Halocarbon with researchers and innovators to tackle real \u003Ca href=\u0022https:\/\/www.sciencedirect.com\/science\/article\/abs\/pii\/S0007850625000319?via%3Dihub\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003Eproduction challenges\u003C\/a\u003E like this. Membership includes access to GTMI\u2019s Advanced Manufacturing Pilot Facility (AMPF), where companies can test ideas and collaborate on new solutions.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EHalocarbon recently teamed up with \u003Ca href=\u0022https:\/\/freemelt.com\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EFreemelt\u003C\/a\u003E, a leader in producing PBF systems and a fellow consortium member, to address this bottleneck. Their goal: to determine whether Halocarbon\u2019s \u003Ca href=\u0022https:\/\/www.halocarbon.com\/machining-mission-critical-metals-the-halocarbon-advantage-in-aerospace-alloys\/\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003Especialized metalworking fluids\u003C\/a\u003E could enhance the finishing process for PBF-manufactured parts made from tungsten and molybdenum, two high-temperature, hard-to-machine metals.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cThe future of manufacturing depends on how well we integrate talent, technology, and collaboration,\u201d says \u003Ca href=\u0022https:\/\/manufacturing.gatech.edu\/people\/steven-ferguson\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003ESteven Ferguson\u003C\/a\u003E, interim director of Research Operations at GTMI and managing director of the consortium. \u201cBy bringing companies together around shared challenges, we\u2019re closing critical gaps and strengthening the nation\u2019s advanced manufacturing capability.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Ch3\u003E\u003Cstrong\u003ESolving the Post-Processing Bottleneck\u003C\/strong\u003E\u0026nbsp;\u003C\/h3\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EEven with advanced methods like electron beam powder bed fusion (E-PBF), which uses an electron beam to fuse metal powders inside a vacuum chamber, finishing remains a critical hurdle. \u201cSurface finish in powder bed fusion is fundamentally tied to the particle size of the metal powder,\u201d says Ian Crawford, a materials and application engineer at Freemelt. \u201cPost-processing will almost always be part of the equation for high-performance components.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EIn traditional machining, coolants and cutting fluids used in these finishing steps are often overlooked, and the methods haven\u2019t changed much in decades. Halocarbon\u2019s metalworking fluid aims to bring these fluids into a new era, using innovative polymer chemistry to extend tool life, improve surface quality, and boost efficiency when machining these challenging alloys.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThe two companies initiated their joint project during their free AMPF equipment use time, which comes with the full level of consortium membership. From there, GTMI designed and executed controlled studies comparing the use of Halocarbon\u2019s fluids to two standard finishing methods, dry machining and EDM-based finishing. The results showed a 6% improvement in side milling and a 26% improvement in end milling versus dry machining, with even greater gains over EDM. These improvements translate into higher-quality parts, tighter specifications, lower scrap rates, extended tool life, and reduced downstream costs \u2014 exactly what aerospace and defense suppliers need to meet stringent requirements. \u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003EThe findings were shared at the 2025 National Space \u0026amp; Missile Materials Symposium, reinforcing the value of industry-academic collaboration.\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cIndustry keeps pushing materials to handle more heat and stress, but that makes post-processing harder,\u201d says \u003Ca href=\u0022https:\/\/manufacturing.gatech.edu\/people\/matthew-carroll\u0022 rel=\u0022noreferrer noopener\u0022 target=\u0022_blank\u0022\u003EMatt Carroll\u003C\/a\u003E, one of the GTMI researchers on the project. \u201cBy bringing equipment makers and chemistry innovators into the same experiment, we were able to prove where the gains really are and give manufacturers data they can act on.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E\u003Cdiv\u003E\u003Cp\u003E\u201cNo single manufacturing method solves every challenge,\u201d says Crawford. \u201cTo achieve the performance and cost targets that aerospace and defense applications demand, we need to bring together the right combination of technologies, and collaborations like this show what\u0027s possible when we do.\u201d\u0026nbsp;\u003C\/p\u003E\u003C\/div\u003E","summary":"","format":"limited_html"}],"field_subtitle":"","field_summary":[{"value":"\u003Cp\u003ECollaborative research at GTMI is helping manufacturers overcome critical challenges in finishing advanced materials for aerospace and defense applications.\u003C\/p\u003E","format":"limited_html"}],"field_summary_sentence":[{"value":"Collaborative research at GTMI is helping manufacturers overcome critical challenges in finishing advanced materials for aerospace and defense applications."}],"uid":"35575","created_gmt":"2025-12-11 18:59:54","changed_gmt":"2025-12-15 14:39:11","author":"adavidson38","boilerplate_text":"","field_publication":"","field_article_url":"","location":"Atlanta, GA","dateline":{"date":"2025-12-15T00:00:00-05:00","iso_date":"2025-12-15T00:00:00-05:00","tz":"America\/New_York"},"extras":[],"hg_media":{"678830":{"id":"678830","type":"image","title":"52029942294_e335c3c0ec_b.jpg","body":"\u003Cp\u003EAdvanced manufacturing methods like E-BPF enable the production of parts with complex geometries that traditional machining can\u0027t achieve, like those seen here at GTMI\u0027s Advanced Manufacturing Pilot Facility. (Photo by Georgia Tech)\u003C\/p\u003E","created":"1765479873","gmt_created":"2025-12-11 19:04:33","changed":"1765479873","gmt_changed":"2025-12-11 19:04:33","alt":"Advanced manufacturing methods like E-BPF enable the production of parts with complex geometries that traditional machining can\u0027t achieve, like those seen here at GTMI\u0027s Advanced Manufacturing Pilot Facility.","file":{"fid":"262918","name":"52029942294_e335c3c0ec_b.jpg","image_path":"\/sites\/default\/files\/2025\/12\/11\/52029942294_e335c3c0ec_b.jpg","image_full_path":"http:\/\/hg.gatech.edu\/\/sites\/default\/files\/2025\/12\/11\/52029942294_e335c3c0ec_b.jpg","mime":"image\/jpeg","size":94216,"path_740":"http:\/\/hg.gatech.edu\/sites\/default\/files\/styles\/740xx_scale\/public\/2025\/12\/11\/52029942294_e335c3c0ec_b.jpg?itok=4l_JPc9m"}},"678829":{"id":"678829","type":"image","title":"finishing-machining-halocarbon.jpg","body":"\u003Cp\u003EHigh-performance parts used in aerospace and defense systems need to be precise and durable. Collaborative research at the Georgia Tech Manufacturing Institute teamed is working to improve the finishing processes for hard to machine metals like tungsten. (Photo via Halocarbon)\u003C\/p\u003E","created":"1765479614","gmt_created":"2025-12-11 19:00:14","changed":"1765479614","gmt_changed":"2025-12-11 19:00:14","alt":"High-performance parts used in aerospace and defense systems need to be precise and durable. Collaborative research at the Georgia Tech Manufacturing Institute teamed is working to improve the finishing processes for hard to machine metals like tungsten.","file":{"fid":"262917","name":"finishing-machining-halocarbon.jpg","image_path":"\/sites\/default\/files\/2025\/12\/11\/finishing-machining-halocarbon.jpg","image_full_path":"http:\/\/hg.gatech.edu\/\/sites\/default\/files\/2025\/12\/11\/finishing-machining-halocarbon.jpg","mime":"image\/jpeg","size":20940,"path_740":"http:\/\/hg.gatech.edu\/sites\/default\/files\/styles\/740xx_scale\/public\/2025\/12\/11\/finishing-machining-halocarbon.jpg?itok=41BlRrZ7"}}},"media_ids":["678830","678829"],"related_links":[{"url":"https:\/\/manufacturing.gatech.edu\/engage\/manufacturing-40-consortium","title":"More about GTMI\u0027s Manufacturing 4.0 Consortium"},{"url":"https:\/\/manufacturing.gatech.edu","title":"Georgia Tech Manufacturing Institute"}],"groups":[{"id":"155831","name":"Georgia Tech Manufacturing Institute (GTMI)"},{"id":"1188","name":"Research Horizons"}],"categories":[{"id":"194609","name":"Industry"},{"id":"194685","name":"Manufacturing"},{"id":"147","name":"Military Technology"},{"id":"135","name":"Research"},{"id":"194611","name":"State Impact"}],"keywords":[{"id":"186857","name":"go-gtmi"},{"id":"187915","name":"go-researchnews"}],"core_research_areas":[{"id":"39461","name":"Manufacturing, Trade, and Logistics"}],"news_room_topics":[],"event_categories":[],"invited_audience":[],"affiliations":[],"classification":[],"areas_of_expertise":[],"news_and_recent_appearances":[],"phone":[],"contact":[{"value":"\u003Cp\u003EWriter: Audra Davidson\u003Cbr\u003EResearch Communications Program Manager\u003Cbr\u003EGeorgia Tech Manufacturing Institute\u003C\/p\u003E\u003Cp\u003EContact: \u003Ca href=\u0022mailto:bvogel30@gatech.edu\u0022\u003EBelinda Vogel\u003C\/a\u003E\u003Cbr\u003EResearch Engagement Manager\u003Cbr\u003EGeorgia Tech Manufacturing Institute\u003C\/p\u003E","format":"limited_html"}],"email":["bvogel30@gatech.edu"],"slides":[],"orientation":[],"userdata":""}}}