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Renishaw unveils revolutionary LIBERTAS™ 3DP tech

Renishaw's new LIBERTAS software technology addresses two of the most persistent challenges in metal AM: poor downskin surface finish and the need for support structures. Users have greater freedom to manufacture complex geometries.
Read the full article.

Innovate like a PRO: Protolabs' new AI-enabled manufacturing platform

ProDesk by Protolabs accelerates innovation for product development and procurement teams. It features real-time, AI-powered quoting with design for manufacturability (DFM) analysis across injection molding, CNC machining, and 3D printing. The platform enables seamless team collaboration and customizes quotes with instant feedback on materials, lead times, secondary operations, and finishes prior to production.
Learn more.

SDP/SI Shaftloc Fastening System

Shaftloc is a unique, reusable locking device for securely mounting mechanical components like gears and sprockets onto shafts without the need for keyways, set screws, or adhesives. Its simple, two-piece design offers a cost-effective alternative to traditional fasteners, providing high clamping force and vibration resistance. Installed with standard tools, Shaftloc is perfect for designers seeking flexible, hubless mounting solutions. Available in four styles.
Learn more from SDP/SI.

How Autodesk Research uses Markforged 3D printing

In advanced R&D, "good enough" doesn't cut it. To pioneer its Performance-Aided Design (PAD) workflow, Autodesk Research partnered with Markforged to close the gap between digital simulation and reality. Using sensors and digital twins, PAD replaces delayed field reports with real-time feedback. To test this high-stakes system, Autodesk built massive UAV platforms -- including a 300-lb aircraft. Facing extreme dynamic loads and weather, these drones provide the ultimate torture test for rapid design iteration.
View the video.

Top Tech Tip: How do you 3D print STL files?

Learn the basics of 3D printing STL files -- the files that serve as the digital foundation for 3D printing -- and a whole lot more from the experts at Xometry. These files have advantages, of course, but did you know they have disadvantages too? Also learn about STL tools and programs, and how to reduce file size or even repair a file you are having trouble with.
Read the Xometry article.

When metals can't survive: Machined ceramics as an alternative

Technical Ceramics are so hard and wear resistant that they cannot be machined with conventional tools -- but they can outlast and outperform other materials in demanding or harsh applications. INSACO's proprietary diamond grinding process and specialized techniques developed over many decades allow the company to produce and document parts to exacting specifications consistently. Learn all about the alternatives you have when metals just can't take it.
Read the INSACO article.

Radio Flyer cuts ebike prototype time radically with Fuse X1 large-format SLS 3D printer

Radio Flyer cut prototype lead times for its Flyer Loop cargo ebike frame from two months to two days using Formlabs' new Fuse X1 SLS large-format 3D printer. "We can now print an entire Flyer Loop cargo ebike overnight and be gluing it together the next day," said Agostino LoBello, product development engineer at Radio Flyer. "I can iterate three times as often with nine times less labor." The Fuse X1 delivers production-quality parts with 50% lower costs and triple the throughput of comparable industrial systems, featuring automated powder handling and a compact, easy-to-install design. [Credit: Image courtesy of Formlabs]
View the video.

Compact industrial sand 3D printer

ExOne has launched the S-Print Pro, a compact industrial sand 3D printer that brings production-grade binder jetting to smaller foundries, pattern shops, and print service providers. Aimed at businesses competing on cost and flexibility, it handles low-volume casting, spare parts, and custom components. The system processes furan binder with silica sand, CeraBeads, or silicon carbide.
Learn more about this capable machine.

Engineer's Toolbox: How to pin a shaft and hub assembly properly

One of the primary benefits of using a coiled spring pin to affix a hub or gear to a shaft is the coiled pin's ability to prevent hole damage. Another is the coiled pin absorbs wider hole tolerances than any other press-fit pin. This translates to lower total manufacturing costs of the assembly. However, there are a few design guidelines that must be adhered to in order to achieve the maximum strength of the pinned system and prevent damage to the assembly.
Read this very informative SPIROL article.

Get reliable labeling done right

Videojet Technologies has released the Videojet 9310 label applicator, designed to simplify everyday labeling on rigid and flexible packaging. Using Intelligent Motion technology, it digitally controls label tension and alignment to ensure consistent placement with minimal manual adjustments. The system features a simple label path, an intuitive touchscreen, and flexible mounting options to reduce downtime and keep production moving.
Learn more.

Your phone is now your smartest hydraulic tool

Commissioning a proportional valve traditionally requires cables, laptops, and complex software. The new Bosch Rexroth 4WRAE valve changes that. Featuring integrated digital electronics and Bluetooth connectivity, it pairs with the "easy2connect" app. Technicians can now visualize performance, adjust settings, diagnose errors, and force solenoids directly from their phones, simplifying setup for IO-Link or analog systems.
Learn more.

A new take on indexing plungers

JW Winco has expanded its extensive standard parts range with the GN 823 indexing plunger. Featuring an intuitive operating lever, it allows easy activation with a single finger, even when wearing gloves or out of sight. Available in screw-on or weldable stainless steel variants, this robust component suits both delicate installations and heavy-duty industrial applications. Available in two installation options: screw fastening or welding.
Learn more.

Fast-cure composite for aero and defense manufacturing

Toray Composite Materials America has launched 3960-FC, a fast-cure variant of its high-performance 3960 prepreg system for mission-critical aerospace and defense applications. This material reduces cure time by up to 45% while maintaining proven mechanical performance, stiffness, and exceptional toughness. It is highly compatible with automated manufacturing technologies like AFP and ATL, as well as traditional processing methods.
Learn more.

Best high-speed rotary bearing in THK history

THK's High-Speed, Double-Row Angular Contact Ring BWH is the fastest rotary bearing in company history. By utilizing balls inside a cage instead of rollers, this new structure achieves unprecedented speeds. It supports loads from all directions while matching the high rigidity and rotational accuracy of standard cross-roller ring design options.
Learn more.

100,000 hours: KNF diaphragm pump achieves exceptional lifetime

Reaching 100,000 hours of uninterrupted performance is a remarkable achievement for micro diaphragm gas pumps. It represents more than 11 years of continuous operation in a controlled environment, exceeding the demands of most real-world applications. This milestone highlights KNF's engineering expertise and the reliability built into every pump.
Get a closer look at the 100,000-hour lifetime test.

'Off-the-shelf' semitrailer becomes Army missile launcher

By Jason B. Cutshaw, USASMDC/ARSTRAT

A tactical ballistic missile being launched off a 25,000-lb-capacity Transportable Target Launcher, or 25K TTL, designed by the U.S. Army Space and Missile Defense Command/Army Forces Strategic Command. [Photo Credit: U.S. Army photo]

 

 

 

 

In times of continuing budgetary constraints, the U.S. Army Space and Missile Defense Command/Army Forces Strategic Command, or USASMDC/ARSTRAT, is making an extended effort to save taxpayers by not only designing low-cost targets, but also by designing low-cost launch vehicles.

Members of the USASMDC/ARSTRAT Test Execution Support Division developed a transportable, mission-configurable, 25,000-lb-capacity Transportable Target Launcher, or 25K TTL, to support Department of Defense operational testing of theater-class tactical ballistic missile targets.

The Transportable Target Launcher (25K TTL) undergoes inspections before returning to the Naval Surface Warfare Center Crane in Indiana for maintenance prior to future test missions. The 25K TTL is designed to support Department of Defense operational testing of theater-class tactical ballistic missile targets. [Photo Credit: Jason B. Cutshaw.]

 

 

 

 

"The 25K TTL is a rapidly deployable (C-17 and C-5 transportable), treaty-compliant rail launch platform for theater-class tactical ballistic missile targets," says Bryon Manley, SMDC Technical Center Test Execution Support Division chief. "The 25K TTL is a cost-effective, transportable launcher that can expand the number of available launch sites, adding a more comprehensive selection of threat scenario geometries for tactical ballistic missile target testing on national ranges."

SMDC developed two 25K TTLs, at a cost of approximately $3 million, that are rapidly deployable. They were designed, analyzed, built, and tested using a modified commercial off-the-shelf semitrailer and hydraulic crane as a portable launch platform.

"Our division is about low cost, so we design things based on commercially off-the-shelf available items so that they are cost effective," says Stephanie Chrisley, SMDC general engineer.

Utilization of the TTL is a cost-effective means of presenting test scenarios in a threat-representative construct due to its ability to operate at both unimproved and improved range sites. Additionally, the launcher is transportable by air or land, permitting use at all ranges. The missile launcher can begin operating within 15 minutes of setting up.

"We can take it onto an unimproved launch site with one generator and a small crew and we launch ballistic missile targets with no problem," Chrisley says.

The TTL, which can hold a missile up to 48 ft long and handle up to 73,000 lb of rocket thrust, is undergoing inspections before returning to the Naval Surface Warfare Center Crane in Indiana for maintenance prior to future test missions.

"We brought it out of storage to have it inspected because we will be using it for a flight test in the spring of 2016," Chrisley says.

The 25K TTL is capable of being transported to a launch site, converted to a fixed installation before target loading and launch, reconfigured for transport after launch, and returned to storage or emplaced for a follow-on mission.

"This gives us the flexibility to launch in any area we want that does not necessarily have to be an improved area; it can be any open area where we can set it up with a small crew," says Kevin Creekmore, Test Execution Support Division acting director. "It does not need existing power, it does not need existing communication lines, and it does not need existing infrastructure. It gives us the flexibility to launch at just about any angle that we want using the adjustable boom.

"We use it to support many different tests for many different customers," he adds. "We have several tests upcoming in the next few years."

SMDC has also developed targets to be launched by the TTLs. Made from existing materials, the program was named Zombie. Zombie uses government-owned material components that have reached the end of their useful lives and are subject to consideration for demilitarization. Using this government hardware instead of demilitarizing it ultimately saves taxpayer dollars.

The command developed the Zombie targets that cut expenses from the around $30 million each for high-end targets to approximately $4 million for SMDC's low-cost Zombie.

"We look for unused rocket motors or some that are going to be demilitarized and just thrown away. The motors are generally still good, so we try to repurpose those with new avionics and new front-end sections and launch them as low-cost targets," Chrisley says.

Published October 2015

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