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Engineer's Toolbox: How to design the optimum hinge

Although many pin styles are available, Coiled Spring Pins are particularly well suited for use in both friction- and free-fit hinges. To achieve optimum long-term hinge performance, designers should observe these helpful design guidelines from SPIROL.
Read the full article.

Innovative new robo welding gun

Comau's newest N-WG welding gun is designed for high-speed spot welding for traditional, hybrid, and electric vehicles, in addition to general industry sectors. It features a patented, single-body architecture that enables rapid reconfiguration between welding types and forces, and it delivers consistent performance across a broad range of applications, including steel and (soon) aluminum welding. It supports both X and C standard gun configurations, has fast arm exchange, and universal mounting options. It is fully compatible with major robot brands and represents a significant advancement in spot welding performance and cost efficiency.
Learn more.

What's a SLIC Pin^®? Pin and cotter all in one!

The SLIC Pin (Self-Locking Implanted Cotter Pin) from Pivot Point is a pin and cotter all in one. This one-piece locking clevis pin is cost saving, fast, and secure. It functions as a quick locking pin wherever you need a fast-lock function. It features a spring-loaded plunger that functions as an easy insertion ramp. This revolutionary fastening pin is very popular and used successfully in a wide range of applications.
Learn more.

Engineering challenge: Which 3D-printed parts will fade?

How does prolonged exposure to intense UV light impact 3D-printed plastics? Will they fade? This is what Xometry's Director of Application Engineering, Greg Paulsen, set to find out. In this video, Paulsen performs comprehensive tests on samples manufactured using various additive processes, including FDM, SLS, SLA, PolyJet, DLS, and LSPc, to determine their UV resistance. Very informative. Some results may surprise you.
View the video.

Copper filament for 3D printing

Virtual Foundry, the company that brought us 3D-printable lunar regolith simulant, says its popular Copper Filamet™ (not a typo) is "back in stock and ready for your next project." This material is compatible with any open-architecture FDM/FFF 3D printer. After sintering, final parts are 100% pure copper. Also available as pellets. The company says this is one of the easiest materials to print and sinter. New Porcelain Filamet™ available too.
Learn more and get all the specs.

Copper foam -- so many advantages

Copper foam from Goodfellow combines the outstanding thermal conductivity of copper with the structural benefits of a metal foam. These features are of particular interest to design engineers working in the fields of medical products and devices, defense systems and manned flight, power generation, and the manufacture of semiconductor devices. This product has a true skeletal structure with no voids, inclusions, or entrapments. A perennial favorite of Designfax readers.
Learn more.

Full-color 3D-printing Design Guide from Xometry

With Xometry's PolyJet 3D-printing service, you can order full-color 3D prints easily. Their no-cost design guide will help you learn about different aspects of 3D printing colorful parts, how to create and add color to your models, and best practices to keep in mind when printing in full color. Learn how to take full advantage of the 600,000 unique colors available in this flexible additive process.
Get the Xometry guide.

Tech Tip: How to create high-quality STL files for 3D prints

Have you ever 3D printed a part that had flat spots or faceted surfaces where smooth curves were supposed to be? You are not alone, and it's not your 3D printer's fault. According to Markforged, the culprit is likely a lack of resolution in the STL file used to create the part.
Read this detailed and informative Markforged blog.

Test your knowledge: High-temp adhesives

Put your knowledge to the test by trying to answer these key questions on how to choose the right high-temperature-resistant adhesive. The technical experts from Master Bond cover critical information necessary for the selection process, including questions on glass transition temperature and service temperature range. Some of the answers may surprise even the savviest of engineers.
Take the quiz.

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.

What's new in Creo Parametric 11.0?

Creo Parametric 11.0 is packed with productivity-enhancing updates, and sometimes the smallest changes make the biggest impact in your daily workflows. Mark Potrzebowski, Technical Training Engineer, Rand 3D, runs through the newest functionality -- from improved surface modeling tools to smarter file management and model tree navigation. Videos provide extra instruction.
Read the full article.

What's so special about wave springs?

Don't settle for ordinary springs. Opt for Rotor Clip wave springs. A wave spring is a type of flat wire compression spring characterized by its unique waveform-like structure. Unlike traditional coil springs, wave springs offer an innovative solution to complex engineering challenges, producing forces from bending, not torsion. Their standout feature lies in their ability to compress and expand efficiently while occupying up to 50% less axial space than traditional compression springs. Experience the difference Rotor Clip wave springs can make in your applications today!
View the video.

New Standard Parts Handbook from JW Winco

JW Winco's printed Standard Parts Handbook is a comprehensive 2,184-page reference that supports designers and engineers with the largest selection of standard parts categorized into three main groups: operating, clamping, and machine parts. More than 75,000 standard parts can be found in this valuable resource, including toggle clamps, shaft collars, concealed multiple-joint hinges, and hygienically designed components.
Get your Standard Parts Handbook today.

Looking to save space in your designs?

Watch Smalley's quick explainer video to see how engineer Frank improved his product designs by switching from traditional coil springs to compact, efficient wave springs. Tasked with making his products smaller while keeping costs down, Frank found wave springs were the perfect solution.
View the video.

Top die casting design tips

You can improve the design and cost of your die cast parts with these top tips from Xometry's Joel Schadegg. Topics include: Fillets and Radii, Wall Thicknesses, Ribs and Metal Savers, Holes and Windows, Parting Lines, and more. Follow these recommendations so you have the highest chance of success with your project.
Read the full Xometry article.

FSU researchers develop thin heat shield for superfast aircraft

Professor Zhiyong (Richard) Liang, left, and research faculty member Ayou Hao hold pieces of carbon fiber-reinforced polymer composites with a protective heat shield made of a carbon nanotube sheet that was heated to a temperature of 1,900 C.

 

 

 

 

By Bill Wellock, Florida State University

The world of aerospace increasingly relies on carbon fiber reinforced polymer composites to build the structures of satellites, rockets, and jet aircraft.

But the life of those materials is limited by how they handle heat.

A team of FAMU-FSU College of Engineering researchers from Florida State University's High-Performance Materials Institute (HPMI) is developing a design for a heat shield that better protects those extremely fast machines. Their work was published in the November edition of the journal CARBON.

"Right now, our flight systems are becoming more and more high speed, even going into hypersonic systems, which are five times the speed of sound," said Professor Richard Liang, director of HPMI. "When you have speeds that high, there's more heat on a surface. Therefore, we need a much better thermal protection system."

The team used carbon nanotubes, which are linked hexagons of carbon atoms in the shape of a cylinder, to build the heat shields. Sheets of those nanotubes are also known as "buckypaper," a material with incredible abilities to conduct heat and electricity that has been a focus of study at HPMI. By soaking the buckypaper in a resin made of a compound called phenol, the researchers were able to create a lightweight, flexible material that is also durable enough to potentially protect the body of a rocket or jet from the intense heat it faces while flying.

Existing heat shields are often very thick compared to the base they protect, said Ayou Hao, a research faculty member at HPMI.

This design lets engineers build a very thin shield, like a sort of skin that protects the aircraft and helps support its structure.

After building heat shields of varying thicknesses, the researchers put them to the test.

One test involved applying a flame to the samples to see how they prevented heat from reaching the carbon fiber layer they were meant to protect. After that, the researchers bent the samples to see how strong they remained.

They found the samples with sheets of buckypaper were better than control samples at dispersing heat and keeping it from reaching the base layer. They also stayed strong and flexible compared to control samples made without protective layers of nanotubes.

That flexibility is a helpful quality. The nanotubes are less vulnerable to cracking at high temperatures compared to ceramics, a typical heat shield material. They're also lightweight, which is helpful for engineers who want to reduce the weight of anything on an aircraft that doesn't help the way it flies.

The project received second place among peer-reviewed posters at the 2019 National Space and Missile Materials Symposium and received third place at the Society for the Advancement of Material and Process Engineering 2019 University Research Symposium.

That recognition is helpful for showing the United States Air Force Office of Scientific Research, which partially supported the work, the promise of further research, Hao said.

Published November 2019

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