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August 05, 2014Volume 10 Issue 29


Image - Electroformed Metal Housing Sharpens Focus of Camera Probes
Electroformed Metal Housing Sharpens Focus of Camera Probes
By switching from a machined camera retainer to a precision electroformed component manufactured by Servometer® that holds higher tolerances, an imaging equipment manufacturer was able to improve the accuracy and repeatability of their camera's focus. Servometer's electroform manufacturing process is an attractive alternative where shape factor limitations or excessive die charges would limit the use of stamping.

Read the whitepaper.


In this issue of Designfax

  • 3D-printed Army weapons
  • Injection molding: High-impact nylon 6 in hammers
  • Spongy material creates steam from the sun
  • Wheels: Best-ever diesel efficiency
  • Mike Likes: New Raspberry Pi module
  • Engineer's Toolbox: Wharton School negotiating techniques
  • Products: Heat pipes cool hot components
  • Products: Torque-resistant plastic hinges
  • Products: Aerospace adhesives, sealants, coatings
  • Products: Low-cost hexapod 6-axis positioner
  • Videos+: Technologies and inspiration in action
    • Universal Robots at Etalex
    • World's smallest, fastest nanomotor
  • Most Popular Last Issue
    • Wheels: Exhaust recirc and the road to 54.5 mpg
    • Engineer's Toolbox: World's smallest production V8
    • Supercapacitors may destroy lithium-ion market
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: Univ. of Wisconsin one-cylinder engine tests gas-diesel mix

News

AAA gauges fuel savings from stop-start tech to be 5 to 7 percent

British create world's darkest material

Why we love the beach: Researchers develop sand-based lithium-ion batteries that outperform standard by three times

MICROMO launches powerful new e-commerce offering: Motion System Selector™



Image - Setting New Standards for Stepper Motors: the FAULHABER FDM0620
Setting New Standards for Stepper Motors: the FAULHABER FDM0620
With the new FDM0620 series, MICROMO presents a high-performance FAULHABER stepper motor with minimal size. With a holding torque rating of 0.25 mNm and a dynamic torque of up to 0.2 mNm, these stepper motors are a great fit for applications in which high power is required in a small space.

Find out more!


Feature articles
3D-printed metals may transform Army logistics, weapons
A Soldier at a forward operating base needs a part for a weapon trigger assembly. Spare parts are not in storage. He goes online, opens the computer-aided design, or CAD, file for the trigger assembly, and hits "PRINT." Impossible?
James Zunino, a materials engineer for the U.S. Army Armament Research, Development and Engineering Center, would say that printing gun parts is no problem; it's just not possible to print qualified gun parts to military standards ... yet.
Read the full article.
Image -
Protogami shows the interaction of materials and surface finishes, and demonstrates features like clips, slots, and hinges. Get your Protogami today!


Image - Injection molding materials:<br>Switch to high-impact nylon 6 corrects fault in industrial hammers
Injection molding materials:
Switch to high-impact nylon 6 corrects fault in industrial hammers

A toughened nylon 6 compound from Teknor Apex Asia Pacific Pte Ltd. has enabled custom molder Austmould Pty Ltd. to injection mold tips for industrial deadblow hammers that withstand rigorous impact testing even in their largest sizes and without need for a lengthy post-mold conditioning in water.
Read the full article.

Image - Graphite spongy material creates steam from the sun
Graphite spongy material creates steam from the sun
A new material structure developed at MIT generates steam by soaking up the sun. When sunlight hits the porous structure's surface, it creates a hotspot, drawing water up through the material's pores, where it evaporates as steam. The brighter the light, the more steam is generated.
Read the full article.

Image - Wheels: <br>Best-ever efficiency points to clean, green gas-diesel engine
Wheels:
Best-ever efficiency points to clean, green gas-diesel engine

The one-cylinder test engine in the basement of a University of Wisconsin-Madison lab is connected to a life-support system of pipes, tubes, ducts, and cables like a patient in intensive care. The elaborate monitoring system shows that the engine can convert 59.5 percent of the chemical energy in its fuel into motion -- significantly better than the 52 percent maximum in modern diesel truck engines.
Read the full article.

Image - Mike Likes: New Raspberry Pi module
Mike Likes: New Raspberry Pi module
Whether you're a hardcore Raspberry Pi fan or have been hesitant to take the plunge into the world of inexpensive playing-card-size computer development, it's a great time to consider the latest board available. The Raspberry Pi B+ board marks the first significant change to the multi-million selling development platform. Priced at $35 and available through element14, the new board offers more sensors and accessories than ever before, enabling users to build bigger and better projects. Advanced power management and enhanced connectivity make it possible to power four USB accessories, such as a 2.5-in. hard drive, through the device. Up to 1.2A can be delivered to the USB ports to connect power-hungry devices and accessories without needing mains power or an external USB hub. Featuring a 40-pin extended GPIO, even more sensors, connectors, and expansion boards can be added, allowing users to increase the complexity of their Raspberry Pi projects -- many of which are featured on the element14 site.
Click here to learn more.

Image - Engineer's Toolbox: <br>13 negotiating techniques taught at the Wharton School of business
Engineer's Toolbox:
13 negotiating techniques taught at the Wharton School of business

Life is a series of negotiations. While we may realize this in theory, we probably don't realize how often it applies in practice. Sharpen your negotiating skills, and you'll unlock options and opportunities that you may have assumed were closed to you.
Read the full article.

Image - Products: <br>Heat pipes cool hot components
Products:
Heat pipes cool hot components

Advanced Thermal Solutions (ATS) has introduced a series of copper heat pipes for transporting power dissipation away from hot electronic components. Thirty-three round and flat profile heat pipes are available to meet application needs. The new ATS heat pipes transfer component heat to heat sinks with minimal temperature difference. They also distribute heat efficiently across the length of heat spreaders. They are effective in temperatures ranging from 30 C to 120 C. Applications include: military electronics, 4G telecommunications electronics, broadband network equipment, high-performance computer processors, Insulated Gate Bipolar Transistor (IGBT) cooling, and aerospace.
Click here to learn more.

Image - Products: <br>Torque-resistant plastic hinges
Products:
Torque-resistant plastic hinges

J.W. Winco now offers EN 222 Technopolymer Plastic Hinges in metric sizes. These RoHS-compliant hinges are very stable and are notable for a high resistant torque of 3 Nm in four indexing positions. This hinge has been tested with more than 20,000 opening and closing cycles, and the value of the resistant torque was unchanged. Hinges are made of matte black glass-fiber-reinforced plastic (Polyamide PA), with a hinge pin of stainless steel.
Click here to learn more.

Image - Products: <br>Aerospace adhesives, sealants, coatings
Products:
Aerospace adhesives, sealants, coatings

Master Bond is offering a new, easy-to-read, 28-page catalog with performance and processing data on its extensive line of epoxies, silicones, UV curing compounds, and specialty systems for the aerospace industry. These products ensure reliability in the assembly of aircraft structures, components, interiors, and MRO applications. They are widely used for structural bonding, sealing, and gap filling.
Click here to learn more.

Image - Products: <br>Low-cost hexapod 6-axis positioner
Products:
Low-cost hexapod 6-axis positioner

The PI H-820 hexapod from Physik Instrumente (PI) was developed for applications that require multi-axis motion and high flexibility but do not need sub-micron precision. This new model caters to these needs with linear travel to 100 mm, rotary travel to 60 deg, and a load capacity of 20 kg. High velocity and long service life are guaranteed by direct-drive brushless servo motors. Position repeatability is in the low micron range. A controller and software are included with all PI hexapods.
Click here to learn more.

Most popular last issue

Image - Wheels: <br>Exhaust recirculation tech and the road to 54.5 mpg
Wheels:
Exhaust recirculation tech and the road to 54.5 mpg

A new engine design that improves fuel economy and lowers exhaust emissions has received a prestigious 2014 R&D 100 Award. R&D Magazine selected Southwest Research Institute's Dedicated Exhaust Gas Recirculation (D-EGR) engine technology as one of the 100 most significant technological achievements introduced in the past year.
Read the full article.

Image - Engineer's Toolbox: <br>World's smallest production V8 optimized with precision honing
Engineer's Toolbox:
World's smallest production V8 optimized with precision honing

Gary Conley's 30-year quest to manufacture a true production V8 engine in quarter-scale almost went up in smoke twice: once in 2001 when a foundry fire claimed all his critical molds, and later when oil smoke proved a stubborn problem during run-offs of the engine. Conley overcame the first setback with years of sheer determination. The second issue required a Sunnen MB 1660 honing machine, abrasives, and some Sunnen know-how.
Read the full article.
Batteries expert: Supercapacitors have potential to destroy lithium-ion battery market
Elon Musk of Tesla once said that he thought supercapacitors are the future. Now he is planning the mother of all lithium-ion battery factories. Nevertheless, it is still probable that supercapacitors will hammer lithium-ion battery sales.
Read the full article.

Videos+: Technologies and inspiration in action
The Safe Choice: Universal Robots at Etalex
Watch how the lightweight, flexible Universal Robots free up seven man-hours per day and cut the price of production at Canadian shelving manufacturer Etalex, where employees no longer have to perform the potentially dangerous task of unloading the brake press. Automating has resulted in a 40% increase in sales with no staff layoffs as a result.
View the video.

Video Image
Engineers build world's smallest, fastest nanomotor
Researchers at the Cockrell School of Engineering at the University of Texas at Austin have built the smallest, fastest, and longest-running tiny synthetic motor to date -- 500 times smaller than a grain of salt. The team's nanomotor is an important step toward developing miniature machines that could one day move through the body to administer insulin for diabetics when needed, or target and treat cancer cells without harming good cells. The nanomotor could fit inside a human cell and is capable of rotating for 15 continuous hours at a speed of 18,000 RPMs, the speed of a motor in a jet airplane engine.
View the video.

Video Image

New products

Electrical/Electronics
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Mechanical
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Motion
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