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February 12, 2019Volume 15 Issue 06


Image - THK World-Class KR Actuators -- Rigid, Accurate and Compact
THK World-Class KR Actuators -- Rigid, Accurate and Compact
The LM guide actuator model KR from THK provides high-rigidity, high-precision functionality and space saving. It is achieved by a nut block designed in a structure that integrates an LM rail having a highly rigid U-shaped cross-sectional form with the LM guide section.

The KR features a four-way equal load rating. The LM guide actuator can be operated in any position, which makes it ideal for loading in directions that are not fixed.
Click here to learn more.


In this issue of Designfax

  • World's largest 3D-printed one-piece rocket engine
  • 50 Years Ago: Apollo Lunar Module is tech leap to Moon
  • Experimental metal coating self-heals over scratches
  • Fastest Camaro is made for the track
  • Top Product: Alternative to traditional drive systems
  • Engineer's Toolbox: Self-clinching fasteners tips
  • Top Tech Tip: Choosing brush or brushless DC motors
  • Guide to overmolding best practices
  • How to convert from hydraulic to electric linear actuators
  • Stepper or servo motor -- Which should it be?
  • SOLIDWORKS add-in for Xometry turbocharges part outsourcing
  • Slip rings improve Ethernet transmission
  • Caterpillar-branded Cat S48c rugged smartphone
  • Videos+: Technologies and inspiration in action
    • Extension springs -- What are they?
    • How a Tesla Model 3 gets made -- in 49 sec
  • Most Popular Last Issue
    • Harley goes electric with LiveWire motorcycle
    • Wards 10 Best Engines 2019
    • Nickel 'metallic wood' has strength of titanium
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: 2019 Camaro ZL1 1LE -- fastest Camaro ever

News

Pacemakers that never miss a beat: Engineers harvest heart's energy to power life-saving devices

Lightweight, long, and lean: Boeing unveils new Transonic Truss-Braced Wing

Airbus creates the first electric airplane race series: Air Race E

Seeing old battlefields through new lenses: Army Soldiers learn warfare lessons using virtual tech



Image - Win Projects with High Fidelity Appearance Models
Win Projects with High Fidelity Appearance Models
3D Systems On Demand creates highly realistic appearance models that perfectly mimic the quality and aesthetics of the real product. Whether you need a physical part for aesthetic review, internal evaluation, trade shows or sales presentations, 3D Systems On Demand can turn your CAD file into a reality. Click here to find out more or get a free quote online now!
Get a Quote.

Feature articles

Image - World's largest 3D-printed rocket engine was made in one piece
World's largest 3D-printed rocket engine was made in one piece
Big things are happening in the small town of Forres in the Scottish Highlands. That is where Orbex, a UK-based spaceflight company, recently opened its new headquarters and design facility -- and took that opportunity to unveil the world's largest 3D-printed Rocket Engine, which was made in a single piece.
Read the full article.

Image - 50 Years Ago: Apollo's Lunar Module bridged the technological leap to the Moon
50 Years Ago: Apollo's Lunar Module bridged the technological leap to the Moon
The lunar module (LM) is mostly remembered for its role between July 1969 and December 1972, when six of the spacecraft successfully landed 12 American astronauts on the Moon. It also served as a "lifeboat" when the Apollo 13 command/service module was disabled en route to the Moon in April 1970. But why did engineers choose a "Lunar Orbit Rendezvous" plan that included linking up with a "mother ship" in orbit rather than a single spacecraft? [Countdown Series: 50th anniversary of Apollo 11]
Read the full article.

Image - Experimental metal coating self-heals over scratches and scrapes to prevent corrosion
Experimental metal coating self-heals over scratches and scrapes to prevent corrosion
A Northwestern University team has developed a new coating strategy for metal that self-heals within seconds when scratched, scraped, or cracked. The novel material could prevent these tiny defects from turning into localized corrosion, which can cause major structures to fail. Remarkably, the coating can even be applied under water.
Read the full article.

Image - Download Photo Etching Precision Parts Guide
Download Photo Etching Precision Parts Guide
This Tech-Etch guide describes how photo etching produces prototype quantities and large production runs of precision parts for many mechanical and electrical applications, without the high cost and long lead times of hard tooling. Custom metal parts from .0005" thick and up are produced with intricate patterns, precise tolerances and burr-free edges, in addition to exact repeatability. By combining photo etching for blanking with inexpensive or universal tooling for forming, Tech-Etch produces complex designs and shapes with complete in-house finishing.
Download the Parts Guide (no registration required).

Image - Fastest Camaro is made for the track
Fastest Camaro is made for the track
The fastest, most track-capable Camaro ever -- the 2019 Camaro ZL1 1LE -- will offer a 10-speed automatic transmission beginning late February. During development, Chevy engineers pushed the limits of the automatic transmission to be more than one-half second faster than the standard manual on General Motors' 2.9-mile Milford Road Course.
Read the full article.

Image - Top Product: Alternative to traditional drive systems
Top Product: Alternative to traditional drive systems
Nexen Group has introduced a stainless steel version of its patented precision roller pinion system (RPS). The Nexen RPS engages two teeth simultaneously to achieve superior accuracy with zero backlash at any length. The system is also extremely quiet and 99 percent efficient. Stainless steel makes the system corrosion resistant, with a long life of up to 36 million meters. Nexen's RPS provides a low-maintenance, durable alternative to rack and pinion, ball screw, and belt drive technology. The RPS is used for a wide range of applications including laser cutting, plasma cutting, and gantry applications.
Learn more.

Image - Engineer's Toolbox: <br>Self-clinching fasteners design tips
Engineer's Toolbox:
Self-clinching fasteners design tips

Dozens of types and thousands of variations of self-clinching fasteners (steel, stainless steel, or aluminum) have been engineered over the years. Leon M. Attarian of PennEngineering provides three mini case studies where manufacturers benefited greatly by switching to self-clinching fasteners in their assemblies. This article is filled with insightful tips and suggestions.
Read the full article.

Image - Top Tech Tip: Choosing between brush and brushless DC motors -- What are the tradeoffs?
Top Tech Tip: Choosing between brush and brushless DC motors -- What are the tradeoffs?
Designing a system that involves motion and performs as intended requires choosing the right motor. The most fundamental decision involves commutation type. In some cases, mechanically commutated brush motors provide the best solution for the budget. In other cases, only brushless DC (BLDC) motors will do. Allied Motion provides a comprehensive review of the technology, along with tips and tricks for choosing the right solution for a given application.
Learn how to make the best motor choice (no registration required).

Image - Guide to overmolding best practices
Guide to overmolding best practices
Overmolding is a great injection molded feature you can utilize in your design to capture color contrasts, add flexibility or eliminate assembly. Take advantage of this feature by learning how to design your part for overmolding.
You'll learn:
  • How to set up your design for complex overmolding
  • Material evaluation and best practices for proper adhesion
  • Feature specifications to consider for good overmolds
Get the Xcentric overmolding guide (no registration required).

Image - How to convert from hydraulic to electric high-force linear actuators
How to convert from hydraulic to electric high-force linear actuators
Machine designers are converting existing linear motion systems from hydraulic to electric due to the technology's many benefits, but the process involves considering the actual force output of the cylinder, the duty cycle, and the motion profile. Specialists at Tolomatic tackle these points. Includes a very informative video.
Read the Tolomatic blog.

Image - Stepper or servo motor -- Which should it be?
Stepper or servo motor -- Which should it be?
Bring out the full capacity of your machines through the most efficient mechatronic design. Hurley Gill, Senior Applications/Systems at Kollmorgen, outlines servo and stepper motor baseline capabilities for selection criteria like torque, speed, accuracy, and repeatability. Technical advantages and disadvantages are discussed, helping machine designers select the best motor-drive system for their application.
Click here to read: Servo or Stepper: Which Should It Be?
Kollmorgen designs and manufactures innovative motion control systems, including servo and stepper motors, drives, amplifiers, gearheads, and actuators.

Image - SOLIDWORKS add-in for Xometry turbocharges part outsourcing
SOLIDWORKS add-in for Xometry turbocharges part outsourcing
The Xometry Add-In for SOLIDWORKS v4.0 is a powerful tool that integrates directly with Xometry's Instant Quoting Engine, allowing engineers to simultaneously design parts and weigh considerations of cost and lead time in a single CAD environment. Machine learning algorithms give you an instant price by analyzing the part's geometry and factor in manufacturing requirements such as the process, material, features, finish, and inspection type. Then, the add-in provides lead time, cost, and manufacturability (DFM) feedback in seconds. Includes CNC machining, 3D printing, sheet metal, urethane castings, and other manufacturing methods.
Learn more.

Image - Slip rings improve Ethernet transmission
Slip rings improve Ethernet transmission
The Kuebler Group offers contact and contactless slip rings for reliable Ethernet transmission, achieving higher data rates and greater cycle synchronicity in demanding industrial environments. Application examples include industrial automation, bottling plants, labeling machines, rotary tables, and other processes requiring high transmission rates. The standard Slip Ring SR120 features an innovative three-chamber system and shield to enable parallel, interference-free Ethernet transmission up to 100 Mbps. It boasts a long service life up to 500 million revolutions and a rugged, modular structure that can be expanded up to 20 channels. Another model, the Slip Ring SR160 with integrated Sendix Encoder, provides position information in addition to contactless Ethernet transmission -- either two channels at 100 Mbps multiplexed or one channel at 1 Gbps.
Learn more.

Image - Caterpillar-branded Cat S48c rugged smartphone
Caterpillar-branded Cat S48c rugged smartphone
The Cat S48c ruggedized phone from the Caterpillar brand is designed with durability at its core. Its heavy-duty rugged credentials (IP68 water and dust proof, MIL SPEC 810G and Non-incendive Class I, Division 2) ensure it can withstand drops, dust, vibration, extreme temperatures, and some hazardous work environments. It can be submerged in up to 4 ft of water for 35 minutes, and its 13 MP camera can take underwater pictures whether on site, in the great outdoors, or on vacation. Its powerful 4,000-mAh battery provides up to 30 hours of talk time. Now available from Sprint and Verizon. Cat offers other phones with integrated thermal imaging and laser distance measuring built in.
Learn more.

Most popular last issue

Image - Harley goes electric with LiveWire motorcycle
Harley goes electric with LiveWire motorcycle
There's a new sound at Harley-Davidson, and it's not that deep rumbling roar you hear from their traditional two-wheelers. It's more of a high-pitched zip, and it comes from LiveWire, the company's first electric production motorcycle, which is now available for pre-order. LiveWire's instant torque rockets riders from 0 to 60 mph in under 3.5 sec, so that mosquito-on-steroids buzz sound is no indicator of the bike's real power.
Read the full article.

Image - Wards 10 Best Engines 2019: Gasoline, electrified, and even hydrogen powertrains
Wards 10 Best Engines 2019: Gasoline, electrified, and even hydrogen powertrains
WardsAuto has announced the winners of its annual Wards 10 Best Engines award program, and for the first time ever three pickup truck engines are honored, while four electrified powertrains make the cut for the second year in a row.
Read the full article.

Image - Nickel 'metallic wood' has the strength of titanium and the density of water
Nickel 'metallic wood' has the strength of titanium and the density of water
University researchers have built a sheet of nickel with nanoscale pores that make it as strong as titanium but four to five times lighter. The empty space of the pores, and the self-assembly process in which they're made, make the porous metal akin to a natural material, such as wood.
Read the full article.

Videos+: Technologies and inspiration in action
Extension springs -- What are they?
Extension springs are used for applications where a very precise amount of force at a certain deflection is needed. They can be pulled from an inch to 100 inches. See the manufacturing process.
View the video.

Video Image
How a Tesla Model 3 gets made -- in 49 sec
Watch this time-lapse video to see Tesla's Model 3, which the company calls "the world's first mass-market electric vehicle," as it whizzes through the assembly line at the Tesla Factory in Fremont, CA. The Model 3 fits five adults. The high-efficiency powertrain provides 0 to 60 mph acceleration in as little as 3.5 sec, and the all-wheel drive has two independent motors that digitally control torque to the front and rear wheels for better handling and traction control. Range is 220 miles.
View the video.

Video Image

New products

Electrical/Electronics
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Mechanical
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