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Primary content focuses on the latest exciting applications and products for Electrical/Electronic, Mechanical, Motion Control, Fluid Power, and Materials engineering, including articles on powerful software programs that serve as a primary engineering tool. Take a look at what Designfax offers and then subscribe.

November 25, 2025Volume 21 Issue 44


Image - Compact Meets Powerful: Discover Smalley's New Nestawave™ Spring
Compact Meets Powerful: Discover Smalley's New Nestawave™ Spring
Introducing Nestawave™ -- the spring that redefines compact power. As the latest innovation in Smalley's wave spring technology, Nestawave combines the deflection of a Crest-to-Crest® wave spring with the force of a nested spring. It delivers high load capacity and significant travel in tight spaces. Ideal for replacing stacks of Belleville washers, it performs in valves, bearing preloads, compressors, and more.
Try the Smalley advantage and request free product samples today.

In this issue of Designfax

  • Turbo hydrogen engine nears power, efficiency of diesel
  • Worldwide winner gets his car made into real Hot Wheels
  • New lightweight polymer film can prevent corrosion
  • Genesis is making a mid-engine V8 supercar!
  • New angle sensors designed for rugged applications
  • Quickparts making big moves for part making
  • New lightweight compound for structural car parts
  • BLDC motors: Performance, flexibility, affordability
  • Full-color 3D-printing Design Guide from Xometry
  • What is laser peening for metal components?
  • Micro-brakes for precise motion control
  • Videos+: Technologies and inspiration in action
    • Metal 3D printing: Right at your desktop
  • Most Popular Last Issue
    • NASA 'RAMPT's up 3D-printed rocket engine size
    • Bentley gets racy: New 657-hp Supersports coupe
    • Composite metal foam: Handles high stress, temps
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: Genesis Magma GT Concept

News

Prototype LED is as thin as wallpaper, glows like the sun

New low-cost carbon capture method for power plants uses only water and pressure

Rolls-Royce successfully tests first pure methanol high-speed marine engine

Novel metal alloy withstands extreme conditions -- sets new benchmarks



Feature articles

Image - Turbo hydrogen engine rivals power, efficiency of a diesel
Turbo hydrogen engine rivals power, efficiency of a diesel
Southwest Research Institute has upgraded its hydrogen-powered heavy-duty internal combustion engine for a Class-8 truck with a state-of-the-art turbocharger, which has significantly improved performance across the board and made the engine competitive with current long-haul diesels.
Read the full article.

Image - Worldwide winner gets his car made into a real Hot Wheels
Worldwide winner gets his car made into a real Hot Wheels
Did you know toymaker Mattel holds an annual contest to find the coolest custom-built car on the planet that they can make into a new, specialty Hot Wheels die-cast vehicle? The 2025 winner has been chosen, with the final three entries hailing from the United States, Mexico, and Poland.
Read the full article.

Image - New lightweight polymer film can prevent corrosion
New lightweight polymer film can prevent corrosion
MIT researchers have developed a lightweight polymer film that is nearly impenetrable to gas molecules. It could be used as a protective coating to prevent infrastructure from corrosion or to slow the aging of packaged food and medicines. The material's degree of impermeability has never been seen before in any polymer.
Read the full article.

Image - Genesis is making a mid-engine V8 supercar!
Genesis is making a mid-engine V8 supercar!
Genesis surprised a lot of people last week when it announced it will make a mid-engine supercar -- and then rolled out a red-hot concept vehicle that looks almost production ready to prove it. The company wants the Magma GT Concept to serve as its high-performance identity for the next decade.
Read the full article.

Image - New angle sensors designed for rugged applications
New angle sensors designed for rugged applications
Novotechnik's new Vert-X 26 Series of non-contacting magnetic angle sensors use the Hall effect to track the position of the shaft and are designed for rugged applications like automotive and off-highway equipment where high humidity, dampness, dust, and/or vibrations are expected. They are plug-in sensors using an AMP MQ5 6-pole connector, with a measurement range from 0 to 360 degrees. Both single and fully redundant versions are available.
Learn more.

Image - Quickparts making big moves for part making
Quickparts making big moves for part making
Quickparts has expanded its Seattle HQ to create an Aerospace & Defense Center of Excellence, strengthening the company's long-standing expertise in high-fidelity casting patterns and advanced stereolithography (SLA). Simultaneously, the company is launching its Quick Mold solution across North America, bringing production-quality molded parts to market in as little as five days.
Read the full article.

Image - New lightweight compound for structural car parts
New lightweight compound for structural car parts
Following four years of collaboration with the University of Toronto, Axiom is proud to announce the creation of AX Gratek PP40 -- a groundbreaking lightweight, high-strength alternative to heavy glass-filled 40-60% PP components. This hybrid composite features graphene nanoplatelets with glass fibers. Patent pending, this material has achieved up to 20% improvement in tensile strength while achieving an impressive 18% weight reduction compared to commercial PPGF60% parts.
Learn more.

Image - BLDC motors: Performance, flexibility, affordability
BLDC motors: Performance, flexibility, affordability
The ElectroCraft RapidPower Enhanced series (RPE series) is an innovative brushless DC (BLDC) motor design that combines performance, flexibility, and affordability, offering OEMs the perfect platform for a wide range of motion applications. Highly configurable, the RPE series can be quickly acquired and adapted into an application. ElectroCraft's BLDCs integrate rare earth magnets and an eight-pole encapsulated core design to provide high torque density, peak torques up to 300% of continuous ratings, wide speed ranges, low cogging, and excellent thermal characteristics.
Learn more and find out all the options.

Image - Full-color 3D-printing Design Guide from Xometry
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.

Image - What is laser peening for metal components?
What is laser peening for metal components?
According to Curtiss-Wright, laser peening (also called laser shock peening) "drives deep plastic strain into a part that creates a high-magnitude residual compressive stress from 1 to 10 mm below the surface." This process involves hitting a part surface with a laser repeatedly through a stream of water, offering designers the ability "to surgically engineer residual compressive stress into key areas of components." Benefits include enhancements to fatigue strength, durability, damage tolerance, and resistance to stress corrosion cracking of critical metallic components.
Read the extensive Curtiss-Wright article.

Image - Micro-brakes for precise motion control applications
Micro-brakes for precise motion control applications
The ultra-compact 112 Model Electromagnetic Micro-Brakes from Miki Pulley ensure fast response in high-torque, demanding applications. The simple design features a stator with integrated mounting flange, proprietary composite friction liner, and armature complete with ring plate spring and hub. These brakes halt rotation mechanically by utilizing an electromagnetic field to create mechanical friction. With fast response, the brake's armature engages the stator when the coil is energized. A constant-force plate spring transfers torque to the rotating brake body, halting all motion.
Learn more.

Most popular last issue

Image - NASA 'RAMPT's up 3D-printed rocket engine size
NASA 'RAMPT's up 3D-printed rocket engine size
NASA's Rapid Analysis and Manufacturing Propulsion Technology project, led by Marshall Space Flight Center, is leading the charge for validating technology to 3D print larger and larger complex parts, which are also created faster, lighter, stronger, and with advantages such as cooling channels built right in. By NASA Spinoff
Read the full article.

Image - Bentley gets racy with new 657-hp Supersports coupe
Bentley gets racy with new 657-hp Supersports coupe
Bentley says its new 657-hp Supersports model is the most driver-focused Continental GT ever. With a twin-turbo 4.0-L V8 at its heart, the racy, rear-wheel-drive, two-seater signals a return to Bentley making more extreme cars that are both luxe and a thrill to drive.
Read the full article.

Image - Composite metal foam: Resilient against high stresses at high temps
Composite metal foam: Resilient against high stresses at high temps
New research shows that composite metal foams are incredibly resilient at high temperatures and can withstand repeated heavy loads. Made of stainless steel, nickel, or other metals or alloys, CMFs can also withstand tremendous force -- enough to punch a hole in a railroad tank car at a much lower weight than solid steel.
Read the full article.

Videos+: Technologies and inspiration in action
Metal 3D printing: Right at your desktop
From prototyping to tooling or batch production of end-use parts, the Studio System 2 from Desktop Metal brings metal 3D printing to any office, studio, or lab setting. This powder- and laser-free system consists of an easy-to-adopt two-step process: print using pre-bound metal rod feedstock and then sinter. It requires minimal training and operator intervention. Combined with next-gen Separable Supports and a software-controlled workflow, the Studio System makes metal 3D printing simpler than ever. This platform offers more materials than any other metal extrusion 3D-printing system on the market. They include Inconel 625, titanium (Ti64), copper, tool steels, and stainless steels.
View the video and learn more.

New products

Electrical/Electronics
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