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What can replace a coil spring? You've got better options!

Traditional coil springs can limit mechanical designs. Wave springs offer a space-saving alternative, providing equivalent force and deflection in up to half the operating height while reducing assembly size and weight. There are four wave spring types that can replace a coil spring. Learn how each variant delivers unique performance capabilities to optimize space, efficiency, and reliability.
Read this informative NEW Smalley technical article.

Next-gen metal bonding: 3M Scotch-Weld 8500 Series

Replace traditional fasteners and streamline assembly with 3M Scotch-Weld Acrylic Adhesive DP8507NS. Engineered for direct bonding to bare or slightly oily metals with minimal surface prep, this high-performance adhesive withstands paint bake cycles up to 200 C (392 F), resists corrosion, and holds strong down to -40 C. Upgrade durability, aesthetics, and design flexibility. Bonds many plastics too!
View the video.

3 things you need to get right when 3D printing gears

When businesses decide to 3D print their own gears, they can reduce lead times and costs associated with replacements, prototypes, and small-batch production runs significantly. According to the experts at igus, however, "achieving industrial-grade reliability requires more than just a digital file; there are several fundamental technical basics you must master first to ensure your gears can withstand the rigors of real-world use."
Read this informative igus tech tip.

DURACON polymer with 30% recycled content

Daicel Corporation's High Performance Polymers SBU has launched four new DURACON^® POM grades featuring 30% post-consumer recycled (PCR) content. Unveiled at CHINAPLAS 2026, the lineup includes Standard, Low VOC, Sliding, and Tough options. Leveraging advanced compounding expertise, Daicel maintains quality and mechanical performance comparable to standard virgin resin grades for demanding global industrial and automotive components.
Learn more.

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.
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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]
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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.

Sandia Labs shows machine learning could lop a year off technology design cycle for new materials

A research team at Sandia National Laboratories has successfully used machine learning -- computer algorithms that improve themselves by learning patterns in data -- to complete cumbersome materials science calculations more than 40,000 times faster than normal.

Their results, published Jan. 4, 2021, in npj Computational Materials, could herald a dramatic acceleration in the creation of new technologies for optics, aerospace, energy storage, and potentially medicine -- while simultaneously saving laboratories money on computing costs.

"We're shortening the design cycle," said David Montes de Oca Zapiain, a computational materials scientist at Sandia who helped lead the research. "The design of components grossly outpaces the design of the materials you need to build them. We want to change that. Once you design a component, we'd like to be able to design a compatible material for that component without needing to wait for years, as it happens with the current process."

The research, funded by the U.S. Department of Energy's Basic Energy Sciences program, was conducted at the Center for Integrated Nanotechnologies, a DOE user research facility jointly operated by Sandia and Los Alamos national labs.

Machine learning speeds up computationally expensive simulations
Sandia researchers used machine learning to accelerate a computer simulation that predicts how changing a design or fabrication process, such as tweaking the amounts of metals in an alloy, will affect a material. A project might require thousands of simulations, which can take weeks, months, or even years to run.

The team clocked a single, unaided simulation on a high-performance computing cluster with 128 processing cores (a typical home computer has two to six processing cores) at 12 minutes. With machine learning, the same simulation took 60 milliseconds using only 36 cores -- equivalent to 42,000 times faster on equal computers. This means researchers can now learn in under 15 minutes what would normally take a year.

Sandia's new algorithm arrived at an answer that was 5% different from the standard simulation's result, a very accurate prediction for the team's purposes. Machine learning trades some accuracy for speed because it makes approximations to shortcut calculations.

"Our machine-learning framework achieves essentially the same accuracy as the high-fidelity model but at a fraction of the computational cost," said Sandia materials scientist Rémi Dingreville, who also worked on the project.

Benefits could extend beyond materials
Dingreville and Montes de Oca Zapiain are going to use their algorithm first to research ultrathin optical technologies for next-generation monitors and screens. Their research, though, could prove widely useful because the simulation they accelerated describes a common event -- the change, or evolution, of a material's microscopic building blocks over time.

Machine learning previously has been used to shortcut simulations that calculate how interactions between atoms and molecules change over time. The new published results, however, demonstrate the first use of machine learning to accelerate simulations of materials at relatively large, microscopic scales, which the Sandia team expects will be of greater practical value to scientists and engineers.

For instance, scientists can now quickly simulate how miniscule droplets of melted metal will glob together when they cool and solidify, or conversely, how a mixture will separate into layers of its constituent parts when it melts. Many other natural phenomena, including the formation of proteins, follow similar patterns. While the Sandia team has not tested the machine-learning algorithm on simulations of proteins, they are interested in exploring the possibility in the future.

Sandia National Laboratories is a multimission laboratory operated by National Technology and Engineering Solutions of Sandia LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy's National Nuclear Security Administration.

Source: Sandia

Published February 2021

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