Designfax weekly eMagazine

Subscribe Today!

Archives

View Archives

Partners

Manufacturing Center
Product Spotlight

Modern Applications News
Metalworking Ideas For
Today's Job Shops

Tooling and Production
Strategies for large
metalworking plants

Surface inspection: From Army depot to factory floor

Born from U.S. Army requirements for rotorcraft inspection, the GelSight Modulus 3D surface measurement system has surpassed 100 units sold to commercial and Department of Defense customers. The handheld, micron-scale tool with interchangeable probe tips delivers fast, high-res measurements in places traditional tools can't reach.
Read the full article.

What is Cold Metal Fusion?

Cold Metal Fusion is an open industry standard for sinter-based metal additive manufacturing. It combines polymer SLS design freedom with reliable debinding and sintering workflows, enabling complex geometries, lightweighting, lattice structures, conformal cooling channels, and high-precision metal parts with predictable shrink behavior. Now available from TriMech Group, this process offers a faster, cost-effective way to produce strong, high-performance metal parts.
Learn more from TriMech Group.

Metal 3D printing: EOS adds four new materials

Industrial 3D-printing supplier EOS has added four new metal additive manufacturing materials to its portfolio: an iron-nickel alloy that boasts stability under fluctuating temps, a nickel alloy with high strength and extreme corrosion resistance, a low-alloyed steel prized for its high toughness and strength, and an industrial-grade stainless steel. Each has been optimized for EOS Laser Powder Bed Fusion systems.
Get all the details.

New materials and finishes from Quickparts

Quickparts has introduced DuraKor, ThermaKor, and vapor smoothing to expand its production-capable materials and finishing portfolio. The new plastics provide polypropylene-like toughness, chemical resistance, and high-temperature stability, while vapor smoothing improves sealing and surface quality. Together, these capabilities help engineers validate designs, refine performance, and transition efficiently from prototypes to scalable manufacturing.
Learn more.

What's the latest in SLA 3D printing?

Learn about the latest offerings in SLA printing from 3D Systems, including the introduction of SLA 825 Dual, the company's most advanced large-frame Stereolithography printer. Other new products include ArrayCast investment casting software that allows users to effortlessly create customized casting trees (complete with configurable runners, sprues, and end effectors), Accura SbF (the latest SLA casting resin), and Accura Xtreme Black (which delivers low shrinkage, large, functional SLA prototype parts with sharp detail).
Learn about all the new 3D Systems products.

meviy cuts CNC milling lead times to just 4 days

meviy, the on-demand custom parts manufacturing service developed by MISUMI Group, has upgraded its Expedite+ service with improved lead times for CNC Milled parts. Customers can now have their parts shipped in as few as four days through meviy's fastest delivery option. The enhanced service helps manufacturers and engineers stay on schedule when projects are behind or production is interrupted. Supported materials include steels and aluminums. Check out their instant quoting too.
Learn more.

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.

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 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.

Print parts in M300 tool steel: Starter kit

Take your 3D printing to the next level with M300 Tool Steel Filamet™ -- a high-strength and wear-resistant material. Virtual Foundry has released a brand-new M300 Tool Steel Kit packed with everything you need to get started, including: 0.5-kg starter filament spool, Filawarmer, 1 kg of steel blend, 0.5 kg of sintering carbon, and an alumina crucible. From the company that brought us 3D-printable lunar regolith simulant.
Learn more, including print instructions.

New laser-weldable PPS plastic

Polyplastics has launched a laser weldable DURAFIDE^® PPS grade with high transmittance. DURAFIDE PPS 1120LW1 (tentative name) utilizes a unique transmittance improvement technology. Although PPS has traditionally been considered difficult to use for laser welding, this new material expands the possibilities for applying laser welding to parts that previously had limitations in terms of heat and chemical resistance. This material is so new you may want to talk to someone at the company.
Learn more.

Expert design tips and tricks for 3D printing

Join Xometry's 3D-printing experts, Greg Paulsen and Matt Schmidt, as they reveal practical strategies to help you optimize your designs, improve print quality, and reduce costs across your 3D-printing projects. Learn about file-prep best practices, how to reduce costs on 3D prints, key design considerations when working on tolerance or resolution, and much more. Lots to learn here.
View the video.

New sheet metal capabilities for faster, cost-efficient builds

meviy, the on-demand custom parts manufacturing service developed by MISUMI Group, has expanded its sheet metal processing capabilities -- a game-changer for engineers and designers working under tight timelines and budgets. The upgrade includes support for thicker materials (up to 0.5"), bending up to 0.25", and new tapped and countersunk hole options -- all while maintaining meviy's trademark speed and simplicity. From fixture plates to machine frames, this opens the door for faster, low-precision structural builds.
Learn about meviy's many new service offerings.

Did you know etching is a machining option for Inconel?

In engineering, the materials that are hardest to work with are often the ones you want most in your design -- and Inconel is no exception. The very qualities that make this family of nickel-chromium superalloys so valuable also make the materials extremely difficult to machine. There is another option, though, for some applications.
Read the full article.

New energy-conversion record set for polymer solar cells: 10.6%

By Wileen Wong Kromhout, UCLA

In the effort to convert sunlight into electricity, photovoltaic solar cells that use conductive organic polymers for light absorption and conversion have shown great potential. Organic polymers can be produced in high volumes at low cost, resulting in photovoltaic devices that are cheap, lightweight, and flexible. In the last few years, a lot work has been done to improve the efficiency with which these devices convert sunlight into power, including the development of new materials, device structures, and processing techniques.

In a new study published last week in the journal Nature Photonics, researchers at the UCLA Henry Samueli School of Engineering and Applied Science and UCLA's California Nanosystems Institute (CNSI) report that they have significantly enhanced polymer solar cells' performance by building a device with a new "tandem" structure that combines multiple cells with different absorption bands. The device had a certified power-conversion efficiency of 8.62% and set a world record in July 2011.

Further, after the researchers incorporated a new infrared-absorbing polymer material provided by Sumitomo Chemical of Japan into the device, the device's architecture proved to be widely applicable and the power-conversion efficiency jumped to 10.6% — a new record — as certified by the U.S. Department of Energy's National Renewable Energy Laboratory.

By using cells with different absorption bands, tandem solar cells provide an effective way to harvest a broader spectrum of solar radiation. However, the efficiency doesn't automatically increase by simply combining two cells. The materials for the tandem cells have to be compatible with each other for efficient light harvesting, the researchers say.

Tandem solar cell.

 

 

Until now, the performance of tandem devices lagged behind single-layer solar cells, mainly due to this lack of suitable polymer materials. UCLA Engineering researchers have demonstrated highly efficient single-layer and tandem polymer solar cells featuring a low-band-gap conjugated polymer specially designed for the tandem structure. The band gap determines the portion of the solar spectrum a polymer absorbs.

"Envision a double-decker bus," says Yang Yang, a professor of materials science and engineering at UCLA Engineering and principal investigator on the research. "The bus can carry a certain number of passengers on one deck, but if you were to add a second deck, you could hold many more people for the same amount of space. That's what we've done here with the tandem polymer solar cell."

To use solar radiation more effectively, Yang's team stacked, in series, multiple photoactive layers with complementary absorption spectra to construct a tandem polymer solar cell. Their tandem structure consists of a front cell with a larger (or high) band gap material and a rear cell with a smaller (or low) band gap polymer, connected by a designed interlayer. When compared to a single-layer device, the tandem device is more efficient in utilizing solar energy, particularly by minimizing other energy losses. By using more than one absorption material, each capturing a different part of the solar spectrum, the tandem cell is able to maintain the current and increase the output voltage. These factors enable the increase in efficiency, according to the researchers. "The solar spectra is very broad and covers the visible as well as the invisible, the infrared and the UV," says Shuji Doi, research group manager for Sumitomo Chemical. "We are very excited that Sumitomo's low–band-gap polymer has contributed to the new record efficiency."

"We have been doing research in tandem solar cells for a much shorter length of time than in the single-junction devices," says Gang Li, a member of the research faculty at UCLA Engineering and a co-author of the Nature Photonics paper. "For us to achieve such success in improving the efficiency in this short time period truly demonstrates the great potential of tandem solar cell technology."

"Everything is done by a very low-cost, wet-coating process," Yang says. "As this process is compatible with current manufacturing, I anticipate this technology will become commercially viable in the near future."

This study opens up a new direction for polymer chemists to pursue designs of new materials for tandem polymer solar cells. Furthermore, it indicates an important step toward the commercialization of polymer solar cells. Yang says his team hopes to reach 15% efficiency in the next few years.

Published March 2012

Rate this article