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

Cool! New energy-efficient R290 enclosure air conditioners

Seifert Systems introduces PFAS-free SoliTherm^® SlimLine NEO air conditioners using eco-friendly R290 refrigerant. These units offer high energy efficiency (EER up to 3.6) and a compact, under-8-in. internal depth. Featuring maintenance-free design with external or recessed mounting options, they deliver up to 8,500 BTU/hr, providing flexible cooling solutions for varied industrial enclosure needs. Several models available based on size/cooling capacity needs.
Learn more and see all your options.

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.

Cool! Internal threading in hard materials now possible

INSACO has a new capability where they can machine an internal thread in ceramic, sapphire, quartz, and other very hard materials. This advance pushes the boundaries of what's possible to support advanced applications that demand high precision and complexity. Ultra-hard materials are alternatives for when metal can't do the job. Ideal for aerospace, medical, and industrial applications.
Learn more. Video available on right side of page.

ClampDisk micro fastener is new alternative for automotive and consumer electronics

Designed as a unique alternative in assemblies for the automotive and consumer electronics markets, the ClampDisk Press-on Fastener is a newer offering from PennEngineering that delivers a fast, simple way to achieve sheet-to-sheet clamped fastening while replacing the use of standard screws, nuts, and adhesives. ClampDisk eliminates over-installation, cross-threading, stripped screw heads, broken screws, and damaged product. This fastener can be removed easily with a sharp-edged tool.
See how ClampDisk works.

Simplify appliance glass assembly

Henkel's Technomelt PUR 9015 BV/WV is a polyurethane hotmelt adhesive providing high initial strength and long-term durability for glass and large-panel appliance assembly. It enables immediate handling, excellent substrate adhesion, and high thermal resistance, while supporting automated, cost-efficient production. It offers a flexible solution for high-reliability manufacturing.
Learn more.

Made-to-order stamped components for insert molding

Traditionally, OEMs source metal inserts and insert molding services separately. Not anymore. Plastics manufacturers and injection molders are now taking on more of the sourcing responsibility for insert molded parts, and they are partnering with Boker's, who has a long-term proven record for delivering precision stampings with quick turnaround times and ensuring metal inserts are mold-ready upon delivery. Boker's has immediate access to over 2,000 commonly specified and hard-to-find materials.
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.

Epoxy engineered for heat-sink bonding

Master Bond EP54TC is a two-component epoxy engineered for heat-sink bonding and thermal management applications. Featuring the highest thermal conductivity in the Master Bond electrically insulating portfolio, it delivers exceptional heat dissipation while remaining electrically non-conductive and compliant with ASTM E595 NASA low outgassing requirements. It supports thin bond lines and efficient void filling to maximize thermal performance.
Learn more.

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, including Inconel 625, titanium (Ti64), copper, tool steels, and stainless steels.
View the video and learn more.

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.

Application Note: Disc springs in mechanical braking system

Braking systems for off-highway equipment are commonly designed to be hydraulically actuated, but without an additional fail-safe system, this design alone has limited reliability. If a hydraulic seal is compromised, or the hydraulic cylinder loses pressure for any reason, the brakes fail. One solid mechanical back-up design uses SPIROL disc springs.
Read the full article.

Configurable welding platform for flexible manufacturing

Emerson's new Branson Polaris Ultrasonic Welding Platform offers a highly configurable, smart solution for advanced manufacturing. It features secure connectivity and real-time control to join diverse materials, from medical devices to food packaging. With adaptable power supplies and actuators, the system scales from benchtop lab trials to fully automated production lines, optimizing footprint and data storage to meet complex application needs.
Learn more.

SPIROL receives 2025 Supplier Excellence Recognition Award from Caterpillar

Kudos to SPIROL! The engineered fasteners manufacturer has received the 2025 Supplier Excellence Recognition Award from Caterpillar Inc. This prestigious award recognizes suppliers who demonstrate world-class performance and a sustained commitment to quality, delivery, and operational excellence.
Read the full article.

Eliminate cotters, bolts, nuts with SLIC Pin^®

The SLIC Pin (Self-Locking Implanted Cotter Pin) from Pivot Point is a pin and cotter all in one. This one-piece locking clevis pin is cost saving, fast, and secure. It functions as a quick locking pin wherever you need a fast-lock function. It features a spring-loaded plunger that functions as an easy insertion ramp. This revolutionary fastening pin is very popular and used successfully in a wide range of applications.
Learn more.

Researchers succeed at 3D printing components for a portable mass spectrometer

By Adam Zewe, MIT

Mass spectrometers, devices that identify chemical substances, are widely used in applications like crime scene analysis, toxicology testing, and geological surveying. However, these machines are bulky, expensive, and easy to damage, which limits where they can be deployed effectively.

Using additive manufacturing, MIT researchers produced a mass filter, which is the core component of a mass spectrometer, that is far lighter and cheaper than the same type of filter made with traditional techniques and materials.

Because additive manufacturing allows the researchers to easily try new designs, they created a number of different quadrupole filters before arriving at the final iteration (h), which is surrounded by a series of triangular lattices to provide durability. [Image credit: Courtesy of the researchers]

 

 

 

 

Their miniaturized filter, known as a quadrupole, can be completely fabricated in a matter of hours for a few dollars. The 3D-printed device is as precise as some commercial-grade mass filters that can cost more than $100,000 and take weeks to manufacture.

Built from durable and heat-resistant glass-ceramic resin, the filter is 3D printed in one step, so no assembly is required. Assembly often introduces defects that can hamper the performance of quadrupoles.

This lightweight, inexpensive, yet precise quadrupole is one important step in Luis Fernando Velasquez-Garcia's 20-year quest to produce a 3D-printed, portable mass spectrometer.

"We are not the first ones to try to do this," he says, "but we are the first ones who succeeded at doing this. There are other miniaturized quadrupole filters, but they are not comparable with professional-grade mass filters. There are a lot of possibilities for this hardware if the size and cost could be smaller without adversely affecting the performance." Velasquez-Garcia is a principal research scientist in MIT's Microsystems Technology Laboratories (MTL) and senior author of a paper detailing the miniaturized quadrupole.

For instance, a scientist could bring a portable mass spectrometer to remote areas of the rainforest, using it to rapidly analyze potential pollutants without shipping samples back to a lab. A lightweight device would also be cheaper and easier to send into space, where it could monitor chemicals in Earth's atmosphere or on those of distant planets.

Velasquez-Garcia is joined on the paper by lead author Colin Eckhoff, an MIT graduate student in electrical engineering and computer science (EECS); Nicholas Lubinsky, a former MIT postdoc; and Luke Metzler and Randall Pedder of Ardara Technologies. The research is published in Advanced Science.

Size matters
At the heart of a mass spectrometer is the mass filter. This component uses electric or magnetic fields to sort charged particles based on their mass-to-charge ratio. In this way, the device can measure the chemical components in a sample to identify an unknown substance.

A quadrupole, a common type of mass filter, is composed of four metallic rods surrounding an axis. Voltages are applied to the rods, which produce an electromagnetic field. Depending on the properties of the electromagnetic field, ions with a specific mass-to-charge ratio will swirl around through the middle of the filter, while other particles escape out the sides. By varying the mix of voltages, one can target ions with different mass-to-charge ratios.

While fairly simple in design, a typical stainless-steel quadrupole might weigh several kilograms. Miniaturizing a quadrupole is no easy task. Making the filter smaller usually introduces errors during the manufacturing process. Plus, smaller filters collect fewer ions, which makes chemical analysis less sensitive.

"You can't make quadrupoles arbitrarily smaller -- there is a tradeoff," Velasquez-Garcia adds.

His team balanced this tradeoff by leveraging additive manufacturing to make miniaturized quadrupoles with the ideal size and shape to maximize precision and sensitivity.

They fabricate the filter from a glass-ceramic resin, which is a relatively new printable material that can withstand temperatures up to 900 C and performs well in a vacuum.

The device is produced using vat photopolymerization, a process where a piston pushes into a vat of liquid resin until it nearly touches an array of LEDs at the bottom. These illuminate, curing the resin that remains in the minuscule gap between the piston and the LEDs. A tiny layer of cured polymer is then stuck to the piston, which rises up and repeats the cycle, building the device one tiny layer at a time.

"This is a relatively new technology for printing ceramics that allows you to make very precise 3D objects. And one key advantage of additive manufacturing is that you can aggressively iterate the designs," Velasquez-Garcia says.

Since the 3D printer can form practically any shape, the researchers designed a quadrupole with hyperbolic rods. This shape is ideal for mass filtering but difficult to make with conventional methods. Many commercial filters employ rounded rods instead, which can reduce performance.

They also printed an intricate network of triangular lattices surrounding the rods, which provides durability while ensuring the rods remain positioned correctly if the device is moved or shaken.

To finish the quadrupole, the researchers used a technique called electroless plating to coat the rods with a thin metal film, which makes them electrically conductive. They cover everything but the rods with a masking chemical and then submerge the quadrupole in a chemical bath heated to a precise temperature and stirring conditions. This deposits a thin metal film on the rods uniformly without damaging the rest of the device or shorting the rods.

"In the end, we made quadrupoles that were the most compact but also the most precise that could be made, given the constraints of our 3D printer," Velasquez-Garcia says.

Maximizing performance
To test their 3D-printed quadrupoles, the team swapped them into a commercial system and found that they could attain higher resolutions than other types of miniature filters. Their quadrupoles, which are about 12 cm in length, are one-quarter the density of comparable stainless-steel filters.

In addition, further experiments suggest that their 3D-printed quadrupoles could achieve precision that is on par with that of largescale commercial filters.

In the future, the researchers plan to boost the quadrupole's performance by making the filters longer. A longer filter can enable more precise measurements, since more ions that are supposed to be filtered out will escape as the chemical travels along its length. They also intend to explore different ceramic materials that could better transfer heat.

"Our vision is to make a mass spectrometer where all the key components can be 3D printed, contributing to a device with much less weight and cost without sacrificing performance. There is still a lot of work to do, but this is a great start," Velasquez-Garcia says.

Published January 2024

Rate this article