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Dual-laser metal AM system makes parts faster

Renishaw's new dual-laser RenAM 500D metal additive manufacturing machine has been designed to offer exceptional product quality and productivity for a wider range of budgets. The RenAM 500D features two 500-W lasers that can access the entire build platform, delivering superior performance when compared with single-laser systems. Additionally, the RenAM 500D Ultra, fitted with Renishaw's TEMPUS technology, allows the laser to fire while the recoater is moving, saving up to nine seconds per build layer and reducing cost per part. This also helps to deliver a production speed up to three times faster than conventional single-laser systems. Many more features.
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NEW! Aluminum Press-In Inserts for plastics

SPIROL is pleased to introduce a range of 2024 aluminum Press-In Inserts. Available in symmetrical (Series INS 50) and headed (INS 51) versions, the new aluminum Press-In Inserts line complements the existing brass line. Threaded Inserts are essential for reinforcing plastic components and provide a reusable thread within a bolted assembly. This ensures a proper seating torque and prevents the potential for plastic creep over time. These inserts are designed to be Pressed-In without heat and provide the lowest cost to install with acceptable joint performance for many applications.
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When glass or plastic can't cut it: Transparent ceramics solve critical design challenges

Complex designs are still possible when grinding and polishing Fused Silica or Sapphire. Ceramic properties such as wear, abrasion resistance, and strength of these optical materials can be a designer's dream solution when high temperatures or severe environments rule out standard optical glass or plastic. INSACO is a machine shop specializing in ultra-hard and extreme materials.
→ Contact Jackson Evans, Sales Engineer at INSACO jpe@insaco.com.
→ Learn more about INSACO materials and capabilities.

New contactless link magnetic couplings use magnetic field to transmit torque

Miki Pulley Magnetic Couplings are shaft couplings that transmit torque from one shaft to another using a magnetic field instead of a physical or mechanical connection. These Magnetic Couplings are non-contact and rely on the attraction and repulsion of magnetic poles to generate rotational power. The full product range can withstand significant misalignments and are silent, vibration-free, and do not generate thermal conduction. Design advantages include configurations that are versatile for use in various engagement angles and installations. Max transmittable torque is adjustable.
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New aero and defense PEKK-based FDM polymers from Stratasys

Stratasys has partnered with top aerospace and defense companies to develop two newly qualified materials for 3D printing. Antero 800NA is a PEKK-based FDM polymer with excellent physical and mechanical properties for demanding applications. Antero 840CN03 is a high-performance PEKK-based FDM polymer with electrostatic dissipative (ESD) properties. These new advanced industrial solution materials were rigorously qualified in collaboration with Northrop Grumman, Boeing, Blue Origin, Raytheon, Naval Air Systems Command, the National Institute for Aviation Research, United States Air Force, BAE, and Stratasys Direct Manufacturing.
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New washer tech for leak-free automotive sealing

Trelleborg Sealing Solutions has launched the Rubore^® Washer, a unique solution offering virtually leak-free sealing beneath screwheads to safeguard critical systems in vehicles, especially electric ones.
Read the full article.

EOS expands its Nickel superalloys for 3D printing

EOS, a leading supplier of manufacturing solutions for industrial 3D printing, has added two new metal additive manufacturing materials: EOS NickelAlloy IN738 and EOS NickelAlloy K500, both delivering excellent performance, part properties, and value to a variety of industries that leverage EOS Laser Powder Bed Fusion (LBPF) 3D-printing technology. The IN738 superalloy is aimed at high-strength, high-stress energy and turbomachinery applications, while the K500 superalloy is a cost-effective, corrosion-resistant option for chemical, maritime, and space industries.
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Ruland acquires RoCom Couplings, expanding beam coupling and machined spring capabilities

Ruland Manufacturing has acquired the assets of RoCom Couplings, a Santa Maria, CA-based company specializing in beaming technology, including beam couplings, machined springs, and custom beamed components. The acquisition expands Ruland's beam coupling offerings and enhances its manufacturing capabilities to better serve customers requiring precision-engineered flexible couplings and custom machined solutions.
Learn more and see what's offered.

norelem adds 30,000 new components to its range

norelem, a global manufacturer and supplier of standard components for machinery and automation, has expanded its product range by adding 30,000 parts to its catalog. Unique in the industry, this expansion brings norelem's selection of high-quality components to over 130,000 products for design engineers and machine technicians. From sensors and clamps to plungers, levers, and measurement instruments, norelem's entire supply is available to order from its online shop with guaranteed fast and reliable delivery times.
Check out what norelem has to offer. They are new to Designfax.

Wear-resistant precision hinges from JW Winco

The precision hinges GN 7580 from JW Winco supply a pivoting movement to elements such as swing arms, spacers, and clamping plates in applications such as jig construction, automation systems, or testing systems. These wear-resistant hinges feature low radial play and adjustable axial play. They are made of black anodized and high-strength alloyed aluminum, while the bearing bushings are made of bronze. Stainless steel is used for the hardened hinge axis as well as the thrust washers and adjusting screws. An additional polyamide coating on the adjusting screws provides for thread locking.
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Supercar of the skies: Autodesk Alias design

Learn how Hill Helicopter is using Autodesk Alias to design the innovative HX50, the "supercar of the skies." The next-gen, private copter marries high-end automotive and aero design and materials to create a futuristic flying five-seat SUV for a discriminating clientele. A neat insider look.
View the video.

CNC machining: How to avoid high costs on thin walls

Parts that are light and strong are crucial to nearly every industry. To achieve better performance without risking part failure, parts must maintain a specific wall-height-to-thickness ratio and wall-height-to-length ratio. Additionally, some geometries and supports can support thin walls to achieve a lighter component weight. Dive deeper into the cost drivers behind CNC-machined thin walls in this Xometry design-for-manufacturing article.
Read the full article.

Before you design your next application, try this

Smalley's industry-leading Spirolox^® Retaining Rings feature a gapless design with 360° of retaining surface. Unlike other rings, Spirolox has no protruding ears to interfere with mating components in your assembly! The highly versatile Spirolox rings are also groove-interchangeable with circlips, meaning they can replace circlips without any design changes. Are you ready to try the Smalley Advantage? Request your free samples today!
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No-cost courses in fastener technology

Master the theory of fastener design to expand your product knowledge and become an even better and more efficient design engineer. PennEngineering's PEM FastenerClass^® courses aim to give participants insight into peer and competitor techniques, a better understanding of loads and stress analysis, and enhanced career opportunities -- all beyond the basics of fastener design, selection, and installation. Self-clinch, threads, press-in inserts, surface-mount options, and sheet-to-sheet are only a few of the many topics covered.
See what courses are offered.

Engineer's Toolbox: The secret to living hinges that fold flat

Living hinges are often used to produce a container and its lid as a single molded part. If properly designed, they can open and close thousands of times without ever losing strength or flexibility. Protolabs provides valuable tips on designing these (sometimes thin and fragile) parts.
Read the full article.

Eye-opener: Copper can't be mined fast enough to electrify the U.S.

According to a new University of Michigan (U-M) study, copper cannot be mined quickly enough to keep up with current U.S. policy guidelines to transition the country's electricity and vehicle infrastructure to renewable energy.

The Inflation Reduction Act, signed into law in 2022, calls for 100% of cars manufactured to be electric vehicles by 2035. However, an electric vehicle requires three to five times as much copper as an internal combustion engine vehicle -- not to mention the copper required for upgrades to the electric grid.

"A normal Honda Accord needs about 40 pounds of copper. The same battery-electric Honda Accord needs almost 200 pounds of copper. Onshore wind turbines require about 10 tons of copper, and in offshore wind turbines, that amount can more than double," said Adam Simon, U-M professor of earth and environmental studies. "We show in the paper that the amount of copper needed is essentially impossible for mining companies to produce."

The study examined 120 years of global data from copper mining companies and calculated how much copper the U.S. electricity infrastructure and fleet of cars would need to upgrade to renewable energy. It found that renewable energy's copper needs would outstrip what copper mines can produce at the current rate. The study, led by Simon and Cornell University researcher Lawrence Cathles, was published by the International Energy Forum and discussed in a webinar, "Copper mining and vehicle electrification."

The shortfall is, in part, because of the permitting process for mining companies. The average time between discovering a new copper mineral deposit and getting a permit to build a mine is about 20 years, according to Simon.

Copper is mined by more than 100 companies operating mines on six continents. The researchers drew data for global copper production back to the year 1900, which told them the global amount of copper mining companies had produced over 120 years. They then modeled how much copper mining companies are likely to produce for the rest of the century.

The researchers found that between 2018 and 2050, the world will need to mine 115% more copper than has been mined in all of human history up until 2018 just to meet "business as usual." This would meet our current copper needs and support the developing world without considering the green energy transition.

To meet the copper needs of electrifying the global vehicle fleet, as many as six new large copper mines must be brought online annually over the next several decades. About 40% of the production from new mines will be required for electric vehicle-related grid upgrades.

"I'm a huge fan of the Inflation Reduction Act. I think it's fantastic. I've got solar panels, batteries, and an electric vehicle," Simon said. "I'm fully on board with the energy transition. However, it needs to be done in a way that's achievable."

Instead of fully electrifying the U.S. fleet of vehicles, the researchers suggest focusing on manufacturing hybrid vehicles.

"We are hoping the study gets picked up by policymakers who should consider copper as the limiting factor for the energy transition, and to think about how copper is allocated," Simon said. "We know, for example, that a Toyota Prius actually has a slightly better impact on climate than a Tesla. Instead of producing 20 million electric vehicles in the United States and globally, 100 million battery-electric vehicles each year, would it be more feasible to focus on building 20 million hybrid vehicles?"

The researchers also point out that copper will be needed for developing countries to build infrastructure, such as building an electric grid for the approximately 1 billion people who don't yet have access to electricity; to provide clean drinking water facilities for the approximately 2 billion people who don't have access to clean water; and wastewater treatment for the 4 billion people who don't have access to sanitation facilities.

"Renewable energy technologies, clean water, wastewater, electricity -- it cannot exist without copper. So we then end up with tension between how much copper we need to build infrastructure in less developed countries versus how much copper we need for the energy transition," Simon said.

"We think our study highlights that significant progress can be made to reduce emissions in the United States. However, the current -- almost singular -- emphasis on downstream manufacture of renewable energy technologies cannot be met by upstream mine production of copper and other metals without a complete mindset change about mining among environmental groups and policymakers."

Source: University of Michigan

Published May 2024

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