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Clever! Indexing plungers with chamfered pins

JW Winco has developed a new type of indexing plunger -- GN 824 -- that can independently latch into edges and grooves. This is made possible by a chamfered plunger pin. When the chamfered pin encounters a raised latching geometry, it retracts and then springs back out again once it reaches the latching point. This new indexing plunger can be ordered with axial thread for fastening and a black plastic knob for operating the indexing plunger. In a clever design, the plunger pin can be adjusted by 360 degrees to ensure that it encounters the mating surface perpendicularly. This hardware is well suited for transport frames, mechanisms, or covers that need to be locked in place quickly and securely, especially without the need for manual intervention.
Learn more.

New flat quarter-turn clamping fastener

IMAO Fixtureworks has expanded its One-Touch Fastener lineup to include a new quarter-turn clamping fastener that features an innovative flat design and is ideal for clamping in limited spaces. The QCFC flat quarter-turn fastener has a recessed body that protrudes only 2 mm from the mounted surface, a knob that rests flush inside the body, visible ON and OFF markings for safety, and an audible click when fully turned to clamped or unclamped position.
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New electro-proportional hydraulics cartridge valves

Helios Technologies has expanded its electro-proportional cartridge valve offerings with new solutions (models RPEP and RPEN) from its operating company Sun Hydraulics. These valves fit into the compact T-10A cavity and are rated to a max pressure of 5,000 psi (350 bar). They have a flow capacity of 25 gpm and are fully compatible with the XMD Mobile Driver, which was co-developed with sister operating company Enovation Controls. The RPEP is well suited for industrial machines like a hydraulic press, which requires precise pressure regulation. The RPEN is well suited for mobile fan drive applications to dynamically control fan speed and ensure proper temperature regulation.
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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.
Learn more.

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.
Learn more.

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.

Could electric vehicle super batteries of the future be made of rock?

DTU researcher Mohamad Khoshkalam has invented a new material based on rock silicates to be used as a solid-state electrolyte that has the potential to replace lithium in future electric car batteries. [Credit: Photo by Frida Gregersen/Courtesy of Technical University of Denmark]

 

 

 

 

As more and more people switch to electric cars, industry needs to develop a new generation of lithium-free batteries that are at least as efficient, but more eco-friendly and cheaper, to produce. This requires new materials for the battery's main components -- anode, cathode, and electrolyte -- as well as developing new battery designs.

At the Technical University of Denmark (DTU), researcher Mohamad Khoshkalam has invented a material that has the potential to replace lithium in tomorrow's super battery: solid-state batteries based on potassium and sodium silicates. These are rock silicates, which are some of the most common minerals in the Earth's crust. The material is found in the stones you pick up on the beach or in your garden. A great advantage of the new material is that it is not sensitive to air and humidity. This makes it possible to mold it into a paper-thin layer inside the battery.

Patented superionic material
The potential of the milky-white, paper-thin material based on potassium silicate is huge. It is an inexpensive, eco-friendly material that can be extracted from silicates, which cover over 90% of the Earth's surface. The material can conduct ions at around 40 degrees C and is not sensitive to moisture.

This will make scaling up and future battery production easier, safer, and cheaper, as production can take place in an open atmosphere and at temperatures close to room temperature. The material also works without the addition of expensive and environmentally harmful metals such as cobalt, which is currently used in lithium-ion batteries to boost capacity and service life.

"The potential of potassium silicate as a solid-state electrolyte has been known for a long time, but in my opinion has been ignored due to challenges with the weight and size of the potassium ions. The ions are large and therefore move slower," says Khoshkalam.

To understand the potential and challenges of Khoshkalam's discovery, one must first understand the crucial role the electrolyte plays in a battery. The electrolyte in a battery can be a liquid or a solid material -- a so-called solid-state electrolyte. The electrolyte allows the ions to move between the battery's anode and cathode, thereby maintaining the electrical current generated during discharging and charging. In other words, the electrolyte is crucial for the battery capacity, charging time, lifespan, and safety.

The electrolyte's conductivity depends on how fast the ions can move in the electrolyte. The ions in rock silicates generally move slower than the ions in lithium-based liquid electrolytes or solid-state electrolytes, as they are larger and heavier. However, Khoshkalam has found a recipe for a superionic material of potassium silicate and a process that makes the ions move faster than in lithium-based electrolytes.

"The first measurement with a battery component revealed that the material has a very good conductivity as a solid-state electrolyte. I cannot reveal how I developed the material, as the recipe and the method are now patented," says Khoshkalam.

The battery everyone is waiting for
Both researchers and electric car manufacturers consider solid-state batteries to be the super battery of the future. Most recently, Toyota announced it expects to launch an electric car with a lithium solid-state battery in 2027-28. However, several car manufacturers have previously announced electric cars with solid-state batteries, only to subsequently sideline the technology.

In a solid-state battery, the ions travel through a solid material and not through a liquid, as in the regular AA+ lithium-ion batteries you can buy in the supermarket. There are several advantages to this; the ions can move faster through a solid material, making the battery more efficient and faster to charge.

A single battery cell can be made as thin as a piece of cardboard, where the anode, cathode, and solid-state electrolyte are ultra-thin layers of material. This means developers can make more powerful batteries that take up less space. This offers benefits on the road, as users will be able to drive up to 1,000 km on a single, 10-minute charge. In addition, a solid-state battery is more fireproof, as it does not contain combustible liquid.

Before we see the solid-state battery on the market, however, there are several challenges that need to be solved. The technology works well in the lab, but it is difficult and expensive to scale up.

First, the materials and battery research is both complex and time consuming, because the materials are super sensitive and require advanced labs and equipment. The lithium-ion batteries we use today took over 20 years to develop, and we're still developing them.

Second, we need to develop new ways of producing and sealing the batteries so the ultra-thin material layers in the battery cell do not break and have continuous contact in order to work. In the lab, researchers solve this by pressing the layers of the battery cell together at high pressure, but it is difficult to transfer to a commercial electric car battery, which consists of many battery cells.

Solid-state rock battery is high-risk technology
Unlike lithium solid-state batteries, solid-state batteries based on potassium and sodium silicates have a low TRL (technology readiness level). This means there is still a long way to go from discovery in the lab to getting the technology out into society and making a difference. The earliest we can expect to see them in new electric cars on the market is 10 years from now.

It is also a high-risk technology, where the chance of commercial success is small and the technical challenges are many. Nevertheless, Khoshkalam is full of optimism.

"We have shown that we can find a material for a solid-state electrolyte that is cheap, efficient, eco-friendly, and scalable -- and that even performs better than solid-state lithium-based electrolytes," he says.

A year after the discovery in the DTU lab, Khoshkalam has obtained a patent for the recipe and is in the process of establishing the start-up K-Ion, which will develop solid-state electrolyte components for battery companies. The K-ion is part of the DTU Earthbound initiative, where participants receive support to get their research out of the lab faster and into society to make an impact.

The next step for Khoshkalam and his team is to develop a demo battery that can show companies and potential investors that the material works. A prototype is expected to be ready within one to two years.

Source: Technical University of Denmark

Published July 2024

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