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5 practical tips for plastic part designers: Design for Manufacturability

Manufactur-ability is an integral part of the design process. By aligning structural design principles with the realities of molding and tooling, engineers can reduce rework, improve dimensional stability, and ensure consistent part quality. Engineers from Kemal Precision Manufacturing share their 5 Top Tips for Designing for Manufacturability. Very good info here.
Read the full article.

Holding firm: Standard parts with increased clamping force

JW Winco has upgraded its proven hand knob nuts, star knob screws, and adjustable hand levers with increased clamping force. Their clamping surface with ball bearing doubles the clamping force while protecting the surface from damage. With typical screws and nuts, roughly half the tightening torque is lost to under-head friction. Get high axial clamping force purely by hand and without tools with these new JW Winco standard parts.
See all your new clamping options.

Trick out your workstation: FATH components for T-slotted rails

Automation-Direct has added additional FATH components for T-slotted aluminum rail including sleek casters with lifting foot options for mobility and stability, an ergonomic dual monitor workstation, monitor mount extensions, and a wide array of tool hooks, holders, and accessories that streamline organization and workflow. From cup holders to storage trays and fastening hardware, every component is crafted for durability and seamless integration into industrial and lean workstation environments.
Learn more.

How a wave spring improves valve performance

Discover how a Smalley Crest-to-Crest^® Wave Spring enhances the performance of a sliding gate valve in this application spotlight snippet. The spring applies a constant load to keep the main shaft threads engaged, delivering precise and repeatable control of flow and pressure. Watch the video to see the internal motion and how this design can elevate your own applications!
View the video.

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.

High-performance fastening for aerospace interiors

The ONSERT fastening element from Böllhoff and DELO PHOTOBOND FB4151 adhesive enable lightweight, flame-retardant, drill-free fastening for aircraft interiors. The UV-curing acrylate cures in seconds, delivers high strength and flexibility, and supports automated, scalable production for cable routing and other lightweight cabin structures. This tech has already demonstrated its potential in the fastening of cable routing in business class seats from Recaro.
Learn more and read about the Recaro seat application.

Tech Tip: Why pins walk and how to ensure it doesn't happen

Lateral movement of installed solid, slotted, or coiled spring pins, commonly referred to as "walking," can occur within a dynamic application if proper design guidelines are not followed. Issues with different pin types may have different causes. Learn the many reasons why pins walk and the design best practices you should follow to avoid the condition.
Read this informative SPIROL Tech Tip.

Engineer's Toolbox: What they didn't teach you about fittings in engineering school

Do you know why an old standard "Christmas-tree" barbed fitting may not be your best choice for your miniature fluid power application? Experts at Beswick Engineering run through the common types of fittings used in these smaller pneumatic applications, along with thread sizes and seals to help you make the correct choice. They also touch on pressure and temp ranges, chemical compatibility issues, rigid and flexible lines, and the ease of assembly and maintenance.
Read the full 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.

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.

When to use Multi Jet Fusion to make your parts

According to the experts at TriMech Advanced Manufacturing, "Multi Jet Fusion is an industrial 3D-printing technology that fuses powdered materials layer by layer into solid plastic parts. It was developed by HP and was commercialized in 2016." Learn the strengths and limits of MJF and key technology benefits in this thorough overview, which also includes: part optimization, standard materials (Nylon PA12) and specs, applications, and post-processing options.
Read the full TriMech article. A solid primer.

Tech Tip: Mastering sheet metal bend calculations in Onshape

Mastering bend calculations in sheet metal design is a key skill that can impact the accuracy and manufactur-ability of your designs significantly. Explore the various options available to become a pro in this Onshape Tech Tip: K Factor, bend allowance, and bend deduction, with guidance on when each should be used. You will probably learn something even if you don't use this software.
Read the Onshape blog.

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.

Turn-to-lock latches: New concepts from JW Winco

JW Winco has expanded its portfolio of latches, adding stainless steel versions and new functional concepts, such as the GN 115.8 series of hook-type latches that use a hook to engage with a mating catch by moving radially to the axis of rotation instead of a latch arm that moves behind a frame. When operated with a socket key, the latches can be used even in extremely wet environments. Also available are classic cam latches and rotary clamping latches.
Learn about latching options from JW Winco.

New Air Cradle for quick and efficient air gun storage

EXAIR now offers the new Air Cradle Safety Air Gun Mount, a simple but innovative accessory designed to keep safety air guns and similarly sized tools within easy reach at workstations and machine centers. With its strong magnetic loop design, the Air Cradle provides a convenient, highly accessible hang point for safety air guns, helping improve workflow, minimize tool misplacement, and promote a more organized, efficient work environment across manufacturing, assembly, shipping, and other general shop applications.
Learn more.

Polymer-based EV battery won't break in the cold

Why cold weather cripples today's batteries -- and what researchers are doing about it.

By Lesley Henton, Texas A&M University

Extreme winter weather can strain power systems, stall electric vehicles, and leave back-up batteries unable to deliver energy when it is most needed. Researchers at Texas A&M University have developed a battery design that continues operating through the coldest conditions.

The team, led by Dr. Jodie Lutkenhaus, professor of chemical engineering and associate dean for research in the College of Engineering, published findings on a polymer-based battery in the Journal of Materials Chemistry A.

A battery designed for subzero conditions
Lutkenhaus said battery performance suffers in cold weather because conventional batteries contain a liquid electrolyte that transports the charge. "If that electrolyte freezes, then charge can no longer be transported. Hence, the battery will not charge or discharge.

"We saw exactly this issue in the cold snap in Chicago in 2024, where electric vehicle batteries were so cold and frozen that they did not charge at their powering stations," she said.

The team's new battery design is capable of maintaining functionality in temperatures as low as 40 degrees below zero.

"We're able to do this because we replace the liquid electrolyte that freezes with a different electrolyte that does not. We also replace the hard inorganic materials that are sluggish at low temperatures with soft polymer materials that are a bit faster," Lutkenhaus said.

The researchers created an organic dual-ion battery that uses redox-active polymers instead of the inorganic electrode materials found in most commercial batteries. They combined these polymer electrodes with a diglyme-based low-temperature electrolyte, which remains fluid and conductive at temperatures where conventional electrolytes begin to crystallize.

As a result, the battery maintained 85% of its capacity at 0 degrees C (32 F) and 55% at minus 40 C (minus 40 F), while sustaining high specific power rates.

Why batteries fail in the cold
Battery chemistry relies on the movement of ions through an electrolyte; as temperatures drop, this motion slows dramatically.

With their new battery design, the team avoided such collapse by pairing the low-temperature electrolyte with soft polymer electrodes, which remain flexible and maintain electrochemical activity even as the system cools. "Hard inorganic materials are often slow at low temperatures, but soft polymer materials can move ions more easily," she said. "When you use materials that naturally tolerate the cold, the battery doesn't have to fight its own chemistry."

Carbon fiber boosts strength and stability
The researchers also tackled mechanical durability, another factor that limits battery performance in demanding environments. Instead of using metal current collectors -- which can add weight and crack under stress -- the team incorporated carbon-fiber weaves. These reinforced the battery while still conducting charge effectively.

The result is a "structural battery," one that stores energy and simultaneously provides mechanical strength. Such dual-function designs can be advantageous in electric vehicles, drones, or any system where weight and structural integrity matter. "Mechanical stress can damage a battery over time," Lutkenhaus said. "By building batteries that act as part of the structure, we can reduce weight and improve durability at once."

A step toward cold-resistant energy storage
Reliable, low-temperature performance could impact systems from personal electronics to critical infrastructure.

"With a massive storm or cold snap, electrical grids can go down. Batteries can cover those outages and gaps," Lutkenhaus said. "If we want an energy system that's resilient in all seasons, we need storage that isn't vulnerable to temperature swings."

While still in the research stage, the battery demonstrates how material innovation can overcome longstanding performance limits.

Lutkenhaus said the work points toward a future where energy storage is more dependable during extreme weather. In the meantime, she provides some practical advice: "If you're concerned about your electric vehicle or your off-grid battery, I suggest moving it inside, keeping it a little warmer in your garage and not exposing it to the elements, so it won't freeze."

Published February 2026

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