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What can replace a coil spring? You've got better options!

Traditional coil springs can limit mechanical designs. Wave springs offer a space-saving alternative, providing equivalent force and deflection in up to half the operating height while reducing assembly size and weight. There are four wave spring types that can replace a coil spring. Learn how each variant delivers unique performance capabilities to optimize space, efficiency, and reliability.
Read this informative NEW Smalley technical article.

Next-gen metal bonding: 3M Scotch-Weld 8500 Series

Replace traditional fasteners and streamline assembly with 3M Scotch-Weld Acrylic Adhesive DP8507NS. Engineered for direct bonding to bare or slightly oily metals with minimal surface prep, this high-performance adhesive withstands paint bake cycles up to 200 C (392 F), resists corrosion, and holds strong down to -40 C. Upgrade durability, aesthetics, and design flexibility. Bonds many plastics too!
View the video.

3 things you need to get right when 3D printing gears

When businesses decide to 3D print their own gears, they can reduce lead times and costs associated with replacements, prototypes, and small-batch production runs significantly. According to the experts at igus, however, "achieving industrial-grade reliability requires more than just a digital file; there are several fundamental technical basics you must master first to ensure your gears can withstand the rigors of real-world use."
Read this informative igus tech tip.

DURACON polymer with 30% recycled content

Daicel Corporation's High Performance Polymers SBU has launched four new DURACON^® POM grades featuring 30% post-consumer recycled (PCR) content. Unveiled at CHINAPLAS 2026, the lineup includes Standard, Low VOC, Sliding, and Tough options. Leveraging advanced compounding expertise, Daicel maintains quality and mechanical performance comparable to standard virgin resin grades for demanding global industrial and automotive components.
Learn more.

Renishaw unveils revolutionary LIBERTAS™ 3DP tech

Renishaw's new LIBERTAS software technology addresses two of the most persistent challenges in metal AM: poor downskin surface finish and the need for support structures. Users have greater freedom to manufacture complex geometries.
Read the full article.

Innovate like a PRO: Protolabs' new AI-enabled manufacturing platform

ProDesk by Protolabs accelerates innovation for product development and procurement teams. It features real-time, AI-powered quoting with design for manufacturability (DFM) analysis across injection molding, CNC machining, and 3D printing. The platform enables seamless team collaboration and customizes quotes with instant feedback on materials, lead times, secondary operations, and finishes prior to production.
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.

How Autodesk Research uses Markforged 3D printing

In advanced R&D, "good enough" doesn't cut it. To pioneer its Performance-Aided Design (PAD) workflow, Autodesk Research partnered with Markforged to close the gap between digital simulation and reality. Using sensors and digital twins, PAD replaces delayed field reports with real-time feedback. To test this high-stakes system, Autodesk built massive UAV platforms -- including a 300-lb aircraft. Facing extreme dynamic loads and weather, these drones provide the ultimate torture test for rapid design iteration.
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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.

Radio Flyer cuts ebike prototype time radically with Fuse X1 large-format SLS 3D printer

Radio Flyer cut prototype lead times for its Flyer Loop cargo ebike frame from two months to two days using Formlabs' new Fuse X1 SLS large-format 3D printer. "We can now print an entire Flyer Loop cargo ebike overnight and be gluing it together the next day," said Agostino LoBello, product development engineer at Radio Flyer. "I can iterate three times as often with nine times less labor." The Fuse X1 delivers production-quality parts with 50% lower costs and triple the throughput of comparable industrial systems, featuring automated powder handling and a compact, easy-to-install design. [Credit: Image courtesy of Formlabs]
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Compact industrial sand 3D printer

ExOne has launched the S-Print Pro, a compact industrial sand 3D printer that brings production-grade binder jetting to smaller foundries, pattern shops, and print service providers. Aimed at businesses competing on cost and flexibility, it handles low-volume casting, spare parts, and custom components. The system processes furan binder with silica sand, CeraBeads, or silicon carbide.
Learn more about this capable machine.

Engineer's Toolbox: How to pin a shaft and hub assembly properly

One of the primary benefits of using a coiled spring pin to affix a hub or gear to a shaft is the coiled pin's ability to prevent hole damage. Another is the coiled pin absorbs wider hole tolerances than any other press-fit pin. This translates to lower total manufacturing costs of the assembly. However, there are a few design guidelines that must be adhered to in order to achieve the maximum strength of the pinned system and prevent damage to the assembly.
Read this very informative SPIROL article.

Get reliable labeling done right

Videojet Technologies has released the Videojet 9310 label applicator, designed to simplify everyday labeling on rigid and flexible packaging. Using Intelligent Motion technology, it digitally controls label tension and alignment to ensure consistent placement with minimal manual adjustments. The system features a simple label path, an intuitive touchscreen, and flexible mounting options to reduce downtime and keep production moving.
Learn more.

Your phone is now your smartest hydraulic tool

Commissioning a proportional valve traditionally requires cables, laptops, and complex software. The new Bosch Rexroth 4WRAE valve changes that. Featuring integrated digital electronics and Bluetooth connectivity, it pairs with the "easy2connect" app. Technicians can now visualize performance, adjust settings, diagnose errors, and force solenoids directly from their phones, simplifying setup for IO-Link or analog systems.
Learn more.

3,000 mpg? Freudenberg-NOK Sealing Technologies helps U-of-M Supermileage team push for ultimate fuel efficiency

Sitting off a main road that runs through the University of Michigan's (U of M) North Campus in Ann Arbor is a large industrial garage with an impossibly bright roof. On a recent windy afternoon, four engineering students sit in one of the building's mechanical bays staring at a car.

The car is a virtual pod, a one-occupant carbon fiber shell balanced on three wheels. It has just enough room for a small driver, small engine, and somewhat touchy steering system. The students, members of U of M's Supermileage Team, acknowledge that their next vehicle will brag improvements, including better steering.

But steering may be secondary because the real challenge these students face is how to squeeze more than 3,000 miles from a single gallon of fuel. The team is one of the newest participating in the SAE International's Supermileage competition. As one of its primary sponsors, FNST is offering the financial and professional resources needed to cross the finish line.

Freudenberg-NOK Sealing Technologies is sponsoring the U of M Supermileage Team. From left: Andy Dun (blue tee), junior, mech. eng.; David Coons, junior, mech. eng.; Rory Pawl, dir., FNST Future Technology; Mike Rowe, FNST strategic product development manager, Technology; Karan Jain, junior, mech. eng.; and John Rockwell, junior, mech. eng. [Photo: 2013 TIF Photographic LLC, Edward Llewellyn Ochal.]

 

 

 

 

"We regularly collaborate with industry partners to develop technologies that address issues like fuel economy and powertrain efficiency," says Dr. Luis Lorenzo, vice president, Advanced Product Engineering, FNST. "Our partnership with U of M's Supermileage Team allows us to build communications and collaboration with the next generation of engineers. It's a fundamental part of our approach to leadership and future growth."

FNST's sponsorship is also fundamental to the U of M team. Not only will the students benefit from professional assistance provided by Mike Rowe, FNST strategic product development manager, Technology, and Rory Pawl, FNST director, Future Technology, they will also tap into some of company's most advanced component technologies.

Among the FNST products that Rowe has identified for use on the Supermileage Team's new car are ultra-low friction crankshaft seals; self-fusing silicone tape for electrical connections, cable management, and emergency repairs; new body seals; low-friction valve stem seals; and even bearing grease and mold release agents from Freudenberg sister companies Kluber Lubrication and Chem-Trend.

"This program is a great fit with the kinds of research and development activities our company is pursuing," Rowe says. "We regularly seek breakthroughs in fuel economy technology. This program will allow us to tap into innovations and frankly, is going to be a lot of fun."

"We're new to engineering, and working with a top-notch company like Freudenberg is extremely helpful in clarifying our ideas and discussing technologies," says David Coons, a mechanical engineering student and the team's chief engineer. "When we're not sure how to do something, they fill in the gaps and offer us advice and guidance."

Going for 3,000 mpg: U of M mechanical engineering students (from left) John Rockwell, Karan Jain, Andy Dun, and David Coons. [Photo: 2013 TIF Photographic LLC, Edward Llewellyn Ochal]

 

 

 

 

The SAE International Supermileage competition requires university engineering and technology students to develop and construct a single-person, fuel-efficient vehicle powered by a four-cycle engine. Vehicles run a specified course, and the vehicle that obtains the highest miles-per-gallon rating, in combination with design points, wins the challenge. All of the vehicles are powered by a one-cylinder, Briggs & Stratton engine that the teams uniquely modify to push efficiency and fuel savings.

More than 24 collegiate teams will participate in this year's race taking place in Marshall, MI, in June. The 2012 winner was Penn State University, Behrend College Pennsylvania, with a winning entry that logged the equivalent of 1,485 mpg. For more information about the race, click here.

The U-of-M team will test drive its 2013 car in April in the Shell Eco Marathon in Houston as a prelude to the SAE International Supermileage event. With a best run of 2,188.6 mpg equivalency, the team from Mater Dei High School in Evansville, IN, won the first-place prize in the Shell Eco Marathon last year in Houston.

For their part, Coons and his teammates admit that their car will not be a blueprint for America's next family sedan. But the experience of pushing boundaries to achieve something they thought was impossible will remain with them throughout their lives, Coons says.

Source: Freudenberg-NOK Sealing Technologies

Published February 2013

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