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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]
View the video.

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.

A new take on indexing plungers

JW Winco has expanded its extensive standard parts range with the GN 823 indexing plunger. Featuring an intuitive operating lever, it allows easy activation with a single finger, even when wearing gloves or out of sight. Available in screw-on or weldable stainless steel variants, this robust component suits both delicate installations and heavy-duty industrial applications. Available in two installation options: screw fastening or welding.
Learn more.

Fast-cure composite for aero and defense manufacturing

Toray Composite Materials America has launched 3960-FC, a fast-cure variant of its high-performance 3960 prepreg system for mission-critical aerospace and defense applications. This material reduces cure time by up to 45% while maintaining proven mechanical performance, stiffness, and exceptional toughness. It is highly compatible with automated manufacturing technologies like AFP and ATL, as well as traditional processing methods.
Learn more.

Best high-speed rotary bearing in THK history

THK's High-Speed, Double-Row Angular Contact Ring BWH is the fastest rotary bearing in company history. By utilizing balls inside a cage instead of rollers, this new structure achieves unprecedented speeds. It supports loads from all directions while matching the high rigidity and rotational accuracy of standard cross-roller ring design options.
Learn more.

100,000 hours: KNF diaphragm pump achieves exceptional lifetime

Reaching 100,000 hours of uninterrupted performance is a remarkable achievement for micro diaphragm gas pumps. It represents more than 11 years of continuous operation in a controlled environment, exceeding the demands of most real-world applications. This milestone highlights KNF's engineering expertise and the reliability built into every pump.
Get a closer look at the 100,000-hour lifetime test.

Metal finishing: With rising carbide prices, when cermet makes sense

As critical raw material access tightens, manufacturers are rethinking cutting tool usage. While essential, carbide is often unnecessary for finishing processes. Cermet -- a ceramic-metal composite -- offers an excellent alternative, delivering exceptional fracture and wear resistance for these specific machining stages.
Read the full article.

Crossed roller bearings for complex loads

Designed with a large contact area where the rollers meet the raceway surfaces, crossed roller bearings (CRBs) from IKO exhibit exceptional rotational accuracy with less deflection under load. Many mechanical designs can benefit from the rigidity, accuracy, speed, and compact size that IKO CRBs provide, and they come in a wide choice of sizes and constructions to fit various rotating mechanisms. Machine tools, industrial robots, and medical equipment are only a few of many applications.
See all your options, including slim and super slim models, from IKO.

Full-color 3D-printing Design Guide from Xometry

With Xometry's PolyJet 3D-printing service, you can order full-color 3D prints easily. Their no-cost design guide will help you learn about different aspects of 3D printing colorful parts, how to create and add color to your models, and best practices to keep in mind when printing in full color. Learn how to take full advantage of the 600,000 unique colors available in this flexible additive process.
Get the Xometry guide.

What's new in hyperMILL 2026?

OPEN MIND Technologies has announced a wide range of new and enhanced capabilities in its hyperMILL 2026 CAD/CAM Software Suite that save time and increase accuracy. For precise and efficient 2.5D, 3D, precision 5-axis, and mill/turn machining, hyperMILL offers users exceptionally productive programming and powerful machining strategies. Check out all the new features.
Learn more.

Solar energy update: New system aims to harness the full spectrum of available solar radiation

By David Chandler, MIT News Office

The key to creating a material that would be ideal for converting solar energy to heat is tuning the material's spectrum of absorption just right: It should absorb virtually all wavelengths of light that reach Earth's surface from the sun -- but not much of the rest of the spectrum, since that would increase the energy that is reradiated by the material, and thus lost to the conversion process.

Now researchers at MIT say they have accomplished the development of a material that comes very close to the "ideal" for solar absorption. The material is a two-dimensional metallic dielectric photonic crystal, and has the additional benefits of absorbing sunlight from a wide range of angles and withstanding extremely high temperatures. Perhaps most importantly, the material can also be made cheaply at large scales.

The creation of this material is described in a paper appearing this week in the journal Advanced Materials, co-authored by MIT postdoc Jeffrey Chou, professors Marin Soljacic, Nicholas Fang, Evelyn Wang, and Sang-Gook Kim, and five others.

The material works as part of a solar-thermophotovoltaic (STPV) device: The sunlight's energy is first converted to heat, which then causes the material to glow, emitting light that can, in turn, be converted to an electric current.

Some members of the team worked on an earlier STPV device that took the form of hollow cavities, explains Chou, of MIT's Department of Mechanical Engineering, who is the paper's lead author. "They were empty, there was air inside," he says. "No one had tried putting a dielectric material inside, so we tried that and saw some interesting properties."

When harnessing solar energy, "you want to trap it and keep it there," Chou says; getting just the right spectrum of both absorption and emission is essential to efficient STPV performance.

This rendering shows the metallic dielectric photonic crystal that stores solar energy as heat. [Image: Jeffrey Chou]

 

 

Most of the sun's energy reaches us within a specific band of wavelengths, Chou explains, ranging from the ultraviolet through visible light and into the near-infrared. "It's a very specific window that you want to absorb in," he says. "We built this structure and found that it had a very good absorption spectrum, just what we wanted."

In addition, the absorption characteristics can be controlled with great precision: The material is made from a collection of nanocavities, and "you can tune the absorption just by changing the size of the nanocavities," Chou says.

Another key characteristic of the new material, Chou says, is that it is well matched to existing manufacturing technology. "This is the first-ever device of this kind that can be fabricated with a method based on current ... techniques, which means it's able to be manufactured on silicon wafer scales," Chou says -- up to 12 inches on a side. Earlier lab demonstrations of similar systems could only produce devices a few centimeters on a side with expensive metal substrates, so were not suitable for scaling up to commercial production, he says.

In order to take maximum advantage of systems that concentrate sunlight using mirrors, the material must be capable of surviving unscathed under very high temperatures, Chou says. The new material has already demonstrated that it can endure a temperature of 1,000 C (1,832 F) for a period of 24 hours without severe degradation.

And since the new material can absorb sunlight efficiently from a wide range of angles, Chou says, "we don't really need solar trackers" -- which would add greatly to the complexity and expense of a solar power system.

"This is the first device that is able to do all these things at the same time," Chou says. "It has all these ideal properties."

While the team has demonstrated working devices using a formulation that includes a relatively expensive metal, ruthenium, "we're very flexible about materials," Chou says. "In theory, you could use any metal that can survive these high temperatures."

The group is now working to optimize the system with alternative metals. Chou expects the system could be developed into a commercially viable product within five years. He is working with Kim on applications from this project.

The team also included MIT research scientist Ivan Celanovic and former graduate students Yi Yeng, Yoonkyung Lee, Andrej Lenert, and Veronika Rinnerbauer. The work was supported by the Solid-State Solar Thermal Energy Conversion Center and the U.S. Department of Energy.

Published October 2014

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