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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.

Graphene is strong, but is it tough? Researches find weakness in one form of the material

Graphene, a material consisting of a single layer of carbon atoms, has been touted as the strongest material known to exist, 200 times stronger than steel, lighter than paper, and with extraordinary mechanical and electrical properties. But can it live up to its promise?

Scientists at the U.S. Department of Energy's Lawrence Berkeley National Laboratory (Berkeley Lab) have developed the first known statistical theory for the toughness of polycrystalline graphene, which is made with chemical vapor deposition, and found that it is indeed strong (albeit not quite as strong as pristine monocrystalline graphene), but more importantly, its toughness -- or resistance to fracture -- is quite low. Their study, "Toughness and strength of nanocyrstalline graphene," was published recently in Nature Communications.

Polycrystalline graphene contains inherent nanoscale line and point defects that lead to significant statistical fluctuations in toughness and strength. [Credit: Berkeley Lab]

 

 

 

 

Ritchie, a senior scientist in the Materials Sciences Division of Berkeley Lab and a leading expert on why materials fail, was co-author of the study along with Ashivni Shekhawat, a Miller Research Fellow in his group. Together they developed a statistical model for the toughness of polycrystalline graphene to better understand and predict failure in the material.

"It's a mathematical model that takes into account the nanostructure of the material," Ritchie said. "We find that the strength varies with the grain size up to a certain extent, but most importantly this is a model that defines graphene's fracture resistance."

Toughness, a material's resistance to fracture, and strength, a material's resistance to deformation, are often mutually incompatible properties. "A structural material has to have toughness," Ritchie explained. "We simply don't use strong materials in critical structures -- we try to use tough materials. When you look at such a structure, like a nuclear reactor pressure vessel, it's made of a relatively low-strength steel, not an ultrahigh-strength steel. The hardest steels are used to make tools like a hammer head, but you'd never use them to manufacture a critical structure because of the fear of catastrophic fracture."

As the authors note in their paper, many of the leading-edge applications for which graphene has been suggested -- such as flexible electronic displays, corrosion-resistant coatings, and biological devices -- implicitly depend on its mechanical properties for structural reliability.

Although pure monocrystalline graphene may have fewer defects, the authors studied polycrystalline graphene as it is more inexpensively and commonly synthesized with chemical vapor deposition. Ritchie is aware of only one experimental measurement of the material's toughness.

"Our numbers were consistent with that one experimental number," he said. "In practical terms, these results mean that a soccer ball can be placed on a single sheet of monocrystalline graphene without breaking it. What object can be supported by a corresponding sheet of polycrystalline graphene? It turns out that a soccer ball is much too heavy, and polycrystalline graphene can support only a ping pong ball. Still remarkable for a one-atom thick material, but not quite as breathtaking anymore."

Next, Shekhawat and Ritchie are studying the effects of adding hydrogen to the material. "We don't know a lot about the fracture of graphene, so we're trying to see if it's sensitive to other atoms," he said. "We're finding the cracks grow more readily in the presence of hydrogen."

The research was funded by the DOE Office of Science.

Source: Lawrence Berkeley National Laboratory

Published February 2016

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