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Siemens Meet at the Machine: Be productive from day one of new CNC machine delivery

Traditionally, many programming, validation, and training activities begin only after a machine is installed. Not anymore. Meet at the Machine is Siemens' new initiative uniting machine builders, software, and automation for next-level CNC through a continuous digital thread across engineering, programming, virtual validation, and execution. By pairing a Digital Twin with Digital CNC powered by SINUMERIK, manufacturers can prepare, validate, train, and optimize workflows before your specialized machine's physical delivery! TRAK Machine Tools is the launch partner -- see what they are doing.
Learn more.

How to master metal powder management in 3D printing

What's the real cost of "good enough" powder tracking for powder-bed fusion 3D-printing machines? According to Tim Wischeropp, CEO and Co-Founder of amsight, the technology is rife with hidden costs. Every cycle, every handling step, every exposure, and every mixing decision plays a part. Surprisingly, though, with the right strategy, users can turn their losses into a competitive edge. Learn how.
Read the full article.

Aluminum oxide filament for FDM printers

Virtual Foundry, the company that brought us 3D-printable lunar regolith simulant, has a new product called Aluminum Oxide Filamet™, giving users the power to print alumina parts using the FDM printers they already own. This composite 3D-printing material allows researchers, engineers, and makers to bypass expensive ceramic tooling and produce pure ceramic components in-house. Print using a 0.6-mm hardened-steel, standard-flow nozzle on virtually any open-architecture printer.
Get all the material specs.

New metal extrusion retrofit system helps manufacturers get into ShAPE

A new invention from the Department of Energy's Pacific Northwest National Laboratory could soon help manufacturers more easily adopt the lab's patented Shear Assisted Processing and Extrusion (ShAPE™) technology, enabling faster manufacturing of superior extrusion products while reducing costs and energy use.
Read the full article.

Pneumatics: Dual guide rod cylinders and exhaust silencers

Automation-Direct has expanded its guided actuator lineup with compact 12-mm dual guide rod cylinders from Metal Work. Ideal for packaging and material handling, these double-acting cylinders feature 10-mm to 250-mm strokes, magnetic pistons, and integral sensor slots. Additionally, new durable acetal plastic silencers are now available in multiple NPT/BSPP sizes to reduce pneumatic exhaust noise.
Learn more.

Expanded injection molding capabilities

Pexco LLC has acquired Recto Molded Products and Legacy Extrusions, expanding its capabilities in complex injection molding, tooling, assembly, and engineered thermoplastic solutions for OEM manufacturers. The Cincinnati-based companies bring more than a century of manufacturing expertise, advanced production technologies, and value-added services that strengthen Pexco's ability to support customers from product design through full-scale production. Injection molding presses ranging from 55 to 500 tons.
Learn about Pexco and its value-added manufacturing services.

Custom 3D-printed steering wheel for jet dragster

Jet dragsters use General Electric J85 engines -- the same turbines pulled from U.S. military F5 Freedom Fighters -- mounted to a custom 26-ft chassis. The racers achieve quarter-miles in 5.5 sec, but standard metal parts can fail custom ergonomic needs. Traditional manufacturing of low-volume aluminum steering wheels demands long, 8-day lead times, high costs, and multi-piece assemblies. Larsen Motorsports solved this by replacing metal with continuous fiber 3D printing using the Markforged X7. Embedding continuous carbon fiber into an Onyx nylon matrix allowed them to target specific load paths, delivering a custom steering wheel that is stiffer, lighter, and faster to produce than aluminum.
View the video.

Application Spotlight: Light-duty ring in an air vent nozzle

Explore how a light-duty Spirolox^® retaining ring is used in an airplane air vent nozzle to regulate airflow. This application spotlight shows how the ring fits into a groove in the plastic housing, securing the nozzle during rotation. Designed for light loads and axial positioning, it offers a simple, economical solution that is easy to install and remove.
View this informative Smalley video.

Fasteners for automotive and agricultural equipment

Norm Fasteners has acquired an automotive fastener manufacturing plant in Plymouth, MI, expanding its North American footprint beyond sales, engineering, and logistics. The local facility produces metric fasteners (M4-M24) and engine bolts. Norm’s portfolio includes wheel bolts, studs, custom fasteners, and licensed MAThread^® and TAPTITE^® products, serving diverse automotive and industrial assembly needs.
Learn more or contact Belgin Tunce for more information.

3M Cooling Film for vehicle roofs launched

New 3M Cooling Film is a roof-applied heat-management solution designed to help keep vehicle cabins cooler, reduce cooling demand, and improve operational efficiency. The aftermarket product uses advanced thermal management technology to reflect more than 85% of solar radiation. Interior vehicle temperatures can be reduced by up to 10 degrees F with this product. Installs like graphics by professional installers using 3M adhesive technologies. Initially designed for fleet and rail operators.
Learn more.

Test your knowledge: High-temp adhesives

Put your knowledge to the test by trying to answer these key questions on how to choose the right high-temperature-resistant adhesive. The technical experts from Master Bond cover critical information necessary for the selection process, including questions on glass transition temperature and service temperature range. Some of the answers may surprise even the savviest of engineers.
Take the quiz.

New Air Holster Safety Air Gun Mount

EXAIR's new Model 5930 Air Holster provides a simple and convenient way to keep Safety Air Guns secure and within easy reach at workstations throughout a facility. Designed to give operators a designated location for their air gun when not in use, the Air Holster helps prevent misplaced tools while keeping work areas organized and efficient. Its practical design makes it an ideal addition to manufacturing, assembly, maintenance, and other industrial workstations where Safety Air Guns are frequently used.
Learn more.

Southco access hardware in rail applications

Discover how Southco's rail access hardware solutions help improve safety, reliability, and operational efficiency across modern rail networks. The video showcases a range of rail applications where Southco's access hardware plays a critical role, including driver cabins, lighting systems, tray tables, headrests, armrests, and other passenger and operator touchpoints. Designed to support dependable performance in demanding moving environments, Southco's solutions help operators streamline maintenance processes, minimize downtime, and enable more proactive asset management.
View the video.

Multi-zone tension leveler for hard-to-flatten alloys

Redex USA's Levelflex^® is a modular, multi-zone tension leveler engineered for continuous processing lines, including coating and heat treatment of aluminum alloys and where flatness is critical to coating adhesion and downstream formability. By stretching material within 95% of its yield strength, it corrects stubborn flatness defects in fewer passes. It comes in open-loop pure stretch or closed-loop tension measurement modes to optimize surface integrity and eliminate crossbow.
Learn more.

Hold any shape with ID and OD Form Holding Clamps

These simple OD and ID clamping solutions from Fixtureworks clamp onto your part in one easy operation, eliminating the need for custom fixtures. They allow users to clamp onto the inner or outer diameter of small-size, irregularly shaped work parts fast. Lots of options.
Learn more.

Researchers look to bones and shells as blueprints for stronger, more durable concrete

By Jennifer Chu, MIT

Researchers at MIT are seeking to redesign concrete -- the most widely used human-made material in the world -- by following nature's blueprints.

In a paper published online in the journal Construction and Building Materials, the team contrasts cement paste -- concrete's binding ingredient -- with the structure and properties of natural materials such as bones, shells, and deep-sea sponges. As the researchers observed, these biological materials are exceptionally strong and durable, thanks in part to their precise assembly of structures at multiple-length scales, from the molecular to the macro, or visible, level.

"If we can replace cement, partially or totally, with some other materials that may be readily and amply available in nature, we can meet our objectives for sustainability," MIT Professor Oral Buyukozturk says. [Image: Christine Daniloff/MIT]

 

 

 

 

From their observations, the team, led by Oral Buyukozturk, a professor in MIT's Department of Civil and Environmental Engineering (CEE), proposed a new bioinspired, "bottom-up" approach for designing cement paste.

"These materials are assembled in a fascinating fashion, with simple constituents arranging in complex geometric configurations that are beautiful to observe," Buyukozturk says. "We want to see what kinds of micromechanisms exist within them that provide such superior properties, and how we can adopt a similar building-block-based approach for concrete."

Ultimately, the team hopes to identify materials in nature that may be used as sustainable and longer-lasting alternatives to Portland cement, which requires a huge amount of energy to manufacture.

"If we can replace cement, partially or totally, with some other materials that may be readily and amply available in nature, we can meet our objectives for sustainability," Buyukozturk says.

Co-authors on the paper include lead author and graduate student Steven Palkovic, graduate student Dieter Brommer, research scientist Kunal Kupwade-Patil, CEE assistant professor Admir Masic, and CEE department head Markus Buehler, the McAfee Professor of Engineering.

"The merger of theory, computation, new synthesis, and characterization methods have enabled a paradigm shift that will likely change the way we produce this ubiquitous material, forever," Buehler says. "It could lead to more durable roads, bridges, and structures; reduce the carbon and energy footprint; and even enable us to sequester carbon dioxide as the material is made. Implementing nanotechnology in concrete is one powerful example [of how] to scale up the power of nanoscience to solve grand engineering challenges."

From molecules to bridges
Today's concrete is a random assemblage of crushed rocks and stones, bound together by a cement paste. Concrete's strength and durability depend partly on its internal structure and configuration of pores. For example, the more porous the material, the more vulnerable it is to cracking. However, there are no techniques available to precisely control concrete's internal structure and overall properties.

"It's mostly guesswork," Buyukozturk says. "We want to change the culture and start controlling the material at the mesoscale."

As Buyukozturk describes it, the "mesoscale" represents the connection between microscale structures and macroscale properties. For instance, how does cement's microscopic arrangement affect the overall strength and durability of a tall building or a long bridge? Understanding this connection would help engineers identify features at various-length scales that would improve concrete's overall performance.

"We're dealing with molecules on the one hand, and building a structure that's on the order of kilometers in length on the other," Buyukozturk says. "How do we connect the information we develop at the very small scale, to the information at the large scale? This is the riddle."

Building from the bottom, up
To start to understand this connection, he and his colleagues looked to biological materials such as bone, deep sea sponges, and nacre (an inner shell layer of mollusks), which have all been studied extensively for their mechanical and microscopic properties. They looked through the scientific literature for information on each biomaterial, and compared their structures and behavior, at the nano-, micro-, and macroscales, with that of cement paste.

A comparison of natural materials and cement paste demonstrates the steps by which smaller pieces assemble to form larger structures. [Image courtesy of the researchers]

 

 

 

 

They looked for connections between a material's structure and its mechanical properties. For instance, the researchers found that a deep sea sponge's onion-like structure of silica layers provides a mechanism for preventing cracks. Nacre has a "brick-and-mortar" arrangement of minerals that generates a strong bond between the mineral layers, making the material extremely tough.

"In this context, there is a wide range of multiscale characterization and computational modeling techniques that are well established for studying the complexities of biological and biomimetic materials, which can be easily translated into the cement community," says Masic.

Applying the information they learned from investigating biological materials, as well as knowledge they gathered on existing cement paste design tools, the team developed a general, bioinspired framework, or methodology, for engineers to design cement, "from the bottom up."

The framework is essentially a set of guidelines that engineers can follow, in order to determine how certain additives or ingredients of interest will impact cement's overall strength and durability. For instance, in a related line of research, Buyukozturk is looking into volcanic ash as a cement additive or substitute. To see whether volcanic ash would improve cement paste's properties, engineers, following the group's framework, would first use existing experimental techniques, such as nuclear magnetic resonance, scanning electron microscopy, and X-ray diffraction to characterize volcanic ash's solid and pore configurations over time.

Researchers could then plug these measurements into models that simulate concrete's long-term evolution, to identify mesoscale relationships between, say, the properties of volcanic ash and the material's contribution to the strength and durability of an ash-containing concrete bridge. These simulations can then be validated with conventional compression and nanoindentation experiments to test actual samples of volcanic ash-based concrete.

Ultimately, the researchers hope the framework will help engineers identify ingredients that are structured and evolve in a way, similar to biomaterials, that may improve concrete's performance and longevity.

"Hopefully this will lead us to some sort of recipe for more sustainable concrete," Buyukozturk says. "Typically, buildings and bridges are given a certain design life. Can we extend that design life maybe twice or three times? That's what we aim for. Our framework puts it all on paper, in a very concrete way, for engineers to use."

This research was supported in part by the Kuwait Foundation for the Advancement of Sciences through the Kuwait-MIT Center for Natural Resources and the Environment, the National Institute of Standards and Technology, and Argonne National Laboratory.

Published June 2016

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