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hyperMILL 2024 CAD/CAM software suite

OPEN MIND Technologies has introduced its latest hyperMILL 2024 CAD/CAM software suite, which includes a range of powerful enhancements to its core toolpath capabilities, as well as new functionality for increased NC programming efficiency in applications ranging from 2.5D machining to 5-axis milling. New and enhanced capabilities include: Optimized Deep Hole Drilling, a new algorithm for 3- and 5-axis Rest Machining, an enhanced path layout for the 3D Plane Machining cycle, better error detection, and much more.
Learn more.

One-part epoxy changes from red to clear under UV

Master Bond UV15RCL is a low-viscosity, cationic-type UV-curing system with a special color-changing feature. The red material changes to clear once exposed to UV light, indicating that there is UV light access across the adhesive material. Although this change in color from red to clear does not indicate a full cure, it does confirm that the UV light has reached the polymer. This epoxy is an excellent electrical insulator. UV15RCL adheres well to metals, glass, ceramics, and many plastics, including acrylics and polycarbonates.
Learn more.

SPIROL Press-N-Lok™ Pin for plastic housings

The Press-N-Lok™ Pin was designed to permanently retain two plastic components to each other. As the pin is inserted, the plastic backfills into the area around the two opposing barbs, resulting in maximum retention. Assembly time is quicker, and it requires lower assembly equipment costs compared to screws and adhesives -- just Press-N-Lok™!
Learn more about the new Press-N-Lok™ Pin.

Why hybrid bearings are becoming the new industry standard

A combination of steel outer and inner rings with ceramic balls or rollers is giving hybrid bearings unique properties, making them suitable for use in a wide range of modern applications. SKF hybrid bearings make use of silicon nitride (twice as hard as bearing steel) rolling elements and are available as ball bearings, cylindrical roller bearings, and in custom designs. From electric erosion prevention to friction reduction and extended maintenance intervals, learn all about next-gen hybrid bearings.
Read the SKF technical article.

3M and Ansys train engineers on simulating adhesives

Ansys and 3M have created an advanced simulation training program enabling engineers to enhance the design and sustainability of their products when using tapes and adhesives as part of the design. Simulation enables engineers to validate engineering decisions when analyzing advanced polymeric materials -- especially when bonding components made of different materials. Understand the behavior of adhesives under real-world conditions for accurate modeling and design.
Read this informative Ansys blog.

New FATH T-slotted rail components in black from AutomationDirect

Automation-Direct has added a wide assortment of black-colored FATH T-slotted hardware components to match their SureFrame black anodized T-slotted rails, including: cube connectors (2D and 3D) and angle connectors, joining plates of many types, brackets, and pivot joints. Also included are foot consoles, linear bearings in silver and black, cam lever brakes, and L-handle brakes. FATH T-slotted hardware components are easy to install, allow for numerous T-slotted structure configurations, and have a 1-year warranty against defects.
Learn more.

Weird stuff: Moon dust simulant for 3D printing

Crafted from a lunar regolith simulant, Basalt Moon Dust Filamet™ (not a typo) available from The Virtual Foundry closely mirrors the makeup of lunar regolith found in mare regions of the Moon. It enables users with standard fused filament fabrication (FFF) 3D printers to print with unparalleled realism. Try out your ideas before you go for that big space contract, or help your kid get an A on that special science project.
Learn more.

Break the mold with custom injection molding by Rogan

With 90 years of industry experience, Rogan Corporation possesses the expertise to deliver custom injection molding solutions that set businesses apart. As a low-cost, high-volume solution, injection molding is the most widely used plastics manufacturing process. Rogan processes include single-shot, two-shot, overmolding, and assembly. Elevate your parts with secondary operations: drilling and tapping, hot stamping, special finishes, punch press, gluing, painting, and more.
Learn more.

World's first current-carrying fastening technology

PEM^® eConnect™ current-carrying pins from Penn-Engineering provide superior electrical connections in applications that demand high performance from internal components, such as automotive electronics. This first-to-market tech provides repeatable, consistent electrical joints and superior installation unmatched by traditional fastening methods. Features include quick and secure automated installation, no hot spots or poor conductivity, and captivation options that include self-clinching and broaching styles.
Learn more about eConnect pins.

New interactive digital catalog from EXAIR

EXAIR's latest catalog offers readers an incredible source of innovative solutions for common industrial problems like conveying, cooling, cleaning, blowoff, drying, coating, and static buildup. This fully digital and interactive version of Catalog 35 is designed for easy browsing and added accessibility. Customers can view, download, print, and save either the full catalog or specific pages and sections. EXAIR products are designed to conserve compressed air and increase personnel safety in the process. Loaded with useful information.
Check out EXAIR's online catalog.

5 cost-saving design tips for CNC machining

Make sure your parts meet expectations the first time around. Xometry's director of application engineering, Greg Paulsen, presents five expert tips for cutting costs when designing custom CNC machined parts. This video covers corners and radii, designing for deep pockets, thread depths, thin walls, and more. Always excellent info from Paulsen at Xometry.
View the video.

What can you secure with a retaining ring? 20 examples

From the watch dial on your wrist to a wind turbine, no application is too small or too big for a Smalley retaining ring to secure. Light to heavy-duty loads? Carbon steel to exotic materials? No problem. See how retaining rings are used in slip clutches, bike locks, hip replacements, and even the Louvre Pyramid.
See the Smalley design applications.

Load fasteners with integrated RFID

A crane, rope, or chain may be required when something needs lifting -- plus anchoring points on the load. JW Winco offers a wide range of solutions to fasten the load securely, including: lifting eye bolts and rings (with or without rotation), eye rings with ball bearings, threaded lifting pins, shackles, lifting points for welding, and more. Some, such as the GN 581 Safety Swivel Lifting Eye Bolts, even have integrated RFID tags to clearly identify specific lifting points during wear and safety inspections and manage them digitally and without system interruption.
Learn more.

Couplings solve misalignments more precisely with targeted center designs

ALS Couplings from Miki Pulley feature a simplistic, three-piece construction and are available in three different types for more precisely handling parallel, angular, or axial misalignment applications. The key feature of this coupling design is its center element. Each of the three models has a center member that has a unique and durable material and shape. Also called a "spider," the center is designed to address and resolve the type of misalignment targeted. Ideal for unidirectional continuous movement or rapid bidirectional motion.
Learn more.

What is 3D-MID? Molded parts with integrated electronics from HARTING

3D-MID (three-dimensional mechatronic integrated devices) technology combines electronic and mechanical functionalities into a single, 3D component. It replaces the traditional printed circuit board and opens up many new opportunities. It takes injection-molded parts and uses laser-direct structuring to etch areas of conductor structures, which are filled with a copper plating process to create very precise electronic circuits. HARTING, the technology's developer, says it's "Like a PCB, but 3D." Tons of possibilities.
View the video.

Can hydrogen paste power motorcycles and scooters?

POWERPASTE is a new, experimental hydrogen fuel source developed at the Fraunhofer Institute. [Credit: ©Fraunhofer IFAM]

 

 

High-pressure hydrogen fuel tanks are not a viable alternative-fuel option for motorcycles and scooters, but researchers in Germany have another plan: POWERPASTE. This material -- which sports a huge energy density -- stores hydrogen in a chemical form at atmospheric pressure and is activated simply by adding water.

The formulation of the new paste is based on magnesium hydride and was developed by a research team at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials in Germany. Among the materials' many positive qualities is that it is easy to transport and replenish without the need for an expensive network of filling stations.

Gasoline and diesel engines powered by fossil fuels are being replaced by new propulsion systems. One fuel with big potential is hydrogen. Hydrogen vehicles are equipped with a reinforced tank that is fueled at a pressure of 700 bar. This tank feeds a fuel cell, which converts the hydrogen into electricity. This, in turn, drives an electric motor that propels the vehicle. The end products are heat and water.

In the case of passenger cars, this technology is well advanced, with several hundred hydrogen-powered automobiles already in operation on roads throughout the world. At the same time, the network of hydrogen stations is also growing -- albeit very slowly. In Germany, for example, the network is projected to grow from 100 to 400 stations over the next three years.

However, hydrogen is not currently an option for small vehicles such as electric scooters and motorcycles, since the pressure surge during refilling would be too great. Researchers at the Fraunhofer Institute wondered if the current designs for storage effectively shut out such vehicles from hydrogen technology. Could there be another way?

TRL 5 demonstrator of a power generator with a POWERPASTE cartridge and a 100-W PEM fuel cell. [Credit: ©Fraunhofer IFAM]

 

 

This was the inspiration to create POWERPASTE, which "stores hydrogen in a chemical form at room temperature and atmospheric pressure to be then released on demand," said Dr. Marcus Vogt, research associate at Fraunhofer IFAM.

Since POWERPASTE only begins to degrade at temperatures of around 250 C, it remains safe even when an e-scooter stands in the baking sun for hours. Moreover, refueling is extremely simple. Instead of heading to the filling station, riders just replace an empty cartridge with a new one and then refill a system partner tank with regular water.

The starting material for POWERPASTE is magnesium, a readily available raw material. Magnesium powder is combined with hydrogen to form magnesium hydride in a process conducted at 350 C and five to six times atmospheric pressure. An ester and a metal salt are then added in order to form the finished product.

Installed on a vehicle, the cartridge releases the POWERPASTE by means of a plunger. When water is added from an onboard tank, the ensuing reaction generates hydrogen gas in a quantity dynamically adjusted to the actual requirements of the fuel cell. Interestingly, only half of the hydrogen originates from the POWERPASTE; the rest comes from the added water.

"POWERPASTE has a huge energy storage density," said Vogt. "It is substantially higher than that of a 700-bar high-pressure tank, and compared to batteries, it has 10 times the energy storage density." This means that POWERPASTE offers a range comparable to -- or even greater than -- gasoline. It also provides a higher range than compressed hydrogen at a pressure of 700 bar.

What can this weird material power?
With its huge energy storage density, the developers think POWERPASTE is also an interesting option for some specialty cars, delivery vehicles, and even as range extenders in battery-powered electric vehicles (although that last option sounds clunky). It could also significantly extend the flight time of large drones, which could fly for several hours using the POWERPASTE energy material rather than a mere 20 minutes on an electric charge -- especially useful for survey work, such as the inspection of forestry or power lines. In another kind of application, campers could use POWERPASTE in a fuel cell to generate electricity to power a coffeemaker or toaster.

In addition to providing a high operating range, POWERPASTE has another point in its favor. Unlike gaseous hydrogen, it does not require a costly infrastructure. In places where there are no hydrogen stations, regular filling stations could sell POWERPASTE in cartridges or canisters instead.

The paste is fluid and pumpable. It could be supplied by a standard filling line, using relatively inexpensive equipment. Initially, filling stations could supply smaller quantities of POWERPASTE from a metal drum, for example, and then expand in line with demand. The capital expenditure for this setup would be quite low. By way of comparison, a filling station to pump hydrogen at high pressure currently costs a few million euros for each fuel pump. POWERPASTE is also cheap to transport. No costly high-pressure tanks are involved, and it doesn't require the use of extremely cold liquid hydrogen. The researchers have not addressed re-use of the cartridges or any residual materials left inside them once the canister is "empty."

The researchers think the new material really holds promise. Fraunhofer IFAM is currently building a production plant for POWERPASTE at the Fraunhofer Project Center for Energy Storage and Systems ZESS. Scheduled to go into operation later this year, this new facility will be able to produce up to 4 tons of POWERPASTE a year. They can test all types of vehicles then and also address key concerns such safety, flammability, any disposal issues, etc.

Source: Fraunhofer IFAM

Published June 2021

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