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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.

State-of-the-art 3D printers cut costs, turnaround time for U.S. Army

By Justin Eimers, CECOM

Engineers and technicians at Tobyhanna Army Depot in Tobyanna, PA, use a highly innovative, cutting-edge fabrication process to significantly cut costs and reduce turnaround time. This facility is the largest full-service electronics maintenance facility in the Department of Defense (DoD).

The depot's additive manufacturing process uses two 3D printers to produce parts out of plastic and other durable materials. Unlike traditional design methods where a part is made from a block of material and the excess is discarded, additive manufacturing uses only material necessary for the part, saving money and minimizing waste.

Engineering Tech Mikael Mead of Tobyhanna Army Depot, PA, removes a small production run of finished lens covers from the printing tray of a polyjet 3D printer. Three-dimensional printers produce parts out of plastic and other durable materials.

 

 

 

 

Electronics engineer Corey Sheakoski said the benefits and potential of this process are nearly unlimited.

"Tobyhanna has the ability to make any type of plastic part, as long as we have a 3D model for it and it fits within a certain set of dimensions," he said. Sheakoski works in the Production Engineering Directorate's, or PED's, Mission Software Branch.

Recently, a shortage of parts was delaying delivery of Harris radios. The radios required the installation of small dust caps prior to shipping to the customer. Finding and getting the part from a vendor could have taken weeks; so instead, mechanical engineer Eugene Haikes designed a 3D model of the part, and the depot printed 600 dust caps in 16 hours.

Mikael Mead, engineering tech in PED's Design and Development Branch, said the decision to make the part at the depot saved a substantial amount of money and precious time.

"If the depot wanted to produce the dust caps but didn't have a rubber mold for them, we could have expected to pay anywhere from $5,000 to $15,000 for the mold," said Mead. "Because Eugene was able to come up with the model, we were able to produce the caps for only a dollar apiece while trimming days, if not weeks, off of our anticipated delivery date."

Haikes, who works in PED's Manufacturing Engineering Branch, said the whole process provides added benefit to both the depot and the customer.

"Some parts can be made through 3D printing that just cannot be produced by conventional methods," he said. "Other advantages with this process are that machine time is not charged to the customer, and it can run overnight and during the weekend."

Tobyhanna has been using additive manufacturing since the arrival of the first 3D printer in the fall of 2006. The process begins with a computerized 3D model that is programmed into one of two high-tech printers. The machine then builds a part, layer by layer, based on the model's design.

The depot's first 3D printer, a fused deposition modeling machine, or FDM, is capable of making parts out of ABS plastic within a 10- x 10- x 12-in. area. The second machine, a polyjet printer, was purchased in April 2012, and can make parts out of hundreds of composite materials within an 8- x 16- x 19-in. area.

The FDM machine produces parts accurate to one one-hundreth of an inch of the computerized model, while the polyjet printer is accurate to .002 in. This capability also allows depot engineers to print parts to use as prototypes and test pieces.

Sheakoski added that the future of additive manufacturing and 3D printing technology holds nothing but promise.

"When you look at some of the benefits of 3D printing -- the cost savings, reduction in turnaround times, reliability -- it's exciting to think where it can go from here," he said. "Additive manufacturing is helping the depot cut costs during tough times while continually supporting the warfighter with high-quality products."

Tobyhanna Army Depot is the Defense Department's largest center for the repair, overhaul, and fabrication of a wide variety of electronics systems and components, from tactical field radios to the ground terminals for the defense satellite communications network. Tobyhanna's missions support all branches of the armed forces.

About 5,100 personnel are employed at Tobyhanna, which is located in the Pocono Mountains of northeastern Pennsylvania. Tobyhanna Army Depot is part of the U.S. Army Communications-Electronics Command. Headquartered at Aberdeen Proving Ground, MD, the command's mission is to research, develop, acquire, field, and sustain communications, command, control computer, intelligence, electronic warfare, and sensors capabilities for the armed forces.

Published April 2013

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