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October 07, 2025Volume 21 Issue 37


Image - Compact Meets Powerful: Discover Smalley's New Nestawave™ Spring
Compact Meets Powerful: Discover Smalley's New Nestawave™ Spring
Introducing Nestawave™ -- the spring that redefines compact power. As the latest innovation in Smalley's wave spring technology, Nestawave combines the deflection of a Crest-to-Crest® wave spring with the force of a nested spring. It delivers high load capacity and significant travel in tight spaces. Ideal for replacing stacks of Belleville washers, it performs in valves, bearing preloads, compressors, and more. Try the Smalley advantage and request free product samples today.
Learn more and get samples of this NEW Smalley product.

In this issue of Designfax

  • Wheel reinvented for giant mining machines
  • Sandia creates next-gen color X-rays
  • Drone triggers -- then survives -- lightning strike
  • All-new 2026 Subaru Outback
  • Cobot laser welding goes mainstream
  • Engineer's Toolbox: Three steps to mount a step motor
  • ABB SP4 motor line: Enhanced bearing protection
  • 3DP steel alloy: Ultra-high strength, exceptional weldability
  • How to cut EMI gasket costs for military projects
  • Stainless steel press-in inserts for casting, soft metals
  • Motion Control: The 6 myths of stage error mapping
  • Videos+: Technologies and inspiration in action
    • Generative AI out-designs humans on jumping robot
  • Most Popular Last Issue
    • How aircon inventor helped chill NASA wind tunnels
    • Friction stir welding breakthrough: Assembly lines
    • Hyundai, Genesis show wild-side mod concepts
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: All-new 2026 Subaru Outback

News

Yikes: AI-generated voices now indistinguishable from real human ones

Weird science: Ice dissolves iron faster than liquid water

High-power microwave weapon defeats 49-drone swarm at live-fire demo

Could your basement become a giant battery for your home?



Feature articles

Image - Wheel reinvented for giant mining machines gains traction in marketplace
Wheel reinvented for giant mining machines gains traction in marketplace
A Phoenix-based engineering innovator called Global Air Cylinder Wheels is making real inroads in the mining industry with its Air Suspension Wheel technology -- a giant steel wheel drum and hub system connected by cylinders and oil dampers. The mechanical technology is aimed at replacing rubber tires and boasts a lifetime as long as the vehicle it supports.
Read the full article.

Image - Sandia team creates next-gen color X-rays for materials testing and more
Sandia team creates next-gen color X-rays for materials testing and more
A team of researchers at Sandia National Laboratories has found a new way to produce X-rays by harnessing different metals and the colors of light they emit. The result is revolutionary image clarity and colored images to boot.
Read the full article.

Image - Drone triggers -- then survives -- lightning strike
Drone triggers -- then survives -- lightning strike
A Japanese telecommunications company has built a wire-connected drone that attracts lightning and survives if struck due to its uniquely built lightning protection cage.
Read the full article.

Image - All-new 2026 Subaru Outback: Growing out of its wagon era
All-new 2026 Subaru Outback: Growing out of its wagon era
The Subaru Outback is 30 years old, and the go-anywhere, wagon-like crossover SUV has grown up. The 2026 model is 2 in. taller, to be exact. It's got some boxy new styling, too, along with improved comfort and ride quality, standard Subaru Symmetrical All-Wheel Drive, and a revised 2.5-liter Subaru Boxer engine.
Read the full article.

Image - Cobot laser welding goes mainstream
Cobot laser welding goes mainstream
Laser welding with cobots is now entering mainstream adoption, overcoming initial concerns about safety, complexity, and costs through advances in control software, turnkey safety engineering, and fiber laser affordability. THG Automation's URW-2LF Collaborative Laser Welding System leverages a UR robot and an IPG fiber laser to offer cleaner, faster welds with minimal heat distortion -- plus laser-based pre-cleaning and discoloration removal for superior aesthetics and workflow simplification.
Learn more.

Image - Engineer's Toolbox: Three steps to mount a step motor
Engineer's Toolbox: Three steps to mount a step motor
Jeff Kordik, chief technical officer, Applied Motion Products, runs through the basic steps to mount a step motor and covers key mounting dimensions. He provides his pro tips along the way and gives advice for determining proper step motor torque as a sidebar. Lots of good info here.
Read the full article.

Image - ABB expands Baldor-Reliance SP4 motor line with shaft-grounded models for enhanced bearing protection
ABB expands Baldor-Reliance SP4 motor line with shaft-grounded models for enhanced bearing protection
Companies can increase motor efficiency by as much as 20% by using units in the ABB Baldor-Reliance SP4 motor line, which features integrated shaft grounding technology. Designed specifically for variable speed drive (VSD) applications, SP4 shaft ground motors offer superior protection against electrical discharge damage, extending motor life and reducing costly downtime. SP4 motors are available in severe-duty cast-iron units covering a power range of 25 to 300 hp, and general-purpose rolled-steel models available in 1/4 to 20 hp.
Learn more.

Image - New steel alloy for 3D printing features ultra-high strength, exceptional weldability
New steel alloy for 3D printing features ultra-high strength, exceptional weldability
Sandvik has introduced Osprey MAR 55, a highly versatile tool steel powder for 3D printing that bridges the gap between maraging steels and tool steels. With this new alloy, manufacturers no longer have to choose between good weldability of carbon-free maraging steels and the performance of carbon-bearing steels. It provides good mechanical properties and wear resistance. This alloy could be considered for general tooling applications. The exceptional fracture toughness at ultra-high-strength levels also paves the way for use in defense and aerospace.
Learn more.

Image - How to cut EMI gasket costs for military projects
How to cut EMI gasket costs for military projects
Specialty Silicone Products (SSP) says it is enabling defense contractors to reduce EMI gasket costs without compromising quality or performance. In addition to cost-effective nickel-graphite materials, SSP provides molded or bonded EMI frame gaskets that maximize yields and reduce waste. SSP also makes continuous rolls that are less expensive to produce and faster to fabricate into finished parts.
Read the SSP blog.

Image - Stainless steel press-in inserts for casting and soft metals
Stainless steel press-in inserts for casting and soft metals
Manufacturers working with soft metals and die-cast alloys now have an innovative time- and labor-saving solution to create strong, durable metal threads. PEM® 300 series stainless steel CASTSERT® inserts are designed for quick, reliable, and cost-effective installations by pressing into an "as-cast" or drilled hole. This rapid installation method, using a flat punch and anvil, outpaces traditional methods by approximately 80%.
Learn more.

Image - Motion Control Tech Tip: The 6 myths of stage error mapping
Motion Control Tech Tip: The 6 myths of stage error mapping
According to the experts at Motion Solutions, stage error mapping -- measuring absolute positioning error at a specified set of sampling points -- has gained a reputation for achieving high-accuracy motion control with lower-cost equipment. The theory is sound, but the problem is that there are a lot of misconceptions around stage error mapping that can lead to its use in unsuitable applications and disappointing results. Want to learn how you can use it for its maximum benefit?
Read the Motion Solutions blog.

Most popular last issue

Image - 84 years ago: How the inventor of air conditioning helped chill NASA's wind tunnels
84 years ago: How the inventor of air conditioning helped chill NASA's wind tunnels
Global tensions were high in the fall of 1941 as U-boats harassed ships in the Atlantic and German forces pushed deep into the Soviet Union. There was a critical need for the United States to get the National Advisory Committee for Aeronautics' new engine lab in operation. It was especially important to complete its Altitude Wind Tunnel, which could be used to improve the engine performance of high-altitude combat aircraft. By Robert S. Arrighi, NASA Glenn
Read the full article.

Image - Breakthrough could bring friction stir welding to assembly lines
Breakthrough could bring friction stir welding to assembly lines
An advanced manufacturing technique called friction stir welding, which can securely join similar and dissimilar materials (particularly metals and alloys) without rivets, fasteners, or adhesive, requires only a fraction of the energy required by conventional techniques. It isn't used on many assembly lines today, but that may change soon.
Read the full article.

Image - Hyundai and Genesis show wild-side mod concepts
Hyundai and Genesis show wild-side mod concepts
One looks ready to take on the Moon, while the other looks set to conquer Mars. That's the public relations styling of the latest concept cars from Hyundai and Genesis. Hyundai's latest concept is the racy, all-electric Concept THREE compact Aero Hatch under its IONIQ sub-brand, while Genesis' first adventure vehicle X Gran Equator Concept aims to redefine what makes a sporty SUV a winner in today's market.
Read the full article.

Videos+: Technologies and inspiration in action
Generative AI out-designs humans on jumping robot project
Researchers at MIT's CSAIL combined GenAI and a physics simulation engine to refine robot designs. The result: a machine that out-jumped a robot designed by humans. Diffusion models are becoming increasingly useful in helping brainstorm new designs. Generative AI created a robot that leaps 41% higher than a similar machine the human researchers created on their own.
View the video and learn more details.

New products

Electrical/Electronics
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Mechanical
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Motion
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