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October 21, 2025Volume 21 Issue 39


Image - Need Inserts? We make it E-Z.
Need Inserts? We make it E-Z.
E-Z LOK threaded inserts allow users to repair or reinforce threads without the need for special taps or installation tools. Our line of threaded inserts is used in metal, plastic, wood, composite and additive industries. Extensive inventories of standard products are available throughout the U.S., and we are also able to produce special threaded inserts to print or per application requirements. Our products are available through a variety of different channels depending on the volume needed.
FREE SAMPLES FOR STANDARD PRODUCTS.
Learn more
or contact Kyle Lindsly-Roach at 310.323.5613 x221.

In this issue of Designfax

  • Autonomous Black Hawk now a front-loader!
  • How Nissan engineers apply Nissan-ness across segments
  • 3D-printed metal molds accelerate auto manufacturing
  • Porsche 911 Turbo S: Most powerful 911 ever
  • Compact, powerful: Smalley's new Nestawave™ spring
  • Fraunhofer creates seals without PFAS
  • What's a SLIC Pin®? Pin and cotter all in one!
  • Keep a firm footing with JW Winco
  • Oxygen analyzer optimizes combustion systems
  • Linear actuator from igus handles up to 600 kg
  • New sheet metal capabilities for faster, cost-efficient builds
  • Videos+: Technologies and inspiration in action
    • Expert design tips and tricks for 3D printing
  • Most Popular Last Issue
    • Builder of largest airplane wants military biz
    • Fly like you're in Star Wars: Volonaut Airbike
    • Aston Martin DB12 S: Top-shelf performance, style
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: Porsche 911 Turbo S 2026

News

Scary science: You can be identified by Wi-Fi -- even if you don't carry an electronic device

Brembo makes first brake caliper that uses 100% recycled aluminum

Next-gen navigation systems reach U.S. Army units

Weird science: Researchers create warm ice



Image - 27,000 Stock Metric Gears from KHK
27,000 Stock Metric Gears from KHK
KHK USA offers the largest selection of stock metric gears in North America -- with over 27,000 configurations. KHK USA offers Metric Spur Gears, Metric Helical Gears, Metric Internal Ring Gears, Metric Gear Racks, Metric Bevel Gears, Metric Worms and Wormwheels all from stock! Free 3D CAD models, technical specs and 24/7 price and availability are all detailed online.
See what KHK USA has in stock for you today!

Feature articles

Image - Autonomous Black Hawk copter now a battle-ready front-loader!
Autonomous Black Hawk copter now a battle-ready front-loader!
Engineers at Sikorsky have been working for almost 10 years on perfecting the transformation of a Black Hawk helicopter into a fully autonomous, unmanned chopper. They've gone a big step further now by making it a robo front-loading craft too.
Read the full article.

Image - How Nissan engineers apply 'Nissan-ness' across segments
How Nissan engineers apply 'Nissan-ness' across segments
What makes a Nissan feel like a Nissan? Traits such as confident handling, everyday comfort, and user-friendly technology are shared across the lineup. To maintain that sense of Nissan-ness, engineers on the new all-electric LEAF engineering team included people who have helped develop trucks, SUVs, sedans, and the legendary Z sports car.
Read the full article.

Image - 3D-printed metal molds aim to accelerate U.S. auto manufacturing
3D-printed metal molds aim to accelerate U.S. auto manufacturing
Recent advancements at the Department of Energy's Oak Ridge National Lab show that 3D-printed metal molds offer a faster, more cost-effective, and flexible approach to producing large composite components for mass-produced vehicles than traditional tooling methods.
Read the full article.

Image - Porsche 911 Turbo S: Most powerful production 911 ever
Porsche 911 Turbo S: Most powerful production 911 ever
The new 2026 911 Turbo S is the most powerful production 911 to date thanks to an innovative twin-turbo powertrain with T-Hybrid technology. The 701-hp all-wheel drive sports car combines outstanding performance with a high degree of exclusivity, long-distance comfort, and everyday usability in Coupe and Cabriolet options.
Read the full article.

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.

Image - Fraunhofer creates seals without PFAS, lubricated with water
Fraunhofer creates seals without PFAS, lubricated with water
Fraunhofer researchers in Germany have succeeded in developing sustainable new seals that are free from environmentally harmful substances such as PFAS (forever chemicals) and suitable for water-based lubricants. Initial prototypes are already in use.
Read the full article.

Image - What's a SLIC Pin<sup>®</sup>? Pin and cotter all in one!
What's a SLIC Pin®? Pin and cotter all in one!
The SLIC Pin (Self-Locking Implanted Cotter Pin) from Pivot Point is a pin and cotter all in one. This one-piece locking clevis pin is cost saving, fast, and secure. It functions as a quick locking pin wherever you need a fast-lock function. It features a spring-loaded plunger that functions as an easy insertion ramp. This revolutionary fastening pin is very popular and used successfully in a wide range of applications.
Learn more.

Image - Keep a firm footing with JW Winco
Keep a firm footing with JW Winco
Every machine, every test system, and every filling station -- none of them floats suspended in the air. They all rest on specific, functionally optimized elements like leveling feet or, if mobility is required, casters. Leveling feet support loads both statically and dynamically, while wheels and casters support units on the move. JW Winco has a huge selection, from light-duty to high-load, available from different material types and loaded with different features. See all your options, including new hybrid units such as EN 22882, which combines a polyamide caster and leveling foot into a single component.
Learn about JW Winco leveling feet, casters, and hybrid solutions.

Image - Oxygen analyzer optimizes combustion systems
Oxygen analyzer optimizes combustion systems
The new Rosemount CX2100 In Situ Oxygen Analyzer from Emerson is designed to provide the critical info needed to optimize combustion processes and help manufacturers meet emissions standards, reduce energy costs, and increase safety. The CX2100 is simple to install with a transmitter that can be mounted up to 300 ft away from the probe. Its guided setup and commissioning are a snap, and maintenance is easy due to the probe's quick connect/disconnect feature. Autocalibration features regularly measure analyzer accuracy. Industries include power and utilities, chemicals, petroleum and refining, metals and mining, and more.
Learn more.

Image - Linear actuator from igus handles up to 600 kg
Linear actuator from igus handles up to 600 kg
The drylin SLX-8060 from igus is a ready-to-install linear axis equipped with a dryspin lead screw drive. The corrosion-resistant system can handle axial loads up to 600 kg (1,323 lb), making it ideal for logistics, robotics, and manufacturing applications in packaging and automated material handling. Designed to simplify and accelerate assembly, the SLX-8060 can be mounted directly to aluminum construction profiles without pre-drilled holes. igus offers the SLX as a complete system with optional motor and control packages, ensuring fast deployment for automation and motion system developers.
Learn more.

Image - New sheet metal capabilities for faster, cost-efficient builds
New sheet metal capabilities for faster, cost-efficient builds
meviy, the on-demand custom parts manufacturing service developed by MISUMI Group, has expanded its sheet metal processing capabilities -- a game-changer for engineers and designers working under tight timelines and budgets. The upgrade includes support for thicker materials (up to 0.5"), bending up to 0.25", and new tapped and countersunk hole options -- all while maintaining meviy's trademark speed and simplicity. From fixture plates to machine frames, this opens the door for faster, low-precision structural builds.
Learn about meviy's many new service offerings.

Most popular last issue

Image - Builder of largest airplane in history wants U.S. military as customer
Builder of largest airplane in history wants U.S. military as customer
A Colorado startup called Radia aims to build the biggest airplane (by volume) in history, and it wants the U.S. military to be one of its clients. Its WindRunner for Defense mega hauler aims to fit six CH-47 Chinooks, 12 Apache helicopters, or even four F-16s inside.
Read the full article.

Image - Fly like you're a Star Wars scout trooper: Volonaut Airbike
Fly like you're a Star Wars scout trooper: Volonaut Airbike
The Volonaut Airbike is a "superbike for the skies" powered by jet propulsion. It is designed to carry one person at speeds up to 63 mph. The vehicle's designer, Polish inventor and entrepreneur Tomasz Patan, says it is "seven times lighter than a typical motorcycle thanks to use of advanced carbon fiber materials, 3D printing, and a minimalistic (design) approach." Empty, it weighs 66 lb. It can carry up to a 209-lb rider using diesel, biodiesel, Jet-A1, or kerosene for fuel. So far, max run time is 10 minutes. Check out the website after the video for more details. [Credit: Video screenshot courtesy of Volonaut]
View the video.

Image - Aston Martin DB12 S: Top-shelf performance and style
Aston Martin DB12 S: Top-shelf performance and style
The DB12 S is the new halo model of Aston Martin's legendary DB bloodline, with "S" denoting the highest performing derivative of an established model. The luxurious and racy coupe features more power through its upgraded 4.0-L twin-turbo V8, high-end lightweighting, and special aero touches. Plus, it just looks cool.
Read the full article.

Videos+: Technologies and inspiration in action
Expert design tips and tricks for 3D printing
Join Xometry's 3D-printing experts, Greg Paulsen and Matt Schmidt, as they reveal practical strategies to help you optimize your designs, improve print quality, and reduce costs across your 3D-printing projects. Learn about file-prep best practices, how to reduce costs on 3D prints, key design considerations when working on tolerance or resolution, and much more. Lots to learn here.
View the video.

New products

Electrical/Electronics
View Products…
Mechanical
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Motion
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