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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.

Engineering challenge: Which 3D-printed parts will fade?

How does prolonged exposure to intense UV light impact 3D-printed plastics? Will they fade? This is what Xometry's Director of Application Engineering, Greg Paulsen, set to find out. In this video, Paulsen performs comprehensive tests on samples manufactured using various additive processes, including FDM, SLS, SLA, PolyJet, DLS, and LSPc, to determine their UV resistance. Very informative. Some results may surprise you.
View the video.

Copper filament for 3D printing

Virtual Foundry, the company that brought us 3D-printable lunar regolith simulant, says its popular Copper Filamet™ (not a typo) is "back in stock and ready for your next project." This material is compatible with any open-architecture FDM/FFF 3D printer. After sintering, final parts are 100% pure copper. Also available as pellets. The company says this is one of the easiest materials to print and sinter. New Porcelain Filamet™ available too.
Learn more and get all the specs.

Copper foam -- so many advantages

Copper foam from Goodfellow combines the outstanding thermal conductivity of copper with the structural benefits of a metal foam. These features are of particular interest to design engineers working in the fields of medical products and devices, defense systems and manned flight, power generation, and the manufacture of semiconductor devices. This product has a true skeletal structure with no voids, inclusions, or entrapments. A perennial favorite of Designfax readers.
Learn more.

Full-color 3D-printing Design Guide from Xometry

With Xometry's PolyJet 3D-printing service, you can order full-color 3D prints easily. Their no-cost design guide will help you learn about different aspects of 3D printing colorful parts, how to create and add color to your models, and best practices to keep in mind when printing in full color. Learn how to take full advantage of the 600,000 unique colors available in this flexible additive process.
Get the Xometry guide.

Tech Tip: How to create high-quality STL files for 3D prints

Have you ever 3D printed a part that had flat spots or faceted surfaces where smooth curves were supposed to be? You are not alone, and it's not your 3D printer's fault. According to Markforged, the culprit is likely a lack of resolution in the STL file used to create the part.
Read this detailed and informative Markforged blog.

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.

Engineer's Toolbox: How to pin a shaft and hub assembly properly

One of the primary benefits of using a coiled spring pin to affix a hub or gear to a shaft is the coiled pin's ability to prevent hole damage. Another is the coiled pin absorbs wider hole tolerances than any other press-fit pin. This translates to lower total manufacturing costs of the assembly. However, there are a few design guidelines that must be adhered to in order to achieve the maximum strength of the pinned system and prevent damage to the assembly.
Read this very informative SPIROL article.

What's new in Creo Parametric 11.0?

Creo Parametric 11.0 is packed with productivity-enhancing updates, and sometimes the smallest changes make the biggest impact in your daily workflows. Mark Potrzebowski, Technical Training Engineer, Rand 3D, runs through the newest functionality -- from improved surface modeling tools to smarter file management and model tree navigation. Videos provide extra instruction.
Read the full article.

What's so special about wave springs?

Don't settle for ordinary springs. Opt for Rotor Clip wave springs. A wave spring is a type of flat wire compression spring characterized by its unique waveform-like structure. Unlike traditional coil springs, wave springs offer an innovative solution to complex engineering challenges, producing forces from bending, not torsion. Their standout feature lies in their ability to compress and expand efficiently while occupying up to 50% less axial space than traditional compression springs. Experience the difference Rotor Clip wave springs can make in your applications today!
View the video.

New Standard Parts Handbook from JW Winco

JW Winco's printed Standard Parts Handbook is a comprehensive 2,184-page reference that supports designers and engineers with the largest selection of standard parts categorized into three main groups: operating, clamping, and machine parts. More than 75,000 standard parts can be found in this valuable resource, including toggle clamps, shaft collars, concealed multiple-joint hinges, and hygienically designed components.
Get your Standard Parts Handbook today.

Looking to save space in your designs?

Watch Smalley's quick explainer video to see how engineer Frank improved his product designs by switching from traditional coil springs to compact, efficient wave springs. Tasked with making his products smaller while keeping costs down, Frank found wave springs were the perfect solution.
View the video.

Top die casting design tips

You can improve the design and cost of your die cast parts with these top tips from Xometry's Joel Schadegg. Topics include: Fillets and Radii, Wall Thicknesses, Ribs and Metal Savers, Holes and Windows, Parting Lines, and more. Follow these recommendations so you have the highest chance of success with your project.
Read the full Xometry article.

What's the latest from 3D Systems? Innovations for different industries, processes

3D Systems unveiled several new solutions at the RAPID+TCT 2025 show in April designed to change the way industries innovate. From new 3D printers and materials for high-mix, low-volume applications to marked improvements in how investment casting can be done, learn what is the state of the art from the original inventors of 3D printing.
Read the full article.

Clever! Indexing plungers with chamfered pins

JW Winco has developed a new type of indexing plunger -- GN 824 -- that can independently latch into edges and grooves. This is made possible by a chamfered plunger pin. When the chamfered pin encounters a raised latching geometry, it retracts and then springs back out again once it reaches the latching point. This new indexing plunger can be ordered with axial thread for fastening and a black plastic knob for operating the indexing plunger. In a clever design, the plunger pin can be adjusted by 360 degrees to ensure that it encounters the mating surface perpendicularly. This hardware is well suited for transport frames, mechanisms, or covers that need to be locked in place quickly and securely, especially without the need for manual intervention.
Learn more.

Army tests aluminum foam for blast protection

Aluminum foam is inexpensive to produce, and it can be made into various sizes and shapes, including panels. While it is currently manufactured and shipped from South Korea and Canada, several companies in the United States are interested in expanding production to make aluminum foam. [Photo: U.S. Army]

 

 

 

 

By Argie Sarantinos, U.S. Army CCDC

Forward Operating Bases are typically surrounded by barbed wire, concrete barriers, gates, watchtowers, and other infrastructures. A new material -- aluminum foam -- may be a possible solution for additional force protection, due to its ability to absorb energy from blasts.

The aluminum foam is added to panels clad with steel that are part of existing structures or bolted together to create larger structures. The panels are also used in jersey-style barriers to protect against truck bombs.

Aluminum foam was recently tested in a lab and at an explosives testing range at Picatinny Arsenal, New Jersey, with funding from the Office of the Under Secretary of Defense - Global Capability Programs Foreign Comparative Testing program. The FCT program provides funding to acquire, test and evaluate mature products from foreign industry that may fill a capability gap or satisfy an urgent need. The aluminum foam is manufactured in South Korea and Canada.

"In products where you need a good amount of strength and stiffness that aluminum provides but not all the weight, using the foam opens up a lot of engineering design space without increasing cost," said Calvin Lim, engineer at Picatinny Arsenal.

Aluminum foam is inexpensive to produce, and it can be made into various sizes and shapes, including panels. While it is currently manufactured and shipped from South Korea and Canada, several companies in the United States are interested in expanding production to make aluminum foam. Creating an affordable supply chain in the U.S. will eliminate difficulties with shipping the product outside the country and create additional jobs in the U.S.

Testing to verify and confirm the manufacturers' claims was conducted at Picatinny Arsenal. Explosives were initiated next to the aluminum foam panels, which were held in place with I-beams.

"These tests showed how the aluminum foam prevents energy from being transmitted to the other side. To fully replicate previous test data, a higher amount of explosives is needed,'' Lim said.

Testing was initially conducted in South Korea; during testing, the panels absorbed the energy from the blast, collapsing the material's cellular structure and preventing any damage from transmitting to the other side. The tests at Picatinny Arsenal, as well as upcoming tests, will determine if aluminum foam will be beneficial for the Army overall, as well as other services.

The FCT program provided funding to purchase additional aluminum foam for Insensitive Munitions testing with XM1128 artillery. This was proposed as a low-cost, easy-to-implement packaging solution to reduce the sensitivity and collateral damage in sympathetic reaction and fragment impact scenarios. This testing has been slated but delayed due to the coronavirus pandemic.

The Foreign Comparative Testing program purchased aluminum foam to ship and/or store 155-mm XM1128 artillery for an Insensitive Munitions Testing. (U.S. Army)[Photo: U.S. Army]

 

 

 

 

In addition to military uses, aluminum foam is used in a variety of applications including sound mitigation, highway barriers, and storm debris mitigation because of its unique properties.

Because of its versatility, aluminum foam has sparked interest and possible use for military ground vehicles, aircraft, and watercraft due to its low weight, stiffness, and buoyancy. Lighter vessels and vehicles will not only move faster and use less fuel, they will require fewer refueling trips and enable Soldiers to maneuver more easily.

The Army is working with several companies on additional energy and resource savings, including an energy-conscious solution that melts raw scrap aluminum to create aluminum foam. This will reduce steps in the recycling supply chain, which will lead to cost savings.

Future efforts could include using aluminum foam to rapidly manufacture, ship, and erect buildings quickly in key locations. Recent research shows many allied countries and adversarial countries have already been using aluminum foam to protect civilian and defense employees.

Published December 2020

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