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Engineer's Toolbox: How to design the optimum hinge

Although many pin styles are available, Coiled Spring Pins are particularly well suited for use in both friction- and free-fit hinges. To achieve optimum long-term hinge performance, designers should observe these helpful design guidelines from SPIROL.
Read the full article.

Innovative new robo welding gun

Comau's newest N-WG welding gun is designed for high-speed spot welding for traditional, hybrid, and electric vehicles, in addition to general industry sectors. It features a patented, single-body architecture that enables rapid reconfiguration between welding types and forces, and it delivers consistent performance across a broad range of applications, including steel and (soon) aluminum welding. It supports both X and C standard gun configurations, has fast arm exchange, and universal mounting options. It is fully compatible with major robot brands and represents a significant advancement in spot welding performance and cost efficiency.
Learn more.

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.

Researchers evaluate 3D printing copper alloy for NASA rocket engines

Graduate student Trupti Suresh Mali uses nanoindentation to determine the hardness of a new printable copper alloy NASA is developing to line combustion chambers of rocket engines. Researchers at South Dakota State University are determining the mechanical properties and microstructure of GRCop-42 parts manufacturing using laser power-based directed energy deposition through a NASA EPSCoR Rapid Response Research grant.

 

 

 

 

Two South Dakota State University professors are evaluating a printable copper alloy NASA is developing for combustion chambers of next-generation rocket engines used for space travel.

Associate professor Todd Letcher and assistant professor Anamika Prasad of the Department of Mechanical Engineering are determining the material properties of a copper-based printable alloy called GRCop-42, testing samples taken from 3D parts printed using a new additive manufacturing technique.

Additive manufacturing, also commonly known as 3D printing, is different from traditional manufacturing methods in that it builds a part one layer at a time. This manufacturing technique makes it possible to create intricate geometries cost effectively, such as those needed to dissipate heat, explained Letcher, whose research focuses on 3D printing and materials characterization.

Graduate student Scott Landes of Glencoe, MN, prepares to do tensile testing of a GRCop-42 specimen in the Department of Mechanical Engineering's Material Evaluation and Testing Laboratory at South Dakota State University.

 

 

 

 

Prasad, whose research focuses on nanomechanics of engineering and biomaterials, said, "This is an excellent opportunity to utilize the equipment at the Materials Testing and Evaluation Laboratory to train our students to conduct material testing on additively manufactured materials and thereby contribute to the development of a highly educated, skilled workforce in South Dakota."

The agreement between NASA and SDSU is supported by a NASA Established Program to Stimulate Competitive Research (EPSCoR) Rapid Response Research grant. EPSCoR is designed to establish partnerships with government, higher education, and industry to develop and improve research infrastructure in areas of importance to the NASA mission. South Dakota is one of 28 states participating in the NASA EPSCoR program.

The SDSU researchers have significant experience testing additively manufactured parts made with polymers/plastics, but this is their first experience with evaluating parts made with copper-based alloys, Letcher explained. "The parts we are testing were manufactured using laser powder-based directed energy deposition," he said.

This additive manufacturing process involves injecting metal powder into a laser-heated pool of molten metal, or melt pool. The nozzle and laser optics are integrated into a build-head attached to a robot that moves in a pattern determined by a computer, building one layer at a time.

The goal of NASA's research is to evaluate new manufacturing techniques to fabricate components more rapidly, according to Paul Gradl, Senior Propulsion Engineer at NASA's Marshall Space Flight Center in Huntsville, AL. "Laser (blown) powder directed energy deposition additive manufacturing allows us to create very large-scale components with complex internal features that were not previously possible. We're able to significantly reduce the time and the cost associated with the fabrication of channel-cooled nozzles and other critical rocket components."

NASA has provided the GRCop-42 parts manufactured by an industry partner to the SDSU researchers with specific instructions about the types of testing that should be done to determine the mechanical properties and microstructure of the additively manufactured material, Prasad said. Small changes in manufacturing parameters can impact the microstructure and properties of the manufactured parts. Two graduate students are also working on the project.

The researchers have examined surface roughness using a laser scanning microscope, hardness using nanoindentation, and residual stresses using x-ray diffraction. Using the scanning electron microscope in the Department of Electrical Engineering and Computer Science, the researchers examined the microstructure of the material. They also performed tensile testing of various material specimens.

"We are contributing to a database on the material properties of GRCop-42 manufacturing using this specific process," Prasad said. Results from the project's first year were presented at the 2020 International Mechanical Engineering Congress and Exposition in November 2020.

The researchers are now performing additional tests on the samples and exploring sample size and cutting methods for low-cycle fatigue testing.

Source: South Dakota State University

Published April 2021

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