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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.

Can hydrogen paste power motorcycles and scooters?

POWERPASTE is a new, experimental hydrogen fuel source developed at the Fraunhofer Institute. [Credit: ©Fraunhofer IFAM]

 

 

High-pressure hydrogen fuel tanks are not a viable alternative-fuel option for motorcycles and scooters, but researchers in Germany have another plan: POWERPASTE. This material -- which sports a huge energy density -- stores hydrogen in a chemical form at atmospheric pressure and is activated simply by adding water.

The formulation of the new paste is based on magnesium hydride and was developed by a research team at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials in Germany. Among the materials' many positive qualities is that it is easy to transport and replenish without the need for an expensive network of filling stations.

Gasoline and diesel engines powered by fossil fuels are being replaced by new propulsion systems. One fuel with big potential is hydrogen. Hydrogen vehicles are equipped with a reinforced tank that is fueled at a pressure of 700 bar. This tank feeds a fuel cell, which converts the hydrogen into electricity. This, in turn, drives an electric motor that propels the vehicle. The end products are heat and water.

In the case of passenger cars, this technology is well advanced, with several hundred hydrogen-powered automobiles already in operation on roads throughout the world. At the same time, the network of hydrogen stations is also growing -- albeit very slowly. In Germany, for example, the network is projected to grow from 100 to 400 stations over the next three years.

However, hydrogen is not currently an option for small vehicles such as electric scooters and motorcycles, since the pressure surge during refilling would be too great. Researchers at the Fraunhofer Institute wondered if the current designs for storage effectively shut out such vehicles from hydrogen technology. Could there be another way?

TRL 5 demonstrator of a power generator with a POWERPASTE cartridge and a 100-W PEM fuel cell. [Credit: ©Fraunhofer IFAM]

 

 

This was the inspiration to create POWERPASTE, which "stores hydrogen in a chemical form at room temperature and atmospheric pressure to be then released on demand," said Dr. Marcus Vogt, research associate at Fraunhofer IFAM.

Since POWERPASTE only begins to degrade at temperatures of around 250 C, it remains safe even when an e-scooter stands in the baking sun for hours. Moreover, refueling is extremely simple. Instead of heading to the filling station, riders just replace an empty cartridge with a new one and then refill a system partner tank with regular water.

The starting material for POWERPASTE is magnesium, a readily available raw material. Magnesium powder is combined with hydrogen to form magnesium hydride in a process conducted at 350 C and five to six times atmospheric pressure. An ester and a metal salt are then added in order to form the finished product.

Installed on a vehicle, the cartridge releases the POWERPASTE by means of a plunger. When water is added from an onboard tank, the ensuing reaction generates hydrogen gas in a quantity dynamically adjusted to the actual requirements of the fuel cell. Interestingly, only half of the hydrogen originates from the POWERPASTE; the rest comes from the added water.

"POWERPASTE has a huge energy storage density," said Vogt. "It is substantially higher than that of a 700-bar high-pressure tank, and compared to batteries, it has 10 times the energy storage density." This means that POWERPASTE offers a range comparable to -- or even greater than -- gasoline. It also provides a higher range than compressed hydrogen at a pressure of 700 bar.

What can this weird material power?
With its huge energy storage density, the developers think POWERPASTE is also an interesting option for some specialty cars, delivery vehicles, and even as range extenders in battery-powered electric vehicles (although that last option sounds clunky). It could also significantly extend the flight time of large drones, which could fly for several hours using the POWERPASTE energy material rather than a mere 20 minutes on an electric charge -- especially useful for survey work, such as the inspection of forestry or power lines. In another kind of application, campers could use POWERPASTE in a fuel cell to generate electricity to power a coffeemaker or toaster.

In addition to providing a high operating range, POWERPASTE has another point in its favor. Unlike gaseous hydrogen, it does not require a costly infrastructure. In places where there are no hydrogen stations, regular filling stations could sell POWERPASTE in cartridges or canisters instead.

The paste is fluid and pumpable. It could be supplied by a standard filling line, using relatively inexpensive equipment. Initially, filling stations could supply smaller quantities of POWERPASTE from a metal drum, for example, and then expand in line with demand. The capital expenditure for this setup would be quite low. By way of comparison, a filling station to pump hydrogen at high pressure currently costs a few million euros for each fuel pump. POWERPASTE is also cheap to transport. No costly high-pressure tanks are involved, and it doesn't require the use of extremely cold liquid hydrogen. The researchers have not addressed re-use of the cartridges or any residual materials left inside them once the canister is "empty."

The researchers think the new material really holds promise. Fraunhofer IFAM is currently building a production plant for POWERPASTE at the Fraunhofer Project Center for Energy Storage and Systems ZESS. Scheduled to go into operation later this year, this new facility will be able to produce up to 4 tons of POWERPASTE a year. They can test all types of vehicles then and also address key concerns such safety, flammability, any disposal issues, etc.

Source: Fraunhofer IFAM

Published June 2021

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