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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.
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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.

New flat quarter-turn clamping fastener

IMAO Fixtureworks has expanded its One-Touch Fastener lineup to include a new quarter-turn clamping fastener that features an innovative flat design and is ideal for clamping in limited spaces. The QCFC flat quarter-turn fastener has a recessed body that protrudes only 2 mm from the mounted surface, a knob that rests flush inside the body, visible ON and OFF markings for safety, and an audible click when fully turned to clamped or unclamped position.
Learn more.

New electro-proportional hydraulics cartridge valves

Helios Technologies has expanded its electro-proportional cartridge valve offerings with new solutions (models RPEP and RPEN) from its operating company Sun Hydraulics. These valves fit into the compact T-10A cavity and are rated to a max pressure of 5,000 psi (350 bar). They have a flow capacity of 25 gpm and are fully compatible with the XMD Mobile Driver, which was co-developed with sister operating company Enovation Controls. The RPEP is well suited for industrial machines like a hydraulic press, which requires precise pressure regulation. The RPEN is well suited for mobile fan drive applications to dynamically control fan speed and ensure proper temperature regulation.
Learn more.

Dual-laser metal AM system makes parts faster

Renishaw's new dual-laser RenAM 500D metal additive manufacturing machine has been designed to offer exceptional product quality and productivity for a wider range of budgets. The RenAM 500D features two 500-W lasers that can access the entire build platform, delivering superior performance when compared with single-laser systems. Additionally, the RenAM 500D Ultra, fitted with Renishaw's TEMPUS technology, allows the laser to fire while the recoater is moving, saving up to nine seconds per build layer and reducing cost per part. This also helps to deliver a production speed up to three times faster than conventional single-laser systems. Many more features.
Learn more.

Low-cost hydrogen sensor detects leaks in an instant -- outperforms commercial detectors

The robust device relies on an innovative polymer.

Hydrogen is a clean-burning fuel that could help to replace fossil fuels in transportation, the chemicals industry, and many other sectors. However, hydrogen is also an explosive gas, so it is essential to have safety systems that can reliably detect leaks in a variety of circumstances.

Researchers at King Abdullah University of Science and Technology (KAUST) in Saudi Arabia have invented a robust, highly sensitive, low-cost hydrogen sensor that outperforms commercial detectors, offering a vital safeguard for the burgeoning hydrogen economy.

"Conventional hydrogen sensors face several limitations," says Suman Mandal of the Physical Science and Engineering Division at KAUST, a member of the team behind the work. "These sensors often respond slowly to hydrogen leaks, cannot detect trace levels of hydrogen, and must be heated during operation, for example."

KAUST's new hydrogen sensor is ultra sensitive, fast, and energy efficient. It can detect 192-ppb hydrogen in complex gas mixtures in under a second. [Credit: Image © 2025 KAUST/Courtesy of KAUST]

The researchers have overcome these problems using a semiconducting polymer called DPP-DTT, which they coated onto a pair of platinum electrodes. Exposure to hydrogen reduced the current flowing through the device by up to 10,000 times, offering a powerful detection signal, with the drop in current corresponding to the concentration of hydrogen.

"This high responsivity ensures rapid and precise detection of gas leaks, which is essential for safety in industrial and transportation sectors," says Mandal.

The device operates at room temperature and can detect traces of hydrogen at just 192 parts per billion. It responds within one second of exposure and consumes barely two microwatts of power. Laboratory tests showed the device could operate over a wide temperature and humidity range and remained functional for two years.

The researchers tested the device in various real-world scenarios, which included hydrogen leaking from a pipe and bursting hydrogen-filled balloons in a room. They even mounted the device on a drone and flew it through an area where a hydrogen leak had occurred. In all scenarios, the device performed better than commercial sensors.

The sensor could also detect hydrogen in mixtures of volatile molecules such as ethanol and acetone, and in complex gas mixtures. The sensor only failed when the atmosphere lacked any oxygen, which provided an important clue about how it works.

Oxygen from the air enters the polymer and draws electrons from the material. This increases the current flowing through the device and leaves oxygen within the polymer and on the electrodes. If there is any hydrogen in the surrounding air, it also passes through the polymer and reaches the electrodes, where the hydrogen atoms stick to the platinum's surface. Hydrogen and oxygen atoms then combine to form water, which escapes the device. Removing this oxygen reduces the current flowing through the device, which signals the presence of hydrogen.

"This is an entirely new hydrogen sensing mechanism," Mandal says.

Using an inexpensive screen-printing method, the sensor could be manufactured at a low cost, making it an affordable and practical way to rapidly identify hydrogen leaks.

The team has filed a patent on the work and plans to collaborate with a company to further develop the technology. "I believe these efforts will help address hydrogen safety issues in a cost-effective and environmentally friendly manner," says Mandal.

Source: King Abdullah University of Science and Technology

Published June 2025

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