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Machine vision enforces zero-defect manufacturing of engine fans

Engine cooling fan failure in commercial vehicle applications can result in power unit overheating and catastrophic engine damage. To mitigate these risks, a leading manufacturer of engine components has deployed an advanced machine vision system based on SVS-Vistek cameras to enforce zero-defect quality standards. The implementation presented substantial technical challenges.
Read the full article.

Do-it-yourself board-level EMI shielding

ProtoShield sheets from Tech-Etch are depth-etched with a checkerboard pattern for folding, so they can be easily formed into many diverse configurations. In the product-development stage, fully functional shields can be created in minutes with just a pair of scissors and a straight edge for folding. Offered in two sizes: standard (.25-in. squares) and metric (5-mm squares). Both versions are solderable and corrosion resistant due to nickel silver material. Shield prototypes can be directly soldered to the board, or shield clips can be used for easy mounting. Samples available.
Learn more.

New angle sensors designed for rugged applications

Novotechnik's new Vert-X 26 Series of non-contacting magnetic angle sensors use the Hall effect to track the position of the shaft and are designed for rugged applications like automotive and off-highway equipment where high humidity, dampness, dust, and/or vibrations are expected. They are plug-in sensors using an AMP MQ5 6-pole connector, with a measurement range from 0 to 360 degrees. Both single and fully redundant versions are available.
Learn more.

Cool Tools: Mobile surface measuring solution

With its lightweight, compact design and the smallest skidless probe system available on the market, the MarSurf M 510 Series is an ideal solution for precise surface measurement across a wide range of applications. The series offers convenient mobile testing of P, R, and W parameters with just one instrument, and users can create up to 1,000 measuring programs. This instrument can cover a broad spectrum of applications in sectors such as mechanical engineering, automotive, medical, and aerospace.
Learn more from Mahr.

Code-free LIN LED driver rewrites the rules of automotive LED design

Melexis has unveiled the MLX80124, a highly configurable, code-free LIN LED driver. It is designed to radically simplify the development of dynamic RGB-LED automotive ambient lighting applications for engineers of all backgrounds. The MLX80124's unique innovation enables engineers to configure behavior without writing or compiling a single line of code. Instead, a GUI provides access to configurable parameters, delivering the full lighting functionality expected by tier 1 suppliers and OEMs.
Learn more.

EMI filters -- the first line of defense in military/aerospace electronics

When failure is not an option, high-reliability EMI filters deliver superior high-frequency EMI suppression for mission-critical applications in aerospace and defense. The experts at Johanson Technology run through your options and what makes each type beneficial for specific applications.
Read the full article.

Fastest workstation for SOLIDWORKS?

What's the fastest new workstation for SOLIDWORKS users? The experts at TriMech Group have done their testing and made their decision. It's the Dell Pro Max Tower T2. Dell's Precision Brand top-range PCs have a new name -- Pro Max -- and they are the only units certified for professional applications such as SOLIDWORKS and CATIA. Learn why TriMech thinks this PC, which replaces the best-selling Dell Precision 3680 model, is a winner.
View the video.

Cool Tools: HandySCAN BLACK Elite handheld 3D scanner

Optimized to meet the needs of design, manufacturing, and metrology professionals, FARO's HandySCAN BLACK Elite provides an effective and reliable way to acquire accurate 3D measurements of physical objects anywhere.
Read the full article.

Rotary sensor counts to 44 turns -- even when you lose power!

Novotechnik, U.S. introduces the MC-1 2800 Series of 44-Turn multi-turn sensors with several new output interfaces. These sensors feature patented, non-volatile technology that retains turn count even when power is lost and reports correct count when power is restored. In addition to the IO-Link interface, the MC-1 now features an analog ratiometric, CANopen, and CAN SAE J1939 interface options. Mechanical life is more than 50 million movements. Applications include automotive and off-highway vehicle steering and driveline, agricultural and construction machinery, medical equipment, and gate drives.
Learn more.

How to cut EMI gasket costs for military projects

Specialty Silicone Products (SSP) says it is enabling defense contractors to reduce EMI gasket costs without compromising quality or performance. In addition to cost-effective nickel-graphite materials, SSP provides molded or bonded EMI frame gaskets that maximize yields and reduce waste. SSP also makes continuous rolls that are less expensive to produce and faster to fabricate into finished parts.
Read the SSP blog.

Great Resources: Flexible circuit design guide

Tech-Etch uses advanced techniques to manufacture flex and rigid-flex circuits to exacting customer specs. Special processes include selective plating a single circuit with two different finishes, contoured circuits with variable metal thickness, semi-additive and subtractive techniques, open window or cantilevered contact leads, plus SMT for component assembly. Tech-Etch specializes in flexible circuits for medical, telecommunications, aerospace, semiconductor, and other high-reliability electronic applications.
Learn about flex circuits and get the guide (no registration required).

Real-World Applications: Automating escape room experiences

"Pay no attention to that man behind the curtain," the Wizard famously said in The Wizard of Oz. See how industrial automation products from AutomationDirect can be applied to unique applications, such as the advanced control needed to make a sophisticated escape room run.
Read the full article.

PFC capacitors for consumer electronics

TDK introduces the B3270xP, a series of ultra-small, metallized polypropylene (MKP) film capacitors tailored for power factor correction (PFC) stages in power supplies for consumer electronics. With their compact design and self-healing properties, these components are engineered for use in high-density circuit designs for devices such as laptops and gaming consoles.
Learn more.

Raspberry Pi releases 1-TB SSD for 70 bucks!

Raspberry Pi, the incredibly popular and affordable single-board computer system, is getting a big bump up in the memory department. A 1-TB solid-state drive is now available for the Raspberry Pi 5 and other devices. Besides the huge storage space, it boasts super-fast startup and fast data transfer. Available directly from Raspberry Pi for right now. Should be hitting U.S. resellers soon. Requires Raspberry Pi 5-compatible M.2 adapter.
Read the Raspberry Pi blog with more specs. Other new add-ons available.

Advanced metrology accelerates performance for American race team

In motorsports, where aerodynamic efficiency and mechanical accuracy can mean the difference between a podium finish and a mid-pack result, precision isn't a luxury -- it's a necessity. As Brian Winters, Product Manager at Hexagon - Manufacturing Intelligence division, writes, Minnesota-based JDC-Miller MotorSports understands this better than most.
Read the full article.

First dynamic digital twin to be launched into space -- smart satellite

The Center for Space Exploration Research at the University of California, Davis (UC Davis), has partnered with Proteus Space to launch a U.S. government-sponsored satellite into space with a custom AI-enabled payload in a brand-new, first-ever rapid design-to-deployment small satellite.

The team will launch the satellite and payload in October 2025 from Vanderberg, CA. From the time the project was fully approved, the design and launch will occur within an unprecedented 13 months. The normal pace for small satellites is often measured in years.

UC Davis graduate students Ayush Patnaik (left) and Adam Zufall (right) work on a payload that will travel into space this fall. The payload is a digital twin that will use AI software to measure the activity and predict the future state of the battery. Developed at the UC Davis Center for Space Exploration Research, it is a step toward fully autonomous spacecraft. The project is in collaboration with Proteus Space. [Credit: Mario Rodriguez/UC Davis]

The UC Davis-designed payload, developed by Professor of Mechanical and Aerospace Engineering Stephen Robinson's Human/Robotics/Vehicle Integration and Performance Laboratory, or HRVIP Lab, is a dynamic digital twin that models the current condition and predicts the future condition of the spacecraft's power system. The novel aspect of this payload is that the system-state model is running in real time onboard the spacecraft, instead of in ground-based mission control.

"The spacecraft itself can let us know how it's doing, which is all done by humans now," said Adam Zufall, a graduate student in the HRVIP Lab who is overseeing the UC Davis side of the project.

The satellite, which includes multiple commercial and research payloads, will monitor its own health in space using sensors that assess voltage and measurements of the batteries it is running on. The digital twin software will continually analyze the health and charge capacity of the battery. Using artificial intelligence, the digital twin will be aware of its own state and learn to predict its future state.

"It should get smarter as it goes," said Robinson, "and be able to predict how it's going to perform in the near future. Current satellites do not have this capability."

Besides the team at Proteus, Zufall and Robinson are working with Associate Professor of Mechanical and Aerospace Engineering Xinfan Lin, whose research specializes in intelligent battery management systems. The team also includes mechanical and aerospace engineering Ph.D. students Jackson Fogelquist and Ayush Patnaik, and Ancha Prashanth, a master's student in computer science.

The satellite, which is about half the size of a standard refrigerator, will launch from Vandenberg Space Force Base in California in October. It will settle into low Earth orbit and operate for up to 12 months. After three years, the satellite will naturally fall back to Earth, burning up in the atmosphere.

Source: University of California, Davis

Published July 2025

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