Manufacturing & Prototyping

Selective Laser Sintering System

3D Systems has developed its fastest fab-grade selective laser sintering (SLS) system yet, the ProX 500 Plus. Building upon last year’s ProX 500 release, the ProX 500 Plus continues the company’s efforts to redefine production 3-D printing, adding upgraded speeds, higher print resolution, and an expanded range of engineered composite materials to the line. As with the ProX 500, the ProX 500 Plus delivers injection molding-grade parts without expensive fixed tooling for highly complex and mass customized production. Parts from ProX-series SLS printers exhibit long-lasting, fab-grade durability and functionality as well as smooth surface finish. More detail at http://articles.sae.org/13729.

Posted in: Products, Aerospace, Defense, Manufacturing & Prototyping, Lasers & Laser Systems
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Dome-Loaded Pressure Regulator

WITT-Gasetechnik’s dome-loaded pressure regulator is impervious to system pressure and withdrawal fluctuations. A design modification to the integrated control pressure regulator ensures an almost complete compensation of supply pressure and outlet fluctuations. Thus, users can rely on constant conditions in the gas supply at any time. In contrast to spring-loaded pressure regulators, dome-loaded pressure regulators are operated by gas pressure. The “control gas” is monitored via a separate control pressure regulator. More detail at http://articles.sae.org/13620.

Posted in: Products, Aerospace, Defense, Manufacturing & Prototyping
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Magnetic Field Lines Made Visible in 3-D and Real Time

Scientists at the Fraunhofer Institute have developed a high-resolution magnetic line camera to measure magnetic fields in real time, which is particularly useful for quality assurance during the manufacture of magnets. Read more at http://articles.sae.org/13706.

Posted in: Articles, News, Aerospace, Defense, Cameras, Manufacturing & Prototyping, Measuring Instruments
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'Reman' Engine Market Steady, but Complexity Challenges Production Efficiency

High-tech design causes time to remanufacture engines to nearly triple and adds to cost, while used engines remain a competitive factor. However, Purdue University data shows remanufacturing is far more energy efficient than installing a new powerplant. Read more at http://articles.sae.org/13703.

Posted in: Articles, News, Aerospace, Defense, Energy Efficiency, Manufacturing & Prototyping
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Racecar with Composite-Intensive Suspension Gets Track Tested in 2015

A racecar fitted with a prototype rear suspension will compete in the Sports Car Club of America's 2015 season as a proof-of-concept demonstrator for using thermoplastic composite suspension components in future light-duty vehicle production applications. Read more at http://articles.sae.org/13523.

Posted in: Articles, News, Aerospace, Defense, Manufacturing & Prototyping
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Isuzu Takes High-Level Approach to T4F Solutions

Depending on which off-highway engine manufacturer you’re talking to, it is either an advantage that its teams of engineers design specifically and solely for the off-highway industry, or it is an advantage that its teams of engineers design for both the on- and off-highway industries. Read more at http://articles.sae.org/13466.

Posted in: Articles, Aerospace, Defense, Consumer Product Manufacturing, Automotive
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Manufacturing Robotic Tools for Piping Inspection and Repair

Fleet piping systems are complex, space-constrained systems that are difficult to inspect using standard external inspection techniques. Pipe lagging, as well as limited space, makes external access prohibitively expensive and difficult. A robotic tool was developed that will deliver a sensor package capable of real-time corrosion/erosion and pipe wall measurements. Implementation of this system will allow for fleet preventative maintenance (PM), ensuring that possible failures are detected and replaced before they occur.

Posted in: Briefs, Manufacturing & Prototyping, Sensors and actuators, Fleet management, Maintenance, Repair and Service Operations, Tools and equipment, Robotics, Inspections
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Design and Fabrication of a Radio Frequency Grin Lens Using 3D Printing

Engineered electromagnetic materials and meta-materials have been researched to explore devices that enable access to electromagnetic properties that are not available in nature. This new class of devices can not only open the door to new functionality, but also be effectively utilized to improve the overall performance of existing systems with respect to electromagnetic performance, cost, size, weight, and repeatability.

Posted in: Briefs, Manufacturing & Prototyping, Rapid prototyping, Optics, Additive manufacturing, Fabrication, Materials properties
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Preparing Carbon-Coated Current Collectors for High-Power Lithium-Ion Secondary Batteries

Achieving high-power capability of a battery requires minimizing the overall resistance of the electrochemical system. For lithium-ion batteries, much effort has been devoted to minimize the ionic diffusion resistances and electronic resistance associated with the electrode active materials. In the typical electrode configuration, the layer containing the active material is supported on a metallic current collector. The interface between the current collector and active layer imposes additional resistance to charge transfer within the electrode. The advancement in material synthesis technologies has reduced the ionic and electronic resistances associated with the active materials to the point that they become competitive to the other resistance sources. Thus, the significance of the electronic resistance at the active layer/current collector (AL/CC) interface is worthy of re-examination.

Posted in: Briefs, Manufacturing & Prototyping, Lithium-ion batteries, Coatings Colorants and Finishes, Materials properties
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Three-Dimensional Plastic Part Extrusion and Conductive Ink Printing for Flexible Electronics

Structural electronics, or structronics, seeks to build wiring and electrical interconnects directly into component structures to diminish the need for structural fasteners. A MakerBot Cupcake Computer Numerical Control (CNC) was used to investigate the fabrication of plastic structures by printing, and a Fujifilm Dimatix Materials Printer (DMP) was used to create flexible Printed Circuit Boards (PCBs). After developing processes to make these machines easier to use, others will be able to utilize them to develop structures with integrated electronics.

Posted in: Briefs, Manufacturing & Prototyping, Electronic equipment, Additive manufacturing, Plastics, Parts
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