Manufacturing & Prototyping

Smarter Prototyping — How Stratasys F123 3D Printers Make Rapid Prototyping More Accessible and Productive

3D printing’s contributions across the design, engineering and manufacturing disciplines are not new. The technology has been available for over thirty years and is often lauded as the next industrial revolution. Despite some inflated claims, there’s no denying that 3D printing has achieved its place as a valuable design and manufacturing methodology, and a cornerstone of rapid prototyping. It lives up to the promise of making businesses competitive by giving them tools streamline and enhance the product-creation processes. This white paper shows there’s never been a better time to invest in 3D printing, a fact made possible by the new Stratasys F123 3D Printer Series. These 3D printers were designed to remove barriers designers and engineers face by making the RP process more efficient and productive. Learn how the Stratasys F123 Series addresses typical rapid prototyping pain points and lets companies create better products faster, reducing the time to market.

Posted in: White Papers, White Papers, Manufacturing & Prototyping
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ANSYS Startup Program: Simulating the Future

Product innovation without foundational simulation practices is a recipe for disaster. Inside, you’ll read about how the “Startup Ecosystem” of entrepreneurs/startups, incubators, accelerators, and investors is viewing simulation as an “up-front must” in the new product design and innovation process.

Posted in: White Papers, Manufacturing & Prototyping
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Unified Approach Improves the Accuracy of Five-Axis Machine Tools

Ph.D. students Jennifer Creamer and Le Ma work in Missouri University of Science and Technology’s Precision Motion Control Laboratory. (Credit: Missouri S&T)

Five-axis machine tools are computer-numerically controlled (CNC) machines that can move, cut, or mill a part on five different axes at the same time. Because of inherent geometric errors, manufacturers must make adjustments when calibrating these machines. Several different approaches exist to help compensate for the errors, but none of them provides a complete picture. Researchers at Missouri University of Science and Technology set out to find a way to eliminate that piecemeal approach and develop a new way to capture complicated geometric errors and automatically generate compensation tables.

Posted in: News, Industrial Controls & Automation, Manufacturing & Prototyping
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Achieving Lower Total Cost of Ownership in Your Enclosure Design

This Tech Talk explains the important differences between modular and unibody welded enclosures. It also details what designers and specifiers of industrial enclosures must consider to achieve lower total cost of ownership.

Posted in: Tech Talks, Manufacturing & Prototyping
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Why Your Leak Test Doesn’t Measure Up – and What Data Can Do About It

On the manufacturing line, the struggle to test for and address leaks that lead to faulty parts and warranty claims is nothing new — but rising expectations for product quality and reliability are putting leak tests to the test. How can quality engineers meet Industry 4.0 requirements for emission control, performance and reliability while coping with increased production volumes that demand shortened cycle times? Make the test better with data.

Posted in: White Papers, Manufacturing & Prototyping, Data Acquisition, Sensors, Test & Measurement
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Metallic Glass Shatters Gear Limitations

Gears play an essential role in precision robotics, and they can become a limiting factor when the robots must perform in space missions. In particular, the extreme temperatures of deep space pose numerous problems for successful gear operation. At NASA’s Jet Propulsion Laboratory (JPL) in Pasadena, CA, technologist Douglas Hofmann and his collaborators aim to bypass the limitations of existing steel gears by creating gears from bulk metallic glass (BMG).

Posted in: Articles, Aerospace, Manufacturing & Prototyping, Metals, Mechanical Components, Motion Control, Motors & Drives, Power Transmission, Robotics, Robotics, Alloys, Glass, Gears, Durability, Spacecraft
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Use of Beam Deflection to Control an Electron Beam Wire Deposition Process

NASA Langley Research Center researchers have a strong technology foundation in the use of electron-beam (e-beam) deposition for freeform fabrication of complex shaped metal parts. While e-beam wire deposition is of interest for rapid prototyping of metal parts, cost-effective near-net shape manufacturing, and potential use in space, it is also of intense interest for industrial welding and fabrication in a range of applications, from small components to large aerospace structures. Through significant advancements in techniques to improve control of the process, NASA greatly expands upon the capabilities of the e-beam fabrication and welding process.

Posted in: Briefs, Manufacturing & Prototyping, Performance upgrades, Fabrication, Welding, Metals
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Thermal Stir Welding Process

NASA's Marshall Space Flight Center is developing an improved joining technology called thermal stir welding that improves upon fusion welding and friction stir welding. This new technology enables a superior joining method by allowing manufacturers to join dissimilar materials and to weld at high rates. NASA's technology offers users an exciting alternative to state-of-the-art fusion and friction stir welding technologies.

Posted in: Briefs, Manufacturing & Prototyping, Manufacturing equipment and machinery, Welding
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Systems, Apparatuses, and Methods for Using Durable Adhesively Bonded Joints for Sandwich Structures

A preform insert enables redundant bond lines and mass efficient load transfer across the joint.

NASA'S Langley Research Center has developed a new adhesively bonded joint concept for curved and flat panel sandwich architectures. A woven preform, inserted into the seam between sandwich panels, provides a larger total bonding area and multiple load paths for an improved distribution of load through the joint. NASA is able to create structures by joining sections of sandwich panels or curved shells. The new joint provides more durable load transfer and redundant load paths compared to current state-of-the-art adhesively bonded strap joints.

Posted in: Briefs, Manufacturing & Prototyping, Product development, Joining, Adhesives and sealants
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Preliminary Design of a Cryogenic Hydrogen Radiation Shield for Human Spaceflight

Liquid hydrogen is the most mass-efficient radiation shielding material.

Human susceptibility to the harsh space radiation environment has been identified as a major hurdle for exploration beyond low-Earth orbit (LEO). High-energy protons and nuclei ions from Solar Energetic Particles (SEPs) and Galactic Cosmic Rays (GCRs) can result in radiation doses that are dangerous to astronaut health and even survivability if the astronauts are not adequately shielded. These high-energy particles also cause significant amounts of secondary radiation when they impinge on the spacecraft structure. Hydrogen or hydrogen-rich materials are ideal materials for radiation shielding because hydrogen does not easily break down to form a secondary radiation source.

Posted in: Briefs, Manufacturing & Prototyping, Hydrogen storage, Human factors, Radiation protection, Spacecraft
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