Manufacturing & Prototyping

The Final Step In Prototyping: Enhancing Your Metal Parts For Accelerated Speed To Market

Electropolishing is often referred to as a “reverse plating” process. Electrochemical in nature, electropolishing uses a combination of rectified current and a blended chemical electrolyte bath to remove flaws from the surface of a metal part.

Posted in: Manufacturing & Prototyping, White Papers

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Engineers Use Resin Inks, 3D Printing to Build Lightweight Cellular Composites

Like other manufactured products that use sandwich panel construction to achieve a combination of light weight and strength, turbine blades contain carefully arrayed strips of balsa wood from Ecuador, which provides 95 percent of the world’s supply.As turbine makers produce ever-larger blades—the longest now measure 75 meters, almost matching the wingspan of an Airbus A380 jetliner—they must be engineered to operate virtually maintenance-free for decades. In order to meet more demanding specifications for precision, weight, and quality consistency, manufacturers are searching for new sandwich construction material options.Now, using a cocktail of fiber-reinforced epoxy-based thermosetting resins and 3D extrusion printing techniques, materials scientists at the Harvard School of Engineering and Applied Sciences (SEAS) and the Wyss Institute for Biologically Inspired Engineering have developed lightweight cellular composite materials.The work could have applications in many fields, including the automotive industry where lighter materials hold the key to achieving aggressive government-mandated fuel economy standards. SourceAlso: See more Materials tech briefs.

Posted in: Manufacturing & Prototyping, Rapid Prototyping & Tooling, Materials, Composites, Aerospace, Aviation, News

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How Paper-based 3D Printing Works: The Technology and Advantages

3D printers have been with us for decades, routinely turning 3D computer designs into detailed physical objects for product design, education, architecture, healthcare, mapping, historic preservation and other applications. These devices create models in a range of materials, including plastic, plaster, photopolymers, metal and sometimes even food. Each of these materials brings inherent advantages and disadvantages, depending upon your application. There’s one more to consider: paper.

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Mobile Robots Help Technicians Manufacture Airplanes

A new mobile assistant is being developed to support technicians in the airplane manufacturing industry when applying sealant, measuring, and testing — without putting them at risk. In the EU project known as VALERI (Validation of Advanced, Collaborative Robotics for Industrial Applications), a European consortium is engineering a mobile robot that operates autonomously and moves independently through a production hall, side-by-side with the engineers and technicians. It is not intended to replace the technician, but instead relieve them of stressful and monotonous duties and take over inspection duties.

Posted in: Manufacturing & Prototyping, Industrial Controls & Automation, Sensors, Test & Measurement, Aerospace, Aviation, Machinery & Automation, Robotics, News

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Engineers Develop Ultrastiff, Ultralight Material

Engineers at MIT and Lawrence Livermore National Laboratory (LLNL) have developed a new ultrastiff, ultralight material. The material is based on the use of microlattices with nanoscale features, combining great stiffness and strength with ultralow density. The actual production of such materials is made possible by a high-precision 3-D printing process called projection microstereolithography.By using the right mathematically determined structures to distribute and direct the loads — the way the arrangement of vertical, horizontal, and diagonal beams do in a structure like the Eiffel Tower — the lighter structure can maintain its strength."We found that for a material as light and sparse as aerogel [a kind of glass foam], we see a mechanical stiffness that’s comparable to that of solid rubber, and 400 times stronger than a counterpart of similar density. Such samples can easily withstand a load of more than 160,000 times their own weight,” said Associate Professor Nick Fang. SourceAlso: See other Materials and Coatings tech briefs.

Posted in: Manufacturing & Prototyping, Rapid Prototyping & Tooling, Materials, Nanotechnology, News

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Thin Films Self-Assemble in One Minute

Researchers with the U.S. Department of Energy (DOE)'s Lawrence Berkeley National Laboratory (Berkeley Lab) have devised a technique whereby self-assembling nanoparticle arrays can form a highly ordered thin film over macroscopic distances in one minute.

Posted in: Electronics & Computers, Electronic Components, Photonics, Optics, Manufacturing & Prototyping, Materials, Coatings & Adhesives, Composites, Nanotechnology, News

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New Algorithms Enable Self-Assembling, Printable Robots

In two new papers, MIT researchers demonstrate the promise of printable robotic components that, when heated, automatically fold into prescribed three-dimensional configurations.One paper describes a system that takes a digital specification of a 3-D shape — such as a computer-aided design, or CAD, file — and generates the 2-D patterns that would enable a piece of plastic to reproduce it through self-folding.The other paper explains how to build electrical components from self-folding laser-cut materials. The researchers present designs for resistors, inductors, and capacitors, as well as sensors and actuators — the electromechanical “muscles” that enable robots’ movements.“We have this big dream of the hardware compiler, where you can specify, ‘I want a robot that will play with my cat,’ or ‘I want a robot that will clean the floor,’ and from this high-level specification, you actually generate a working device,” said Daniela Rus, the Andrew and Erna Viterbi Professor of Electrical Engineering and Computer Science at MIT.SourceAlso: Learn about Self-Assembling, Flexible, Pre-Ceramic Composite Preforms.

Posted in: Electronics & Computers, Electronic Components, Manufacturing & Prototyping, Rapid Prototyping & Tooling, Motion Control, Motors & Drives, Power Transmission, Sensors, Software, Computer-Aided Design (CAD), Mathematical/Scientific Software, Machinery & Automation, Robotics, News

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