Manufacturing & Prototyping

Survival of the Fittest - the Process Control Imperative

In tough times, manufacturers focus on reducing their operating costs, but may not be able to afford to spend their way out by buying more productive machinery. With that pathway closed, what are the opportunities for radically reducing costs without replacing existing machines? This paper explores Productive Process Pyramid™ and the four areas where substantial savings can be found if firms are prepared to change the way they control their machining processes.

Posted in: White Papers, Defense, Energy, Manufacturing & Prototyping


Hot Isostatic Pressing of 60-Nitinol

The material 60-Nitinol (60wt%Ni-40wt%Ti) has a unique combination of physical properties, including high hardness, low apparent elastic modulus, and resistance to saltwater corrosion. These properties give the material tremendous potential for use in aerospace and defense-related components such as bearings, gears, and other apparatuses. Various methods of primary processing are being explored for fabrication of high-performance components that are free of metallurgical defects that might lead to premature failure. Hot isostatic pressing (HIP) is one process under consideration. The steps in the HIP process include (a) filling a sealed canister of the appropriate dimensions with powder, (b) heating the canister under vacuum to remove volatile and gaseous contents, (c) applying heat and pressure to the evacuated and sealed canister to consolidate the contents, and (d) removing the canister.

Posted in: Briefs, Manufacturing & Prototyping, Fabrication, Materials properties, Reliability


Logistics for Building Radiation Storm Shelters and their Operational Evaluation

Various habitat structures were tested for use in exploration activities.Over the past three years, NASA has been studying the operational effectiveness and astronaut protection efficacy of numerous radiation protection shelters for use in space exploration activities outside of Earth's magnetosphere. The work was part of NASA's Advanced Exploration Systems (AES) RadWorks Storm Shelter project. Fabricated items were integrated into mockup deep space habitat vehicle sections for operational evaluations. Two full-scale human-in-loop simulations were designed, fabricated, and implemented. The goal was to provide design and performance assessment information for consideration by mission designers who must quantify the radiation protection characteristics of their exploration trade space.

Posted in: Briefs, Manufacturing & Prototyping, Protective structures, Radiation protection, Spacecraft


Vapor-Barrier Vacuum Isolation System

Applications include metal fabrication in the automotive, aerospace, sporting goods, and medical industries.Electron Beam Freeform Fabrication, or EBF3, is a process that uses an electron beam gun, a dual wire feed, and computer controls to manufacture metallic structures for building parts or tools in hours, rather than days or weeks. EBF3 can manufacture complex geometries in a single operation, and provides efficient use of power and feedstock. The technology has a wide range of applications, including automotive, aerospace, and rapid prototyping. It can build large metallic parts measuring feet in length, and has been reduced in size and power to enable zero-gravity experiments conducted on NASA's Reduced Gravity aircraft.

Posted in: Briefs, Manufacturing & Prototyping, CAD, CAM, and CAE, Rapid prototyping, Fabrication, Metallurgy


Silicon Micro-Emitters for Microfluidic Electrospray Propulsion Systems

Advances in microfabrication capabilities are enabling the development of micro-needles for highly compact electrospray systems.JPL's Microfluidic Electrospray Propulsion (MEP) thruster design is based on a microfabricated electrospray system with a capillary-force-driven feed system that uses indium metal as the propellant. This architecture provides an extremely compact, modular system scalable to a wide range of applications from micro spacecraft to large, space-based telescopes.

Posted in: Briefs, Manufacturing & Prototyping, Architecture, Microelectromechanical devices, Propellants, Spacecraft fuel, Silicon alloys


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


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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