Kendall. Thanks for getting back to me. I was thinking of something similar to the way fiberglass panels are made with a metal mesh replacing the glass mesh. Don't know if that is even practical or has been tried. It just seemed like an interesting idea.
Scott, not sure what sort of construct you mean specifically by a 'hybrid.' Some of our systems are filled with various substances. Metals sometimes play a role. But the metal itself doens't play a role for strength. Obviously the trade-off when systems are more highly filled is for strength properties (flex mod, impact). I think maintaining this balance is more critical for automotive applications than say electronics. We are also looking at composite-based constructs for these types of properties. Best, Kendall -
I agree Kendall. The improved thermal conductivity of many polymers is now opening design doors that were previously closed for us. In addition to metal heat sinks that may have been overspecified in the past, new LED technologies burn cooler and brighter, so the opportunity to replace a metal heatsink with a thermally conductive plastic heatsink may now be available.
I found myself wondering if there were some polymer/metal hybrid materials out there for use in automotive applications? Is that a practical tradeoff for weight, strength, conductivity, etc.? Any thoughts?
Not that conductive, but sounds like a great material that can both house and supply data for low voltage sensors. I wonder if this is being explored. Also, a great way to send power or a signal through a enclosed container. That is if both conductive and non-conductive plastics can be molded together. Sound like this will revolutionize the automotive sector sometime soon.
Designing trade-offs are always more complex than getting exact matches of properties. The thermally conductive compounds referenced in the article have thermal conductivities up to about 20 W/mK. While that isn't quite equivalent to aluminum at 100W/mK, it's over 3 orders of magnitude improvement over base plastics which sit at around 0.1 W/mK.
That does make these formulations viable options for heat management. We've done several design cases in areas such as automotive lighting and have shown that those sorts of conductivities are more than enough to replace metal heat sinks which in many cases are *overspecified* for thermal conductivity.
As to 3D printing. We have 3D printing capability and development programs to be able to print some of our key functional formulations. Happy to discuss further if you like.
The low-hanging fruit of plastic-to-metal conversion is no longer there for the taking, but that doesn't mean there are no opportunities. This article does a good job of explaining how to go about finding these opportunities: design engineers should sit down with suppliers or other experts, with a focus on part function. You are probably not going to make the same exact part out of plastic that you made out of metal -- at least, not if you want the part to work! But, with a little creativity, you might be able to get the same function. It takes design ingenuity, along with a knowledge of what's out there in terms of materials. This is where suppliers and outside experts can help.
Iterative design — the cycle of prototyping, testing, analyzing, and refining a product — existed long before additive manufacturing, but it has never been as efficient and approachable as it is today with 3D printing.
People usually think of a time constant as the time it takes a first order system to change 63% of the way to the steady state value in response to a step change in the input -- it’s basically a measure of the responsiveness of the system. This is true, but in reality, time constants are often not constant. They can change just like system gains change as the environment or the geometry of the system changes.
At its core, sound is a relatively simple natural phenomenon caused by pressure pulsations or vibrations propagating through various mediums in the world around us. Studies have shown that the complete absence of sound can drive a person insane, causing them to experience hallucinations. Likewise, loud and overwhelming sound can have the same effect. This especially holds true in manufacturing and plant environments where loud noises are the norm.
The tech industry is no stranger to crowdsourcing funding for new projects, and the team at element14 are no strangers to crowdsourcing ideas for new projects through its design competitions. But what about crowdsourcing new components?
It has been common wisdom of late that anything you needed to manufacture could be made more cost-effectively on foreign shores. Following World War II, the label “Made in Japan” was as ubiquitous as is the “Made in China” version today and often had very similar -- not always positive -- connotations. Along the way, Korea, Indonesia, Malaysia, and other Pacific-rim nations have each had their turn at being the preferred low-cost alternative to manufacturing here in the US.
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