In a new process, a metal insert is partially premolded and then overmolded using conventional technology with traditional plastics used for housings. In the premolding ptocess, conductive paths are affixed in place, and are also tightly sealed in one step. Application targets are sophisticated automotive mechatronic parts such as transmission and brake controls, sensors and plug-in connectors. A key new material is a nonreinforced copolyamide that overmolds the electrical conductive paths in electronic components, ensuring there is no contact with moisture or oil. According to a technical expert at BASF, the material’s developer, the polymer adheres very well to either metals or plastics. To compensate, other sealing methods, such a silicon adhesives or hot melts, were used. Some engineers even precoated metals to improve adhesion
HP revealed more of its 3D printing plans in a recent webinar. Senior vice president of inkjet and graphics solution business Stephen Nigro spoke about how the technology works and expanded on HP's vision of open collaboration to commercialize its Multi Jet Fusion 3D printing technology for end-production, and open collaboration on new materials. He also said HP will create software to help users decide when to use Multi Jet Fusion versus conventional subtractive manufacturing.
A lightweight electric urban concept car designed by several European companies weighs only 992 lb without its battery. It would have weighed 26.7 lb more if its windows were made of glass instead of the specially coated LEXAN polycarbonate resin from SABIC Innovative Plastics.
Skylar Tibbits' team in MIT's Self-Assembly Lab is now 4D printing self-assembling shapes made of programmable carbon composites and custom wood grain. The composites are being used in a sport car airfoil, and the wood grain is beautiful.
The NanoSteel Company has produced high-hardness ferrous metal matrix composite (MMC) parts using a new nanosteel powder in a one-step 3D-printing process. Parts are 99.9% dense, crack-free, and with wear resistance comparable to M2 tool steels.
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