One of my favorite themes in recent months has focused on how engineers can fight rising materials costs with new designs. Metals costs are still about double what they were four years ago. It looks like steel prices will be rising another 10 to 20 percent in coming months based on what’s happening in iron ore and coking coal contracts. Contract prices for the coal used as fuel in blast furnaces are rising 200 percent.
One way to mitigate rising metals prices is to consider net shape forming processes, such as metal injection molding. This is still a relatively small business, mostly because of its newness. Specialist molders mold metal powder mixed with plastic in injection molding machines that are only slightly modified. Green parts go into a furnace where the plastic is molded out, creating a “nearly” isotropic part. Metal molding makes a lot of sense when it competes against mutli-step processes, say where you are welding to a stamping to a machined part. Metal molding is best suited for complex parts under 100 grams.
I’ll be writing about metal molding in detail in coming months. For now, a great resource is the Metal Injection Molding Association, which is one of six trade groups organized within the Metal Powder Industries Federation.
Many of the new adhesives we're featuring in this slideshow are for use in automotive and other transportation applications. The rest of these new products are for a wide variety of applications including aviation, aerospace, electrical motors, electronics, industrial, and semiconductors.
A Columbia University team working on molecular-scale nano-robots with moving parts has run into wear-and-tear issues. They've become the first team to observe in detail and quantify this process, and are devising coping strategies by observing how living cells prevent aging.
Many of the new materials on display at MD&M West were developed to be strong, tough replacements for metal parts in different kinds of medical equipment: IV poles, connectors for medical devices, medical device trays, and torque-applying instruments for orthopedic surgery. Others are made for close contact with patients.
New sensor technology integrates sensors, traces, and electronics into a smart fabric for wearables that measures more dimensions -- force, location, size, twist, bend, stretch, and motion -- and displays data in 3D maps.
As we saw on the show floor this week at the Pacific Design & Manufacturing and co-located events in Anaheim, Calif., 3D printing is contributing to distributed manufacturing and being reinvented by engineers for their own needs. Meanwhile, new fasteners are appearing for wearable consumer and medical devices and Baxter Robot has another software upgrade.
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