Highly porous carbon foam structures bonded with polymers such as polypropylene replace lead plates in typical vehicle batteries in a novel materials’ solution to problems with battery life and weight. The innovation comes from a company called Firefly Energy, using technology developed in the R&D Labs at Caterpillar, which was looking for a better battery for its vehicles. In the invention, carbon-graphite foam “grids” are loaded with lead oxides. The foam structure, creates huge surface-area advantages over conventional lead acid grid structures. Active material utilization levels go from the historical 20-50 percent up into the range of 70-90 percent as well as enhanced fast-recharge capability and greater high-rate / low-temperature discharge times, according to Firefly. Costs to produce energy will be higher than conventional lead acid batteries, but below other new technologies, such as lithium batteries. Firefly hopes the approach will be competitive for electric vehicles under development. North Star Battery will produce prototypes for possible use by the US Army.
At this year's MD&M West show, lots of material suppliers are talking about new formulations for wearables and things that stick to the skin, whether it's adhesives, wound dressings, skin patches and other drug delivery devices, or medical electronics.
Researchers at Lawrence Livermore National Laboratory have published two physics-based models for the selective laser melting (SLM) metals additive manufacturing process, so engineers can understand how it works at the powder and scales, and develop better parts with less trial and error.
Materials and assembly methods on exhibit at next week's MD&M West and other co-located shows will include some materials you should see, as well as several new and improved processes. Here's a sampling of what you can expect.
The Food & Drug Administration has approved a 3D-printed, titanium, cranial/craniofacial patient-specific plate implant for use in the US. The implant is 3D printed using Arcam's electron beam melting (EBM) process.
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