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.
New versions of BASF's Ecovio line are both compostable and designed for either injection molding or thermoforming. These combinations are becoming more common for the single-use bioplastics used in food service and food packaging applications, but are still not widely available.
The 100-percent solar-powered Solar Impulse plane flies on a piloted, cross-country flight this summer over the US as a prelude to the longer, round-the-world flight by its successor aircraft planned for 2015.
GE Aviation expects to chop off about 25 percent of the total 3D printing time of metallic production components for its LEAP Turbofan engine, using in-process inspection. That's pretty amazing, considering how slow additive manufacturing (AM) build times usually are.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This radio show will show what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.