Engineers are looking for ways to boost value and gain business. One example comes from Mazda, which is leveraging a plastic foaming process developed at MIT. Mazda’s injection molding process cuts part weight 20 to 30 percent by mixing supercritical fluid with plastic resin, such as nylon, in the injection barrel. The SCF causes the melt to expand rapidly when injected into a mold, requiring less resin. After initial injection, the mold core is precisely retracted, creating an outer layer with microscopic bubbles that ensure each part has the necessary strength and rigidity. The size of the bubbles in the core layer are adjusted to reduce density as desired, thus allowing control of the resin savings. Mazda says the technique can be used on most plastic car parts, and will be introduced on 2011 models.Mazda’s initial announcement called the technology proprietary, and Mazda has in fact been awarded patents for the development. Mazda, however, neglected to mention that the microcellular foam technology was developed at MIT and licensed to a Massachusetts company called Trexel. More than 300 molding machines use the SCF technology. Eighty-five discrete components have already been developed for use in cars, Trexel President David Bernstein told me in a recent meeting in Woburn, MA. MuCell works best with semi-crystalline engineering resins.
Mazda apparently did develop the concept of using core-back or “expansion” molding with the process, a brilliant idea. Trexel and Engel will be showing their approach to core-back molding at the National Plastics Exposition in Chicago June 22-26.
I’ll be posting more ideas on microcellular foam here at www.designnews.com, and writing articles for the print edition as well. One big issue I’ll explore is how the microcellular foam process can improve component properties.
Inspired by the hooks a parasitic worm uses to penetrate its host's intestines, the Karp Lab has invented a flexible adhesive patch covered with microneedles that adheres well to wet, soft tissues, but doesn't cause damage when removed.
Engineers at the University of California, San Diego are designing a robotic arm that takes inspiration from the loose, flexible, yet very strong structure of the armored plates on a seahorse's tail.
Researchers at the Missouri University of Science & Technology have designed a new nanoscale material that can transmit light faster than the 186,000 miles per second it usually takes to travel through air.
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A quick look into the merger of two powerhouse 3D printing OEMs and the new leader in rapid prototyping solutions, Stratasys. The industrial revolution is now led by 3D printing and engineers are given the opportunity to fully maximize their design capabilities, reduce their time-to-market and functionally test prototypes cheaper, faster and easier. Bruce Bradshaw, Director of Marketing in North America, will explore the large product offering and variety of materials that will help CAD designers articulate their product design with actual, physical prototypes. This broadcast will dive deep into technical information including application specific stories from real world customers and their experiences with 3D printing. 3D Printing is
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