Novelis, an Alcan spinoff that is now part of the Aditya Birla Group, has developed a new aluminum alloy that is making impressive gains in automotive and elsewhere. Novelis Fusion is based on a conventional direct chill (DC) mold that is modified in order to allow multiple metal streams to be cast into one single aluminum sheet ingot. The result is an alloy, not unlike multilayer polymer sheet, that is joined together by a metallurgical bond. One of the heavyweight users is the BMW 7 Series, which uses lightweight door components made from Novelis Fusion. A new grade (PA221) designed for appliances is also now available.
Many of the materials in this slideshow are resins or elastomers, plus reinforced materials, styrenics, and PLA masterbatches. Applications range from automotive and aerospace to industrial, consumer electronics and wearables, consumer goods, medical and healthcare, as well as sporting goods, and materials for protecting food and beverages.
Engineers trying to keep track of the ever-ballooning number of materials and machines for additive manufacturing and 3D printing now have some relief: a free searchable database with more than 350 machines and 450 different materials.
At JEC Europe Dow Automotive introduced a new ultra-fast, under-60-second molding cycle time for its commercial-grade VORAFORCE 5300 epoxy resin matrix for carbon composites. It's aimed at high-volume automotive manufacturing.
Proto Labs is now offering an optical liquid silicone rubber (LSR) quick-turn molding service using Dow Corning's LSR material. Optical LSR is a transparent, flexible thermoset material that's replacing glass in many optical applications, especially lighting.
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