Metal clamps are eliminated because of a new spin welding process used in the pressure line of the award-winning diesel exhaust fluid system (DEF) in the 2011 Ford Superduty pickup truck. A 50 percent glass reinforced polyamide quick connector is friction welded to a polyamide line in one of the many technical innovations in the DEF system, which won the Grand Prize at the 40th Annual Automotive Innovation Awards Gala held by the Society of Plastics Engineers International in November. The all PA12 inner tube line construction is 40 percent lighter than competitive EPDM rubber lines, according to Scott Cooper, an engineer with Ford Powertrain Engineering.
Spin welding, a technical strength at Ford, is used to join spherical plastic parts. Generation of friction at the mating surface by spinning one part (upper) against a fixtured (lower) part, fastens the assembly.
Airbus Defence and Space has 3D printed titanium brackets for communications satellites. The redesigned, one-piece 3D-printed brackets have better thermal resistance than conventionally manufactured parts, can be produced faster, cost 20% less, and save about 1 kg of weight per satellite.
At IMTS last week, Stratasys introduced two new multi-materials PolyJet 3D printers, plus a new UV-resistant material for its FDM production 3D printers. They can be used in making jigs and fixtures, as well as prototypes and small runs of production parts.
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