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March 04, 2025Volume 21 Issue 09


Image - Save Up to 50% in Axial Space with Smalley's Wave Springs (C2C)
Save Up to 50% in Axial Space with Smalley's Wave Springs (C2C)
Smalley's Crest-to-Crest® Wave Springs save up to 50% in axial space compared to standard coil springs. Their flat-wire design is lightweight and accurate with predictable loads. With a compact design, Crest-to-Crest Wave Springs fit in tight spaces and can help reduce the spring cavity size within your application. Try the Smalley Advantage for yourself with a complimentary product sample -- request one on our website!
Learn more.

In this issue of Designfax

  • Amazing results: Microactuator driver for microdrones
  • AI 'hears' when Li-ion battery is about to catch fire
  • New superelastic alloy handles extreme temp range
  • Hennessey creates 850-hp SUPER VENOM Mustang
  • Top Product: 3M Friction Shims -- over 300 million sold
  • Engineer's Toolbox: Gear crowning -- a cheap noise fix
  • Telescopic rail system is PTFE-free
  • Bonding instead of soldering: MiniLEDs and microLEDs
  • Hollow-shaft angle sensor tracks even if power cut
  • EXAIR's new Catalog 36: Comprehensive guide to industrial solutions
  • Stepper drives detect stalls in open-loop control mode
  • Videos+: Technologies and inspiration in action
    • See how Craftsman tool boxes are made
  • Most Popular Last Issue
    • Most powerful Rolls-Royce: Black Badge Spectre
    • Magnets reduce flaws in 3D-printed components
    • Super LiDAR: 3D images of objects 1 km away
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: Hennessey SUPER VENOM Mustang

News

Innovative electrode for lithium-ion batteries is made from tin foam

Student refines 100-year-old math problem, expanding wind energy possibilities

Novel network dynamic approach presents new way for aeroengine performance evaluation

Weird science: Trying to be happy makes us unhappier, study finds



Feature articles

Image - Amazing results: New microactuator driving system for microdrones
Amazing results: New microactuator driving system for microdrones
How long do you think you could keep a battery-powered microdrone flying -- say one that is so small it could perch on your fingernail? Two minutes? Ten? A research team from the University of California San Diego says it could blow those guesses away big time with its innovative circuit design.
Read the full article.

Image - AI 'hears' when Li-ion battery is about to catch fire
AI 'hears' when Li-ion battery is about to catch fire
Researchers at the National Institute of Standards and Technology have developed a way to use sound to detect when lithium-ion batteries are about to catch fire. Could this tech be used to build a new kind of fire alarm?
Read the full article.

Image - New superelastic alloy handles extreme temp range
New superelastic alloy handles extreme temp range
Researchers in Japan have developed a groundbreaking titanium-aluminum-based alloy that is not only lightweight but also strong, offering the unique superelastic capability to function across a broad temperature range. Currently, most shape-memory alloys are limited to smaller specific temperature ranges.
Read the full article.

Image - Hennessey creates 850-hp SUPER VENOM Mustang to celebrate the company's 1991 founding
Hennessey creates 850-hp SUPER VENOM Mustang to celebrate the company's 1991 founding
If an off-the-rack muscle car is just not enough for you, Texas-based high-performance vehicle creator Hennessey has taken it up a big notch. The new SUPER VENOM Mustang features a wide range of performance, aerodynamic, and styling enhancements -- including power boosted 70% from the factory 5.0L V8 engine and 55% higher torque -- that create the ultimate Hennessey Mustang.
Read the full article.

Image - Top Product: 3M Friction Shims -- Why have more than 300 million been sold?
Top Product: 3M Friction Shims -- Why have more than 300 million been sold?
3M Friction Shims are small, thin steel shims with a big impact. They can increase maximum load and peak torque in bolted connections without additional fasteners or redesigns. What else makes them so popular -- and so useful?
Read the full article.

Image - Engineer's Toolbox: <br>Gear crowning -- a cheap fix for noise
Engineer's Toolbox:
Gear crowning -- a cheap fix for noise

With smaller gearboxes transmitting more power at higher rpm and the incumbent demands for greater efficiency, gear engineers are always searching for ways to reduce vibration and limit noise -- without increasing costs.
Read the full article.

Image - Telescopic rail system is PTFE-free
Telescopic rail system is PTFE-free
igus has introduced an aluminum version of its drylin NT-60 telescopic rail, eliminating the use of polytetrafluoroethylene (PTFE) and over 100 per- and polyfluoroalkyl substances (PFAS). This rail system extends up to 2 m and is suitable for many applications, including vehicles, furniture, and medical technology. Despite incorporating a new, PTFE-free plain bearing, the drylin NT-60-4 telescopic rail does not compromise performance.
Learn more.

Image - Bonding instead of soldering: MiniLEDs and microLEDs
Bonding instead of soldering: MiniLEDs and microLEDs
With LED chips for backlighting units becoming smaller and smaller, DELO says adhesives are the best alternative to pick-and-place soldering for miniLED applications. Solder pastes used in serial production are increasingly reaching their limits in terms of mechanical properties and isotropic electrical conductivity. As part of a feasibility study, DELO has developed a test board to demonstrate the suitability of adhesives for miniLEDs in a flip-chip design. It proves that adhesives can create both mechanical and electrical connections in even the smallest of spaces.
Learn more.

Image - Ultra-compact hollow-shaft angle sensor tracks angle even if power is cut
Ultra-compact hollow-shaft angle sensor tracks angle even if power is cut
Novotechnik's WAL 200 Series of hollow shaft angle sensors provides absolute rotary position -- even if power is removed. After power is restored, this sensor provides the correct angle. With a 7-mm profile and 22-mm diameter, it is designed to fit in applications with very limited space. The WAL 200 Series has a measurement range of 0 to 340 degrees. Mechanical range is a continuous 0 to 360 degrees. Applications include volumetric dosing systems, joysticks, and more.
Learn more.

Image - EXAIR's new Catalog 36: BETE products and a comprehensive guide to industrial solutions
EXAIR's new Catalog 36: BETE products and a comprehensive guide to industrial solutions
EXAIR is excited to introduce Catalog 36 -- a full-color, in-depth resource designed to help businesses tackle conveying, cooling, cleaning, blowoff, drying, coating, and static control challenges. This latest edition features an expanded selection of products, technical guides, certifications, and expert insights to help manufacturers optimize their operations. A new addition is BETE's robust lineup of precision spray solutions. Catalog 36 is also a valuable reference for industry standards, safety best practices, and energy conservation techniques in compressed air systems.
Get your EXAIR Catalog 36 today.

Image - Stepper drives detect stalls in open-loop control mode
Stepper drives detect stalls in open-loop control mode
AutomationDirect has added the new Titanio series of stepper drives from Ever Motion Solutions. These drives offer peak performance, a rich feature set, and work seamlessly with AutomationDirect SureStep® stepper motors. Three new drives are available with two open-loop (no encoder feedback) models and one open/closed-loop version (a motor-mounted encoder provides position feedback to the drive). Unlike typical stepper drives, Titanio steppers can detect stalls in open-loop control mode by monitoring the motor's back EMF. This allows system designers to take advantage of stall detection without the hassle and expense of a closed-loop system.
Learn more.

Most popular last issue

Image - Most powerful Rolls-Royce ever: Black Badge Spectre
Most powerful Rolls-Royce ever: Black Badge Spectre
If you want to get your hands on the most powerful Rolls-Royce motor car in history, get ready to dig deep into ye olde piggy bank. The 659-hp Black Badge Spectre is a bad-boy dark knight coupe with a stardust interior, but you'll have to accept some tradeoffs from the maker's traditional car build.
Read the full article.

Image - Magnets shown to reduce flaws in 3D-printed metal components
Magnets shown to reduce flaws in 3D-printed metal components
Safety-critical metal components for aircraft, Formula 1 racing cars, and medical devices could one day be 3D printed via a new technique that substantially reduces imperfections in the manufacturing process.
Read the full article.

Image - Super single-photon LiDAR delivers detailed 3D images of objects 1 km away
Super single-photon LiDAR delivers detailed 3D images of objects 1 km away
Researchers have designed a single-photon time-of-flight LiDAR system that can acquire a high-resolution 3D image of an object or scene up to 1 km away. The new system provides detailed imaging even in challenging environmental conditions or when objects are obscured by foliage or camouflage netting.
Read the full article.

Videos+: Technologies and inspiration in action
See how Craftsman tool boxes are made
YouTuber ChrisFix takes viewers on a step-by-step tour of how Craftsman makes one its best-selling, multi-drawer tool boxes at the company's giant factory in Sedalia, MO. Who doesn't like to see all the metal cutting and forming it takes to make something so long lasting and useful? [Credit: Image courtesy of Craftsman]
View the ChrisFix video.

New products

Electrical/Electronics
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