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December 02, 2025Volume 21 Issue 45


Image - Compact Meets Powerful: Discover Smalley's New Nestawave™ Spring
Compact Meets Powerful: Discover Smalley's New Nestawave™ Spring
Introducing Nestawave™ -- the spring that redefines compact power. As the latest innovation in Smalley's wave spring technology, Nestawave combines the deflection of a Crest-to-Crest® wave spring with the force of a nested spring. It delivers high load capacity and significant travel in tight spaces. Ideal for replacing stacks of Belleville washers, it performs in valves, bearing preloads, compressors, and more.
Try the Smalley advantage and request free product samples today.

In this issue of Designfax

  • Voyager mission logs 45 years in space! Milestones
  • Lightning-prediction tool for protecting planes
  • New metallic gel could transform batteries
  • Hyundai Crater concept: A drive on the wild side
  • When metals can't survive: Machined ceramics
  • Engineer's Toolbox: How to pin a shaft and hub assembly
  • More precision, less friction: Strain wave gearheads
  • Build-to-order knobs and hand hardware
  • Why switch from weld fasteners to clinch fasteners?
  • Do-it-yourself board-level EMI shielding
  • Tech Tip: How to create quality STL files for 3D prints
  • Videos+: Technologies and inspiration in action
    • Triumph electric moto bikes for kids ages 3+
  • Most Popular Last Issue
    • Genesis is making a mid-engine V8 supercar!
    • Hydrogen engine nears power, efficiency of diesel
    • Worldwide winner gets car made into Hot Wheels
  • New Products
    • Electrical, Mechanical, Motion
    Cover Image: Hyundai Crater SUV concept

News

Hardware vulnerability allows attackers to hack AI training data

Researchers make better magnets at a lower cost

More efficient aircraft engines: Researchers reveal optimization potential

Weird science: After nearly 100 years, scientists may have detected dark matter!



Feature articles

Image - Voyager, NASA's longest-lived mission, logs 45 years in space! Milestones
Voyager, NASA's longest-lived mission, logs 45 years in space! Milestones
NASA's twin Voyager probes have become, in some ways, time capsules of their era: They each carry an eight-track tape player for recording data, they have about 3 million times less memory than modern cellphones, and they transmit data about 38,000 times slower than a 5G internet connection. Yet the Voyagers remain on the cutting edge of space exploration.
Read the full article.

Image - Lightning-prediction tool could help protect the planes of the future
Lightning-prediction tool could help protect the planes of the future
More than 70 aircraft are struck by lightning every day. Lightning-protection systems work well, largely because they are designed for planes with a "tube-and-wing" structure, a simple geometry common to most aircraft today. Future airplanes may not look and fly the same way, however.
Read the full article.

Image - Newly discovered metallic gel could transform batteries
Newly discovered metallic gel could transform batteries
Researchers at Texas A&M University have developed the first known metallic gel. Unlike everyday gels, like those used in hand sanitizers, this new material is made entirely of metals and can withstand extreme heat. The discovery could be a game changer for energy storage.
Read the full article.

Image - Hyundai Crater concept: A drive on the wild side
Hyundai Crater concept: A drive on the wild side
Hyundai made a big impact at the AutoMobility LA 2025 show in Los Angeles Nov. 20 when it debuted its Crater SUV concept, a rugged, compact off-roader that takes the idea of the brand's eXtreme Rugged Terrain (XRT) trim level to new heights. Crater is angling to be cool, fun, and ready to tackle all the adventurous terrain you can throw at it.
Read the full article.

Image - When metals can't survive: Machined ceramics as an alternative
When metals can't survive: Machined ceramics as an alternative
Technical Ceramics are so hard and wear resistant that they cannot be machined with conventional tools -- but they can outlast and outperform other materials in demanding or harsh applications. INSACO's proprietary diamond grinding process and specialized techniques developed over many decades allow the company to produce and document parts to exacting specifications consistently. Learn all about the alternatives you have when metals just can't take it.
Read the INSACO article.

Image - Engineer's Toolbox: How to pin a shaft and hub assembly properly
Engineer's Toolbox: How to pin a shaft and hub assembly properly
One of the primary benefits of using a coiled spring pin to affix a hub or gear to a shaft is the coiled pin's ability to prevent hole damage. Another is the coiled pin absorbs wider hole tolerances than any other press-fit pin. This translates to lower total manufacturing costs of the assembly. However, there are a few design guidelines that must be adhered to in order to achieve the maximum strength of the pinned system and prevent damage to the assembly.
Read this very informative SPIROL article.

Image - More precision, less friction: Strain wave gearheads
More precision, less friction: Strain wave gearheads
With the new Strain wave gearheads, maxon expands its portfolio, especially for applications with high demands on precision in torque transmission. The backlash-free design ensures exact motion control in minimal installation space -- ideal for robotic arms, surgical instruments, or optical applications. In combination with maxon drives, this results in a perfectly matched drive system from a single source. Available in diameters of 55 mm and 62 mm. Additional sizes and variants on the way.
Learn more.

Image - Build-to-order knobs and hand hardware
Build-to-order knobs and hand hardware
Rogan Corp.'s innovative use of two-shot plastic injection and insert molding has been providing customers with high-quality plastic clamping knobs, levers, and control knobs for more than 90 years. Rogan offers concurrent engineering, product design, and assistance in material selection to ensure customer satisfaction for standard or customized parts, with a focus on cost optimization and on-time delivery. Custom colors, markings, decorative inlays, or engineered materials to meet special requirements, such as adding extra strength or utilizing a flame-retardant material, are all offered.
Learn more.

Image - Why switch from weld fasteners to clinch fasteners?
Why switch from weld fasteners to clinch fasteners?
According to the experts at Penn-Engineering, engineers usually make the switch from weld fasteners to self-clinching fasteners due to two key motivators: environmental impact and cosmetic appeal. Additional benefits often materialize, though, that have positive effects on time, costs, and end-product quality. Find out how.
Read this PennEngineering PEM blog with real-world examples.

Image - Do-it-yourself board-level EMI shielding
Do-it-yourself board-level EMI shielding
ProtoShield sheets from Tech-Etch are depth-etched with a checkerboard pattern for folding, so they can be easily formed into many diverse configurations. In the product-development stage, fully functional shields can be created in minutes with just a pair of scissors and a straight edge for folding. Offered in two sizes: standard (.25-in. squares) and metric (5-mm squares). Both versions are solderable and corrosion resistant due to nickel silver material. Shield prototypes can be directly soldered to the board, or shield clips can be used for easy mounting. Samples available.
Learn more.

Image - Tech Tip: How to create high-quality STL files for 3D prints
Tech Tip: How to create high-quality STL files for 3D prints
Have you ever 3D printed a part that had flat spots or faceted surfaces where smooth curves were supposed to be? You are not alone, and it's not your 3D printer's fault. According to Markforged, the culprit is likely a lack of resolution in the STL file used to create the part.
Read this detailed and informative Markforged blog.

Most popular last issue

Image - Genesis is making a mid-engine V8 supercar!
Genesis is making a mid-engine V8 supercar!
Genesis surprised a lot of people last week when it announced it will make a mid-engine supercar -- and then rolled out a red-hot concept vehicle that looks almost production ready to prove it. The company wants the Magma GT Concept to serve as its high-performance identity for the next decade.
Read the full article.

Image - Hydrogen engine nears power, efficiency of diesel
Hydrogen engine nears power, efficiency of diesel
Southwest Research Institute has upgraded its hydrogen-powered heavy-duty internal combustion engine for a Class-8 truck with a state-of-the-art turbocharger, which has significantly improved performance across the board and made the engine competitive with current long-haul diesels.
Read the full article.

Image - Worldwide winner gets his car made into real Hot Wheels
Worldwide winner gets his car made into real Hot Wheels
Did you know toymaker Mattel holds an annual contest to find the coolest custom-built car on the planet that they can make into a new, specialty Hot Wheels die-cast vehicle? The 2025 winner has been chosen, with the final three entries hailing from the United States, Mexico, and Poland.
Read the full article.

Videos+: Technologies and inspiration in action
Triumph makes first electric moto bikes for kids ages 3+
Triumph Motorcycles has announced the launch of its first electric youth motorcycles: the new Triumph TXP range powered by OSET. The 600-W TXP-12 for riders ages 3+ and 765-W TXP-16 for riders ages 5 to 7 are the first models available in the United States. Each bike is engineered from the ground up with age-specific lightweight steel frames, geometry, controls, components, and electric performance, with everything scaled and optimized for the rider's size and experience. Smart control systems like Field-Oriented Control manage performance as the battery depletes and provide real-time torque management, while Active Performance Stabilization smooths acceleration and improves stability across all terrain types. Includes built-in safety features.
View the video.

New products

Electrical/Electronics
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