Reference Articles 1 - 100 of 493
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Case Study: Gerber- Proven Commitment, Proven Results
In 1985 Gerber began a relationship with Plastic Ingenuity as their thermoforming partner. At its peak, PI thermoformed 21 different jobs for Gerber. After a seven year run, Gerber began running some...(read more)
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13 Easy Steps to Cutting Your Energy Costs by 50% (.doc)
When the price of gas increases so does your energy bill. Every aspect of your operations is affected. Profits are eroded. Jobs are threatened. But there are some easy steps you can take - a road map...(read more)
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Aligned Parts Assembly System: An Innovative Approach for Small Parts Assembly (.pdf)
The Aligned Parts Assembly System (APAS) has the potential to revolutionize assembly operations. APAS is an innovative, low-cost, manufacturing assembly approach that increases the speed, accuracy,...(read more)
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Laser Welding
Applied Energy Systems incorporates primarily tungsten inert gas processes in welding everything from semiconductor tubing to pressure transducers to regulator bodies to purifiers. There are some...(read more)
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Orbital Welding
Orbital welding is performed when the part being welded is held stationary and the welding torch or tungsten is orbited around the tube or pipe. It is normally preferable to rotate the part rather...(read more)
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Industrial Flooring - The Who, What and Where
Industrial flooring can be used in numerous environments by a number of different types of individuals for safety purposes. You do not need to be located in a manufacturing facility to find a need for...(read more)
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Influence of Nitinol Wire Surface Preparation Procedures (.doc)
As the use of nitinol continues to grow in medical applications, so also does the need to acquire additional fundamental information regarding the stability of the material, in specific areas of...(read more)
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Optimization of Melt Chemistry and Properties of Drawn Filled Tube
The purpose of this paper is to review the property improvements of this alloyed wire through the use of enhanced melting chemistry. The new chemistry is the 35N LT® material which meets the...(read more)
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Anodize & Hardcoat Anodize - Aluminum Protection From Within (.pdf)
The anodize process refers to the passing of DC current through an aluminum part (the anode) while the aluminum part is submerged in a sulfuric acid electrolyte bath. Contrary to some beliefs, anodize...(read more)
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Chromate Conversion Coating - When Bonding and Corrosion is Critical (.pdf)
Chromate treatments (sometimes called chemical film) produce effective paint bonds through molecular adhesions with the film being bound to the metal, in turn offering the same type of adhesion to the...(read more)
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Creating 3D Digital Art Pieces
ProtoCAM has specific experience working with artists to create 3D art pieces. Applying 3D modeling, rapid prototyping, rapid manufacturing and direct digital manufacturing techniques to 3D art models...(read more)
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Alternative Energy: Solar / Wind / Batteries
Alternative energy production requires a much broader and innovative use of materials, such as in solar, where there are semiconductors for photovoltaics (PV), enhanced thermally conductive materials...(read more)
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Aluminum Structures
Aluminum structures are normally brazed, welded or soldered. Braze joining of aluminum uses Si-rich Al alloys that have brazing temperatures ~ 25 - 50 ºC below the melting points of the base aluminum....(read more)
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Cold Plates
Actively cooled cold plates utilize copper or aluminum tubes. They are typically bonded into aluminum plates to reduce weight and optimize thermal conductivity thus minimizing hot spots on the...(read more)
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New Precision Galvanizing Technology - Clean, Green, Cost Effective (.pdf)
A new precision zinc galvanizing process has been developed by Distek Ltd., providing superior wear and corrosion protection on steel and iron parts. The process eliminates environmental problems with...(read more)
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Semiconductor Industry Helps to Green Solar
Not only must the photovoltaics industry work to reach grid parity, but it must also maintain an environmentally sound manufacturing profile so as not to negate the benefits of solar's clean energy....(read more)
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A Supervisory Control to Manage Brakes and Four-Wheel-Steer Systems (.pdf)
This paper presents the development of coordinated control of vehicle systems, specifically for controlled brakes and controlled steering systems. By utilizing a control structure to oversee a...(read more)
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Arc Fault Detection Schemes for an Automotive 42 V Wire Harness (.pdf)
Introduction of higher DC system voltage distribution networks greater than 24V in future passenger vehicles appears to be an unavoidable consequence of meeting the increasing future electrical power...(read more)
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Blow-Molded Plastic Active Knee Bolsters (.pdf)
Deployable or active knee bolsters are being introduced by many OEMs, primarily on the driver side, as an improvement to the fixed or passive knee bolsters. There are shortcomings with the fixed knee...(read more)
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Development Of A Slush Molded TPO Instrument Panel Skin (.pdf)
Slush molding is a unique processing operation that was developed originally for polyvinyl chloride (PVC) based materials. It has been utilized to produce a variety of automotive interior products,...(read more)
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Discrimination of Spatially Confused Beams for Ranging with Single Camera (.pdf)
It has been demonstrated that multiple beam ranging can be achieved with a single camera and spatially encoded probing beam matrix. However, as the density of the beam matrix increases, identification...(read more)
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Dual Depth Passenger Air Bag (.pdf)
A dual depth passenger air bag technology has been developed which provides two different deployed cushion shapes coupled with two inflation levels, but only uses two initiators, one for a single...(read more)
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Twin Sheet Thermoforming, Cycle Time Minimization by Maximizing Heater Cycle Temperature Profile that Prevents Sheet over Temperature (.pdf)
Twin Sheet Thermoforming. Minimization of cycle time for heating sheets of a polymer of various sizes. Providing, improved quality, and cycle time reduction. A process optimization algorithm....(read more)
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Math-Based Design of Sensing Bladders (.pdf)
Through the use of finite-element modeling, pressure patterns on the underside of seat foam can be computed for a variety of occupants and seating positions. A design tool has been created which...(read more)
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Mechanical, Thermal and Rheological Properties of Polymers Used in Plastic Fuel Tanks (.pdf)
The materials used for making plastic fuel tanks are: virgin high-density polyethylene; fuel tank regrind; ethylene vinyl alcohol copolymer (EVOH) fuel barrier; and maleic anhydride modified linear...(read more)
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Cylinder Pressure-Based Control of Pre-Mixed Diesel Combustion (.pdf)
Implementation of real-time combustion feedback for use in closed-loop combustion control is a technology that has potential to assist in the successful production implementation of advanced diesel...(read more)
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Design and Development of a 2-Step Rocker Arm (.pdf)
2-Step variable-valve lift and timing is a high-value technology for the further development of automotive internal combustion engines. 2-Step valve train systems provide improved engine efficiency,...(read more)
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Design of an Automotive Grade Controller for In-Cylinder Pressure Based Engine Control Development (.pdf)
This paper describes a new tool to capture cylinder pressure information, calculate combustion parameters, and implement control algorithms. There are numerous instrumentation and prototyping systems...(read more)
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Design of the Occupant Protection System for Frontal Impact Using the Axiomatic Approach (.pdf)
The functional requirements (FRs) and design equation of a flexible system change in a continuous manner with respect to a variable such as time. An event driven flexible system is defined as a...(read more)
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Improvements of the KIVA Dense Spray Modeling for HSDI Diesel Engines (.pdf)
A numerical study has been performed to investigate the soot emission from a high-speed single-cylinder direct injection diesel engine....(read more)
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Model-based Development for Event-driven Applications using MATLAB: Audio Playback Case Study (.pdf)
Audio playbacks are mechanisms which read data from a storage medium and produce commands and signals which an audio system turns into music. Playbacks are constantly changed to meet market demands,...(read more)
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Palladium/Rhodium Dual-Catalyst LEV 2 and Bin 4 Close-Coupled Emission Solutions
Dual-monolith catalyst systems containing Pd/Rh three-way catalysts (TWCs) provide effective emission solutions for LEV2/Bin 5 and Bin 4 close-coupled applications at low PGM loadings. These systems...(read more)
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Why Have a Systems Engineering (SE) Capability for Automotive Product Development? - Questions and Answers (.pdf)
A clear understanding of Customer and User requirements is essential to successfully develop, design, build, test and produce components and systems for Customer Programs. Systems Engineering (SE) is...(read more)
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Ammonia Sensor for Closed-Loop SCR Control (.pdf)
Selective Catalytic Reduction (SCR) is the dominant solution for meeting future NOx reduction regulations for heavy-duty diesel powertrains. SCR systems benefit from closed-loop control if an...(read more)
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Techniques for Reprogramming the Boot in Automotive Embedded Controllers (.pdf)
Typically, automotive embedded microcontrollers will have flash ROM-resident boot (boot loader) software in order to reprogram the application software and/or the calibration data. However, depending...(read more)
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The Impact of Injection Strategies on Emissions Reduction and Power Output of Future Diesel Engines (.pdf)
Future light, medium and heavy duty diesel engines will need to satisfy the more stringent emission levels (US 2014, Euro 6, etc.) without compromising their current performance and fuel economy,...(read more)
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The Value of Joint Customer and Supplier Quality Function Deployment (QFD) and Design for Six Sigma (DFSS) Toolset Applications (.pdf)
The purpose of this paper is to show the power of joint ownership between suppliers and customers to create a superior product for the end user. This effort translates into competitive advantages for...(read more)
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Dichroic Beamsplitters (.pdf)
Dichroic beamsplitters are used to combine or separate beams of two different wavelengths. An LWP long wave pass dichroic beamsplitter always transmits the longer wavelength and reflects the longer...(read more)
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B-COOL Project - Ford Ka and Fiat Panda R-744 MAC Systems (.pdf)
The B-COOL project, funded by the European Union, is devoted to the development of low cost and efficient R-744 system for small cars. In the framework of this initiative a Fiat Panda and a Ford Ka...(read more)
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Closed Loop Pressure Control System Development for an Automatic Transmission (.pdf)
This paper presents the development of a transmission closed loop pressure control system. The objective of this system is to improve transmission pressure control accuracy by employing closed-loop...(read more)
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Design and CFD Simulation of a Battery Module for a Hybrid Electric Vehicle Battery Pack (.pdf)
Computational Fluid Dynamic (CFD) analysis was performed using FLUENT to analyze the fluid thermal performance of a Battery cell container for the Ford Fusion Hybrid Electric Vehicle. The objective of...(read more)
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Development of a Practical Tool for Residual Gas Estimation in IC Engines (.pdf)
As engines advance toward greater efficiency and lower emissions, there is increasing need for accurate realtime residual models for engine control. Both the formulation of real-time-capable models...(read more)
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Energy-Efficient Air Conditioning Systems Utilizing Pneumatic Variable Compressors (.pdf)
Air Conditioning systems with reheat reduction based for energy efficiency have generally been implemented with either electronic variable compressors through active stroke control or with fixed...(read more)
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Evaluation of the Operating Range of Partially Premixed Combustion in a Multi Cylinder Heavy Duty Engine with Extensive EGR (.pdf)
Partially Premixed Combustion (PPC) is a combustion concept by which it is possible to get low smoke and NOx emissions simultaneously. PPC requires high EGR levels and injection timings sufficiently...(read more)
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Heated Injectors for Ethanol Cold Starts (.pdf)
Ethanol is commonly employed as a transportation fuel in Brazil. However, since pure ethanol's flash point is 12°C, flex-fuel vehicles marketed in Brazil are currently equipped with a redundant fuel...(read more)
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Low Cost Switched Diversity System (.pdf)
This paper presents a low-cost switched diversity receiver system utilizing a single tuner, simple remote antenna unit and one RF cable. The switched diversity algorithm is implemented in the receiver...(read more)
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Model Based Control of SCR Dosing and OBD Strategies with Feedback from NH3 Sensors (.pdf)
This paper presents a model-based control system for SCR urea dosing employing an embedded real-time SCR chemistry model and a NH3 sensor. The control algorithm consists of a number of control...(read more)
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Should I Use a Metal Machining Company to Manufacture my Plastic Parts?
This article explains the difference between companies that machine metal and companies that machine plastic, and explains the hazards of using a metal machinist to produce plastic parts....(read more)
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Spray Pattern Recognition for Multi-Hole Gasoline Direct Injectors Using CFD Modeling (.pdf)
This paper describes a correlation study on fuel spray pattern recognition of multi-hole injectors for gasoline direct injection (GDi) engines. Spray pattern is characterized by patternation length,...(read more)
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The Role of the Data Dictionary in the Model-Based Development Process (.pdf)
Data dictionaries in embedded automotive applications are used for storing data elements and definitions supporting functional and software development. A robust model-based development process should...(read more)
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Volumetric Efficiency and Pumping Torque Estimation and Compressor Recirculation Control of Turbocharged Engines (.pdf)
This paper presents three sub-models of production Engine Management Systems software for turbocharged engines; 1) new load variable for volumetric efficiency modelling, 2) new pumping torque model,...(read more)
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Aging Aircraft (.pdf)
Corrosion and corrosion related fatigue of structural components threatens the readiness of military aircraft and greatly increases the cost of maintenance of virtually all legacy aircraft. Annual...(read more)
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Friction Stir Weld Finishing (.pdf)
Friction stir welding (FSW) offers great promise as a means of joining dissimilar alloys and producing welds with superior metallurgical properties and strengths. Fasteners may be eliminated from many...(read more)
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LPB™ Reduces Propeller Blade Repair and Maintenance Costs and Increases Fatigue Strength in Navy's Anti-Sub Aircraft (.pdf)
The P-3C is a land-based, long-range, anti-submarine warfare (ASW) patrol aircraft, which has effectively served the U.S. Navy since July of 1962. The veteran aircraft is set in motion by four Allison...(read more)
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Mitigation of Fretting Fatigue (.pdf)
Often, turbine engine components are retired from service before "full life" is reached. Turbine disks are a typical example. One of the most common reasons for turbine disk retirement is accumulated...(read more)
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Surface Treatment Program Improves Damage Tolerance and Eliminates Stress Corrosion Cracking (SCC) in Landing Gear (.pdf)
Degradation processes such as foreign object damage (FOD), fretting, active corrosion fatigue, corrosion pitting, and stress corrosion cracking (SCC) are recognized to seriously affect military...(read more)
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Turbine Engine Sustainment (.pdf)
The threat of high cycle fatigue (HCF) failure greatly increases the cost of inspection, maintenance, and operation of legacy turbine engines. As these components continue to age, the probability of...(read more)
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Avoiding Plating Headaches
Machinists and platers are constantly in a battle over narrowing tolerances and while many advances have been made in CNC machines, not much has helped electroplaters hold close dimensions since...(read more)
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Is The LEAD Out Yet?
Let's talk for a moment about those exempt industries, those folks that produce the medical, aerospace and defense items that do not fall under the RoHS ban. The products which they produce must have...(read more)
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Zinc Blackening
There are many ways to blacken both electrodeposited and cast zinc and its alloys. We have solution formulations in our technical library dating back to 1896 (Metal Colouring). Over the forty-five...(read more)
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Zinc Plating
Zinc plating back in 1960, when Anoplate was founded by purchasing a small metal finisher by the name of Noxon Plating Works, contained the old standby, standard high cyanide, 4 ½ ounces per gallon...(read more)
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Advanced Quality Planning: A Commonsense Guide to AQP and APQP
Advanced Quality Planning: A Commonsense Guide to AQP and APQP This guide clearly explains the AQP process and how to situate development in the structure of planning strategies....(read more)
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FIA - What Are the Types of Forging Processes
There are basically three methods (or processes) to make a forged part. Impression Die Forging Cold Forging Open Die Forging Seamless Rolled Ring Forging...(read more)
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The Principles of Shortening the Supply Chain Applies to Your IT Vendor Too! (.pdf)
Major retailers have been long versed in the disciplines of shortening the supply chain to maximize value in their own product lines. But now they must apply those same principles to their technology...(read more)
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Invisible Parts
If you look at core technology, it can be divided into three levels of technology. Traditionally, small metal parts are made by stamping, taking multiple dies on a tool, a high-pressure press, and...(read more)
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Laser-Marking Technology (.pdf)
Laser marking is state-of-the-art technology, which permanently applies computer-generated text, graphics, and machine-readable code on many materials-most notably metal, plastic, and elastomeric...(read more)
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Green Lasers Micromachine Medical Implants
These holes were produced in tubular stainless steel using mechanical drilling (left), conventional laser cutting (center) and micromachining with a high-power, frequency-doubled Nd:YAG laser. When...(read more)
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High-Resolution Laser Micromachining
St. Louis, MO - Gateway Laser Services utilizes a high-resolution laser micromachining process to micromachine "very small parts" with feature sizes down to 0.001 inch and tolerances to ± 0.0002 inch....(read more)
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Laser Welding Creates Potential for Small Parts Applications
Laser welding is an effective method for joining small parts with tight tolerances. In the future, it will compete with traditional methods of welding or replace assembly/joining technologies...(read more)
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Newsletter -- Champion New Technologies (.pdf)
Business does not stop in a recession, because we develop strategies for survival," disclosed Richard Dennis, President of Die-Tech. Manufacturing floors these days seem a little less crowded, but...(read more)
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Newsletter -- Embrace Continuous Process Improvement (.pdf)
In the December 2008 Newsletter, Richard Dennis, President of Die-Tech, revealed the company's strategy for thriving during an economic downturn. "A good defense is not enough," he said, relating to...(read more)
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Newsletter -- How Healthy is Your Supply Chain? (.pdf)
How important are your suppliers to your success? What would happen if one of your key suppliers shut down? These are the questions that keep Supply Chain Managers up at night. And, in these very...(read more)
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Newsletter -- Let Go of Traditional Management Practices (.pdf)
The flood of statistical evidence showing reduced demand, lower production and diminished profits in the manufacturing sector makes many wonder whether manufacturing in the United States is a dying...(read more)
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Newsletter -- When is Good Enough NOT Good Enough? (.pdf)
Have you ever been approached in a restaurant by a server who, in the middle of your meal, asks, "Is everything okay?" Is it really the expectation of the restaurant owner to provide merely "okay"...(read more)
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Watch This Video on How Die-Tech Stamps Cell Phone Components
Die-Tech Stamps Cell Phone Components for the Telecommunications Industry. See how it's done....(read more)
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Watch This Video on How Die-Tech Stamps Hybrid Edge Clips
Die-Tech stamps hybrid edge clips for the consumer electronics industry. See how it's done....(read more)
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Backing Ring Welding Procedure (.doc)
Robvon Backing Rings are inserted into the beveled pipe end with the spacer nubs flush against the pipe land and the ring gap positioned in the area of first bead deposition. The beveled end of the...(read more)
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Consumable Insert Welding Procedure (.doc)
The Robvon Consumable Insert Ring is to be used with tungsten inert gas (TIG). DC and Straight polarity is used for "TIG" welding. The weld joint and immediate adjoining area of parts to be welded...(read more)
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CASE STUDIES - Cast Urethane Prototypes & Products
From portable toilet nozzles to MRI tables, cast urethanes are ideal for marketing samples, test prototypes, or other situations where 1-100 pieces are required, but time and money do not allow a...(read more)
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OEM Guideline to Selecting PCB Suppliers
Many large Original Equipment Manufacturers (OEMs) have a detailed procedure and a significant capital investment in place for the selection of printed circuit board suppliers. This approval process...(read more)
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Precision Parts in CVD Silicon Carbide
A customer pioneering in the life sciences industry contacted Insaco for a quote on Aluminum Nitride machining for their developmental part requiring excellent hardness and good thermal conductivity....(read more)
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The Effects of Frequency in HF Welding (.pdf)
A comprehensive theory for how frequency affects the high frequency welding process is now availablei and has been validated through experiment and comparison to actual tube welding data from numerous...(read more)
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A Coupled Filling-Structural Simulation on a Water Manifold Injection Mold (.pdf)
An injection mold for a water manifold was experiencing deflection on an extremely long core, causing a high defect rate on the finished product. In addition, inserted small plastic capillaries were...(read more)
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Texture Mapping Aesthetic Defects of Injection Molded Parts: Advances in Virtual Molding
Virtual Molding promises to dramatically improve the ability of the non-specialist to interpret and effectively utilize plastic process simulation results. This paper explores one facet of this...(read more)
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M Programming: A Comprehensive Guide
M Programming: A Comprehensive Guide An A-Z guide to the programming language now known as MUMPS....(read more)
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Laser & Electron Beam Welding of Capillary Tubes
When welding capillary tubes it is preferable to weld on the end of the tube, which is normally flush or slightly protruding from the parent. This technique avoids the possibility of the beam...(read more)
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Materials: Engineering, Science, Processing and Design
Materials: Engineering, Science, Processing and Design Written for students taking undergraduate level courses in engineering materials, MS&E, manufacturing and design, and related mechanical...(read more)
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ISO 9001:2000 Audit Procedures, Second Edition
ISO 9001:2000 Audit Procedures, Second Edition With comprehensive detail on the structure, aims, benefits and requirements of ISO 9001:2000, this book describes the methods for completing...(read more)
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Paper Prototyping: The Fast and Easy Way to Define and Refine User Interfaces
Paper Prototyping: The Fast and Easy Way to Define and Refine User Interfaces This book is a practical, how-to guide that will prepare you to create and test paper prototypes of all kinds of user...(read more)
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Shield Design Methodology
If the application requires the shielding of a small circuit or a component, then a basic can will always provide the most cost-effective solution. In cases where significant test or rework is...(read more)
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Automotive Quality Systems Handbook, Second Edition
Automotive Quality Systems Handbook, Second Edition A comprehensive guide to understanding and satisfying the requirements of ISO/TS 16949:2002, this book formalizes, under a single world-wide...(read more)
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Training the Next Generation of Welders
The US is lacking in trained and professional welders. Currently there are over 200,000 welders in the field but with future demands and aging welders new welders are going to be in high demand....(read more)
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Catheter Assembly (.pdf)
A large medical product design firm has determined that it will introduce a new "safety" Catheter to the marketplace. This is in response to legislation and a market recognition of the need for...(read more)
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Diesel Engine Assembly System (.pdf)
This project represents the integration of ATW's LogiTrack LT-40 AEM as the main transport for Diesel Engine assembly and test. It began as joint Simultaneous Engineering white paper design for...(read more)
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High Speed Data Port Connector Assembly (.pdf)
Ever increasing transmission rates for data forced all telecommunications equipment manufacturers to constantly upgrade and redesign their products to adapt to the market needs. This manufacturer of...(read more)
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Hydraulic Motor Assembly System (.pdf)
This semi-automated hydraulic motor assembly line was designed and manufactured in order to give the customer the ability build the majority of the models of a certain motor class on one assembly...(read more)
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Large Machinery Weld Fixturing (.pdf)
This project represents the first phase of several projects in which ATW worked with our customer to take multiple sizes of different parts of construction equipment and give them the ability to weld...(read more)
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Oven Project (.pdf)
Assembly & Test Worldwide was a single source for the tooling, special forming and welding equipment for this Oven project. This is only one of many projects where ATW has combined the tooling and the...(read more)
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A New Source For Instant Prototypes (.pdf)
Business success depends upon product speed-to-market. A new service from Phillips Plastics, www.protowire.com is your source for instant stereolithography (SLA) and fused deposition modeling (FDM)...(read more)
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Multi-Shot Holds it All Together (.pdf)
The innovative OmniPod® Insulin Management System makes the process of controlling diabetes less invasive and easier to manage. Phillips Plastics became engaged early on in the process of...(read more)
