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EV manufacturers must overcome a unique set of challenges to meet future customer expectations. Among them is the challenge to create innovative designs that meet safety requirements, performance criteria and keep costs down in the face of growing competition and a widening skills gap.

From Copper to Filaments, engineers are developing new materials for 3D printing, advancing its practical use. In February, Markforged, Watertown, Mass., commercialized a pure copper filament for its printers so they can use this hard-to-machine metal.

Composite materials have clear benefits for manufactured parts in aerospace, medical, automotive applications and many other industries. Ensuring the highest part accuracy is critical. Force measurement and material testing are essential processes for product designers and manufacturers to gain insightful data to create high-quality composite components.

Fluence Analytics (formerly Advanced Polymer Monitoring Technologies), a manufacturer of smart industrial and laboratory monitoring systems, recently released the third generation of its ACOMP, an automated system that performs continuous, real-time monitoring and characterization of polymers for 3D printing and other uses during manufacturing and post-processing.

A new breed of turbochargers constructed of super tough alloys operates at higher temperatures and rotational speeds than ever before, resulting in greatly increased output in a smaller package for gas and diesel engines alike.

Manufacturers continually seek ways to make their products stronger and last longer. High Velocity Oxygen Fuel (HVOF) spray coatings help achieve those goals. However, grinding the coatings can be a challenge.

With today’s focus on lightweighting, hollow parts made from composite materials, such as ducting, fuel tanks, mandrels, and rocket shrouds, are in higher demand than ever before. The composite ducting market in the aerospace and defense sector alone is expected to reach $864.7 million by 2024, according to a recent report from Stratview Research.

The Copper Development Association (CDA) is eager to help shops discover and tap into the high-speed machining advantages of brass. The substantial benefits of doing so have an increasing number of shops rethinking their part materials and, when possible, converting those parts to brass.

A Michigan company that displays instructions for manual manufacturing processes on work stations via augmented reality (AR) is adding wearables to provide similar guidance.

When I graduated with an engineering degree some decades ago, I learned that the organizations I was going to work for had internal communication problems. This was especially true for those that designed and manufactured complex machinery such as engines, aircraft, or automobiles.