Apr 30, 2018

April 26, 2018 – If trade show attendance is an indicator of the health of manufacturing in the United States, then the industry is off to a great start in 2018. Design-2-Part (D2P) Shows, a series of eleven annual design and contract manufacturing trade shows across the U.S., has set attendance records in each of the three shows held so far in 2018. Two of the shows, in Grapevine, Texas and Secaucus, NJ, recorded all-time record highs for D2P shows in those cities. The third show in Atlanta, Georgia posted its highest attendance since 1995. “We are obviously thrilled with the attendance and the start that our shows have had for 2018,” said Jerry Schmidt, President of Design-2-Part Shows. “But we are also encouraged by what this could indicate for America’s manufacturing industry and the U.S. economy as a whole. What’s really encouraging about this “snap shot” is the spread of regions that have all responded: the Southwest, the Southeast, and the Northeast.” Design-2-Part Shows provide U.S. manufacturers an efficient opportunity to meet local and national job shops and contract manufacturers face-to-face to source custom parts, components, services, and design. Exhibiting companies showcase their design-through-manufacturing services featuring more than 300 product categories for the metal, plastics, rubber and electronics industries. D2P Shows exclusively feature exhibiting job shops and contract manufacturers with manufacturing operations in the United States. Companies that do not have facilities in the U.S. are not permitted to exhibit. D2P will continue its 2018 spring schedule with shows in Schaumburg, Illinois, Santa Clara, California, and Minneapolis, MN. For information on exhibiting or attending any Design-2-Part Show, visit...

Apr 19, 2018

“Butler Technologies Plays Key Role in Printed Heater Technology for U.S. Olympic Team” By Mark Shortt, Design-2-Part Magazine Butler Technologies, Inc., a specialist in user interface design and printed electronics, has made great strides during its 28-year history. Founded in 1990 by William Darney (now deceased), and Nadine Tripodi, Butler began as a brokerage firm that represented board manufacturers and screen printing companies, before venturing into manufacturing in 1993. Although the company has expanded and enhanced its offerings through the years, it never lost its original core manufacturing focus as a precision printer. “That’s what we started as, and that’s where our true passion lies, in printing, and especially in conductive inks,” said Butler Technologies President Nadine Tripodi, in a phone interview with D2P in February. “We are, in most cases, a contract printer, and on top of that, a solutions provider for those of our customers who aren’t really sure what they want or what the best approach to a print solution might be, especially in user interfaces and different types of graphic overlays.” Today, Butler is heavily focused on printed electronics, a growth market that has the company designing and manufacturing a range of wearable electronics, capacitive touch circuits, and flexible printed heaters, among other products. The company supports its customers’ product design and development goals through the efforts of an approximately 10-member engineering design team that continues to grow. “That’s one place that in the past couple of years, we’ve really added more people, and they’re good—they really are,” Tripodi said. She credited Butler’s head engineer, Mike Wagner, as being instrumental in the company’s ability to offer leading-edge printed electronics. “He is the one who really has a penchant for this and has helped tremendously in getting us more ingrained in the printed electronics world.” Butler’s engineering team offers expertise in mechanical engineering, electrical engineering, and project management. Its electrical engineers can work with customers to design and integrate custom printed electronics that meet specific size, shape, and functional requirements of a given project, the company said on its website. Sometimes, customers come to Butler with a drawing showing exactly what they need, and don’t make any modifications or alterations to it. But...

Mar 9, 2018

Featured in Design-2-Part Magazine TROY, Mich.—Magna has put a new twist on joining thermoplastic materials in order to help automakers cut weight and costs: torsional welding. The torsional welding process, developed by Magna (www.magna.com) for automotive applications at its exteriors plant in Liberec, Czech Republic, presents a new way to join plastics. It features a high-speed twisting motion that creates enough friction-based heat to join a plastic bracket to a thermoplastic fascia. The innovative technology achieves an approximate 10 percent weight reduction because it allows thinner materials to be joined, which, in turn, reduces material costs. Torsional welding is currently used to make the front fascia of the 2017 Skoda Octavia, and it has potential for other applications where materials of similar composition need to be joined.   There may also be uses for torsional welding with the increase of advanced driver assistance systems and the development of self-driving cars. The trend will be for automotive fascias to become heavier with the increase in autonomous features, due to the addition of sensors. With torsional welding, it’s now possible to reduce weight on the outer skin and brackets so more sensors can be added without impacting the overall weight of the vehicle. The Society of Plastics Engineers’ Detroit Chapter recognized Magna’s torsional welding process with an innovation award at its TPO conference last fall in Troy, Michigan. “We seek every opportunity, from design and materials to enabling technologies, to help customers meet their lightweighting goals,” said Magna Exteriors President Grahame Burrow, in a press release. “We appreciate this recognition from SPE and look forward to expanding the use of this innovative process.”...

Feb 20, 2018

“Airbus Installs First 3D Printed Titanium Part on Series Production Commercial Aircraft” Featured in Design-2-Part Magazine NEW YORK—Several months ago, Airbus and Arconic achieved a 3D printing first—the installation of a 3D printed titanium bracket on a series production Airbus commercial aircraft, the A350 XWB. Arconic, a global technology, engineering, and advanced manufacturing company, announced in September that it is 3D printing these parts for Airbus’s newest widebody aircraft at Arconic’s additive manufacturing facility in Austin, Texas.  “Arconic is proud to partner with Airbus to advance aerospace additive manufacturing,” said Jeremy Halford, president of Arconic Titanium and Engineered Products, in a company release. “Our comprehensive capabilities, from materials science leadership to qualification expertise, helped make this achievement possible. We look forward to continuing to advance the art of the possible in additive for aerospace.” This first installation of a 3D printed titanium part on a series production Airbus commercial aircraft marks a milestone for additive manufacturing in aerospace. Although airplane makers have been using 3D printed parts for quite some time, largely for components inside the cabin, equipping airframes with metal parts produced via additive manufacturing is new. Airbus’s installation of this 3D printed titanium bracket on a series production commercial airplane, as opposed to a test airplane, is said to mark a significant step forward in the qualification of more complex 3D printed parts for production aircraft. 3D-printed parts, including metal printed cabin brackets and bleed pipes, are already flying on Airbus A320neo and A350 XWB test aircraft. The 3D printed titanium bracket is part of an ongoing partnership between Airbus and Arconic. In 2016, Arconic (www.arconic.com) announced three agreements with Airbus to produce titanium and nickel 3D printed parts for commercial aircraft, including the A320 platform and A350 XWB. Arconic’s 3D printing technology capabilities include laser powder bed and electron beam...

Feb 12, 2018

“How Do You Optimize the Structure of the World’s Largest All-Composite Aircraft?” Featured in Design-2-Part Magazine Manufacturers of the Stratolaunch air-launch platform used Collier Research’s automated sizing and analysis software to inform laminate design and production, optimize the fuselage and wing structure, and reduce weight. NEWPORT NEWS, Va.—When the Stratolaunch aircraft rolled out of the Mojave, California Air and Space Port hangar last spring in preparation for ground testing, it was a clear example of how far the design and manufacturing of composite materials have progressed in recent years. In September, the first phase of engine testing on the aircraft’s six Pratt & Whitney turbofan engines was completed.   The world’s largest aircraft by wingspan (wider than a football field is long) is almost entirely fabricated from composite materials, which provide light weight, high stiffness, and strength characteristics that are increasingly in demand in aerospace, automotive, sports, medical, and industrial fields. But when you’re building the world’s largest all-composite aircraft, how do you know it can carry the load? One option is to test the materials using HyperSizer, a computer-aided engineering (CAE) software product from  Collier Research Corporation. The simulation software has already been used to test materials used in Bell’s V280 helicopter, the NASA Orion crew module, the Ares 1, the Ares 5, and many commercial rockets across the globe. And recently, engineers used HyperSizer to simulate, analyze, and optimize the composite structures that make up most of the Stratolaunch aircraft. Stratolaunch (www.stratolaunch.com) is the brainchild of Paul Allen, Microsoft co-founder, and Burt Rutan, the noted aircraft designer who founded Scaled Composites. It is a 238-foot-long jet aircraft with two fuselages that are connected by a giant single wing. Designed to serve as a mobile launch pad for carrier rockets, Stratolaunch is powered by six engines that will enable it to take off from a runway carrying a payload of up to 550,000 pounds.  The plan is to fly to 35,000 feet, the cruising altitude of a commercial airliner, and release the launch vehicle’s payload, and then return to the airport for reuse. It is expected to operate in 2019. Collier Research’s HyperSizer optimization software was used extensively by Stratolaunch manufacturer Scaled Composites...