Browse Topic: Polymers

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Genetic algorithm based optimization of Chaboche kinematic hardening parameters along with the validation of FE model through characterized crack initiation2026-28-0086To be published on 02/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a low voltage (LV) connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for thermo-plastic composite material Ultramid A3U44G6, we have adopted a novel approach of determining non-linear Chaboche Kinematic Hardening (CKH) model parameters from monotonic uniaxial temperature dependent tensile test data of Ultramid A3U44G6. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for Ultramid A3U44G6, here von Mises yield
Basu, Parichay, Srinivasappa, Naveen
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, Lokesh, Bhaskara Rao, Lokavarapu
Mechanical Performance & Vibration Analysis of Hybrid Composite Plates Composed of E - Glass and Areca Fibers2026-28-0073To be published on 02/12/2026
This study investigates the vibration characteristics of hybrid composite laminated plates made from E-glass and areca fibers, targeting applications that demand both mechanical performance and environmental sustainability. The motivation stems from the growing interest in replacing synthetic fibers with natural alternatives in structural applications, particularly for lightweight and vibration-sensitive components. Areca fiber, an abundant and biodegradable natural material, was combined with high-strength E-glass fiber to form hybrid laminates using the Vacuum Assisted Resin Transfer Moulding (VARTM) process. Three distinct composite plates were fabricated with different stacking sequences and filler variations using epoxy resin and brake lining powder. The mechanical integrity and vibrational behavior of these plates were then studied using experimental modal analysis. The tests were conducted under three boundary conditions: fully clamped (C-C-C-C), two-edge clamped (C-F-C-F), and
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
A study on the thermal degradation of chlorinated Polyethylene rubber2026-26-0276To be published on 01/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
Thiruppathi, Anandhi, Mishra, Nitish, Krishnamoorthy, Kunju
Vehicle interior material emissions and contributions in passenger vehicle cabin air quality2026-26-0287To be published on 01/16/2026
Polymer compounds used in the manufacturing of automotive interiors are formulated with various kind of additives, pigments, fillers, and resins. These compounded polymers are prone to the emission of chemicals called volatile organic compound (VOC) over a period of usage, temperature exposure etc. VOCs include a variety of chemicals, some of which may have short term adverse health effects like nausea, headache, vomiting, and long-term adverse health effects like cancer, even death if beyond the permissible limits. Studies indicates the concentrations of many VOCs are consistently higher in indoors (up to ten times higher) than outdoors and hence these chemical emissions are required to be controlled within the defined limits. This paper is focused on the identification part and material, evaluation against the recommended test (Odor/Fogging/VOC/Carbonyl compound emissions) and development of materials used inside the car cabin. This study further provides the guidelines for the
Shukla, Sandeep Kumar, Balaji, K V, Varatharajan, Senthilkumaran
Electric mobility and materials circularity - a study of recycled PET textiles for automotive interiors2026-26-0237To be published on 01/16/2026
The adoption of sustainability in electric mobility has made it crucial to investigate environmentally friendly materials. Polymer materials used in automotive application plays very important role in material circularity contributing significant value addition to the overall carbon footprint index. This study discloses the development of recycled polyester textiles from PET bottle waste, use for automotive interior parts and carbon footprint impact. The use of recycled textiles is directly helping the organization in scope 3 emissions to get the lower carbon footprint value by eliminating the use of fossil fuel resources in making the PET textiles. In this study, the development road map methodology adopted, and validation cycle of recycled polyester textiles (PET) were explained broadly with results of different constructions, color and finishes against automotive critical requirements such as sun load UV resistance, abrasion durability, color migrations, soiling resistance
Palaniappan, Elavarasan, Varatharajan, Senthilkumaran, Balaji, K V, Dodiya, Rohanbhai
New generation Natural Rubber-Based Bump Stopper with Improved NVH Characteristics2026-26-0292To be published on 01/16/2026
In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria. Traditionally, Natural rubber (NR) has traditionally been favoured for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. PU's high compressibility, low lateral expansion, and low compression set make it the material of choice across automotive, aerospace, and industrial sectors. Other materials like thermoplastic elastomers (TPE/TPU) and EPDM rubber are also used, offering advantages such as recyclability, ease of
Murugesan, Annarajan, Hingalaje, Abhijeet, Perumal, Mathavan, Pawar, Rohit
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Optimizing Stick Slip Performance in Automotive Interiors by Material Selection, Additives, and Design Strategies2026-26-0325To be published on 01/16/2026
The automotive industry is highly competitive, especially in terms of design and perceived quality. The use of hard plastics with a high gloss finish is driven by styling trends and the push towards zero gaps, making interfaces critical. In-cabin mood lighting is another feature being offered as a theme for interiors. Dashboard or cockpit designs often incorporate a significant amount of polycarbonate-acrylonitrile butadiene styrene (PC-ABS) and polycarbonate (PC). These materials provide strength and design flexibility but have the disadvantage of material incompatibility when used together, leading to stick-slip phenomena. Traditionally, felt tapes were used as interface isolation to solve this problem, but this increased manufacturing costs and assembly complications. The study focuses on the stick-slip phenomenon and material interface modifications. Specifically, it examines selecting the right surface finish on one side of the PC & PC-ABS interface to change adhesion and friction
Mohammed, Riyazuddin, R, Prasath, Rahman, Shafeeq
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-0280To be published on 01/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charging System2026-26-0283To be published on 01/16/2026
This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal
Naikwadi, Amol Tarachand, Mali, Manoj, Patil, Bhushan, Tata, Srikanth
Material-Optimization in Rib-Stiffened Polymer structures: A Computational & Analytical Study2026-26-0498To be published on 01/16/2026
Background The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel micro-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending and shear performance. Key objective: This study systematically evaluates how parallel rib configurations influence mechanical performance in polypropylene plates, with specific focus on:  Bending stiffness preservation through optimized moment of inertia distribution  Shear resistance enhancement via controlled rib spacing  Coupled effect of the bending and shear resistance Prior art and their limitations: Current literature primarily
Sreejith, M P, Jain, Deepak, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
Determination of Acrylonitrile Content in Nitrile Butadiene Rubber Vulcanizates by Py-GCMS Techniques2026-26-0546To be published on 01/16/2026
Nitrile Butadiene Rubber (NBR), a copolymer of butadiene and acrylonitrile is known for its superior resistance to hydrocarbon oil, low gas permeability and excellent thermal stability. It is extensively used in seals, O-rings, conveyor belts and pneumatic tires. It is worth mentioning that these performance attributes are predominantly influenced by acrylonitrile content. While solid-state 13C Nuclear Magnetic Resonance (NMR) is an established technique for structural characterization of rubber vulcanizates, its high cost and accessibility limits its application in routine industrial analysis. This study aims to develop Pyrolysis-Gas Chromatography/Mass Spectrometry (Py-GCMS) as a robust, precise, cost-effective alternative to determine acrylonitrile content in NBR vulcanizates. This research demonstrates and establish a method to determine the acrylonitrile (ACN) content in finished rubber vulcanizates through pyrolysis gas chromatography-mass spectrometry (Py-GCMS). This method
Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Methodology for optimizing the bench testing of Steering I shaft using vehicle level data to reduce overall product development time and cost.2026-26-0560To be published on 01/16/2026
Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at vehicle level on different
Kabdal, Amit
Sustainable Tyre- A Journey to Meet Future Requirements of Tyre Industry2026-26-0291To be published on 01/16/2026
Sustainability and environmentally friendly business practices are becoming essential. Tyre industries are embracing the green initiatives to reduce its impact on the environment by exploring the eco-friendly strategies. Starting from the ethical raw material sourcing to a creative recycling technique, strategies are widely distributing in every step of tyre manufacturing to disposition. Each stage of a tyre's life cycle viz. raw material procurement, manufacturing, transportation both upstream and downstream as well as during the end-of-life phases have an emission-saving potential. It is important to reduce emissions at every stage of tyre's lifecycle. We, JK Tyre has recently developed a Sustainable Tyre with 11% less GHG emission through sustainable raw material approach. Bio sourced or bio attributed raw materials like Styrene Butadiene Rubber (SBR), Polybutadiene Rubber (PBR), Rubber process oil (RPO) and Silica along with natural rubber (NR) had been used. Beside the raw
Bhandary, Tirthankar, Singha Roy, Sumit, Paliwal, Mukesh, Dasgupta, Saikat, Chattopadhyay, Dipankar, Das, Mahuya, Mukhopadhyay, Rabindra
High-Frequency Dynamic Stiffness Measurements of Automotive Elastomers for Electric Vehicles2026-26-0312To be published on 01/16/2026
The increasing adoption of electric vehicles (EVs) has intensified the demand for advanced elastomeric materials capable of meeting stringent noise, vibration and harshness (NVH) requirements. Unlike internal combustion engine (ICE) vehicles, EVs lack traditional powertrain-induced masking noise. In the automotive industry the dynamic stiffness of elastomers for internal combustion engines are determined traditionally using hydraulic test rigs up to test frequencies of max. 1000 Hz. Measurements in excess of these frequencies were not possible and are only carried out using computerized FE or CAE calculation models. Electric drive systems generate distinct tonal noise components in the high-frequency range up to 10 kHz , which are well perceptible even at low sound pressure levels. Consequently, the dynamic stiffness characteristics of elastomers up to 3000 Hz are critical for optimizing NVH performance. This study focuses on the high-frequency dynamic stiffness testing of automotive
Bohne, Christian, Gröne, Michael
Assessment of emissions behaviour of Volatile compounds from polymeric materials used in automobile interiors2026-26-0222To be published on 01/16/2026
There is an increasing trend of using polymeric materials in the vehicle interior compartment. While the polymers provide benefits in terms of flexibility in profiling, lighter weight and aesthetics but one of the challenges with the polymers is emission of volatile organic compounds (VOCs) during their usage and particularly at a temperature prevailing in the vehicle cabin. VOCs adversely impact the vehicle interior air quality and can pose a risk to occupants’ health. However, there is a lack of information on volatile organic compound (VOC) emissions from automotive interior materials. There are two types of methods, a whole vehicle chamber method (ISO 12219-1) and a bag method (ISO 12219-2) for evaluation of VOCs emissions from materials used in vehicle interior parts. ISO 12219-2 method describes quantitative testing of VOCs and semi-VOCs. This test method is quick and cost effective for analysis of materials for quick emission checks and can prove to be very effective in
PAtil, Yamini Jitendra, Thipse, Sukrut, Bawase, Moqtik
Predictive Analysis of Slip Distance of Highway Loess Slopes Based on Intense Rainfall Infiltration2025-99-024112/23/2025
Based on field investigations of loess slopes along highways in the Lüliang region, a numerical infiltration model of highway loess slopes was established using the ABAQUS finite element software. The study examined the time to plastic zone coalescence and variations in infiltration range under two intense rainfall scenarios for slopes of different heights. Furthermore, a landslide numerical model of the loess slope was constructed using the FEM-SPH method, and a predictive formula for landslide runout distance of highway loess slopes was derived through data fitting.The results indicate that under the same slope height, increased rainfall intensity leads to a certain degree of reduction in landslide runout distance. Conversely, under the same rainfall condition, greater slope height significantly increases the runout distance. This study provides a theoretical foundation and methodological support for stability evaluation and runout distance prediction of loess slopes under intense
Liu, Manfeng, Li, Hong
Study on the Influence of Liquid Composite Swivel Arm Positioning Nodes on the Dynamic Performance of High-Speed Trains2025-99-025512/23/2025
Rubber components are an important part of the suspension system of high-speed trains, and the complex nonlinear characteristics of rubber parts have a significant impact on the vehicle dynamic performance. This paper establishes a nonlinear dynamics model of the liquid composite swivel arm positioning node, which can reflect the dynamic stiffness and dynamic damping characteristics of the rubber components that change nonlinearly with the frequency and amplitude, and also has a fast calculation speed. The vehicle dynamics simulation model considering the longitudinal stiffness nonlinear characteristics of the arm node is established, and the influence of the stiffness nonlinearity of the liquid composite arm positioning node on the dynamic performance of the vehicle, such as straight-line stability and curve passing ability, is studied in depth through numerical simulation.
Cheng, Junqiang, Yang, Chen, Li, Longtao, Cong, Rilong, Hu, Tingzhou
Injection Molding Parameters Optimization to Enhance Mechanical Properties of Glass-Fiber Reinforced PA9T Polymer2025-36-012412/18/2025
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Mendonça, Arthur S., Michelotti, Alvaro Canto, Berto, Lucas F., Salvaro, Diego B., Binder, Cristiano
Biocomposite of Euterpe oleracea Mart and Cocos nucifera l. : Sustainable Materials2025-36-016312/18/2025
Euterpe oleracea Mart.Cocos nucifera L.
Dias, Roberto Yuri Costa, Santos Borges, Larissa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Influence of the PTFE on the Tribological and Mechanical Properties of a Fiber-Reinforced Polyphthalamide2025-36-022112/18/2025
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Hromatka, Matheus, Salvaro, Diego B., Binder, Cristiano, Michelotti, Alvaro C., Berto, Lucas F.
Natural Fibers Applied in the Automotive Industry in Brazil: A Review2025-36-017012/18/2025
There is a growing demand for new materials that meet mechanical and structural performance requirements, with specific properties, especially in the automotive industry. From a context of innovation and global needs to be met, there is the appreciation of composite materials, specifically applied in the automotive sector, since these can be obtained from the combination of two or more different materials, obtaining certain properties from the individual characteristics of its phases, expanding the availability of materials to be used in this sector. In recent years the use of natural fibers in composite materials for automotive applications has gained relevance due to factors such as sustainability, low weight and good mechanical properties. The attempt to combine innovation and environmental preservation make such applications promising, aiming to obtain ecological solutions, considering that natural fibers of vegetable origin such as sisal, jute and flax are biodegradable and
Dias, Roberto Yuri Costa, Santos Borges, Larissa dos, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor de, Silva de Mendonça, Alian Gomes da, Fujiyama, Roberto Tetsuo
Mechanical Tensile Behavior of Polyester Composites with Addition of Banana and Sugarcane Fibers2025-36-015412/18/2025
Musa sapientumSaccharum officinarum L
Santos Borges, Larissa, Dias, Roberto Yuri Costa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Review of Through-the-Thickness Reinforcement Technologies Applied to Aircraft CFRP Composites2025-99-035512/17/2025
Carbon fiber-reinforced polymer (CFRP) composites are widely used in aircraft structures for weight reduction due to their high specific strength and modulus. However, their weak interlaminar properties lead to high sensitivity to out-of-plane loads such as impact, making them prone to delamination damage, which threatens flight safety. To enhance interlaminar performance, through-thickness reinforcement technologies, particularly Z-pinning and stitching, have become key research focuses. This paper systematically reviews the manufacturing processes, structural mechanical characteristics, and application progress in aerospace structures of these two mainstream through-thickness reinforcement technologies. Research shows that Z-pintechnology, by implanting metal or CFRP pins, and stitching technology, by sewing multiple fabric layers with fiber threads, both effectively bridge interlaminar cracks, significantly improving the impact resistance of composites. However, the implantation
Cui, Bo, Zhang, Yongjie, Zhang, Chuzhe, Jin, Tao
HOSE ASSEMBLY, POLYTETRAFLUOROETHYLENE CRES BRAID REINFORCED, 400 °F, 5080 PSI FLARELESS, 90° ELBOW TO 90° ELBOWAS5966C (Current)12/16/2025
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Advances in Polyimide Tubing for Next-Generation Medical DevicesTBMG-5433512/01/2025
Minimally invasive and interventional platforms increasingly demand smaller profiles, tighter tolerances, and components that maintain performance under thermal, chemical, and mechanical stress. Polyimide (PI) has emerged as a workhorse within these parameters because it combines high strength, thermal stability, chemical inertness, dielectric performance, and biocompatibility in thin-wall formats suitable for catheters, electrophysiology tools, and neurovascular systems. 1- 3
Robotic Skin Allows Tiny Robots to Navigate Complex, Fragile EnvironmentsTBMG-5428512/01/2025
Researchers at the University of California San Diego have developed a soft robotic skin that enables vine robots that are just a few millimeters wide to navigate convoluted paths and fragile environments. To accomplish this, the researchers integrated a very thin layer of actuators made of liquid crystal elastomer at strategic locations in the soft skin. The robot is steered by controlling the pressure inside its body and temperature of the actuators.
Programming Robots with Rubber BandsTBMG-5428412/01/2025
From sorting objects in a warehouse to navigating furniture while vacuuming, robots today use sensors, software control systems, and moving parts to perform tasks. The harder the task or more complex the environment, the more cumbersome and expensive the electronic components.
SAE TOMORROW TODAY - Conquering the Australian Outback with Solar Power1354411/21/2025
What does it take to race 3,000 kilometers across the unforgiving Australian Outback powered only by the sun? Listen in as we sit down with Martijn Boonen, Electrical Engineer & Driver, Brunel Solar Team, and Tony Mathew, Global Market Manager, Teijin Aramid, to reveal the secrets behind their record-breaking solar car victory at the 2025 Bridgestone World Solar Challenge. Discover how cutting-edge engineering, relentless teamwork, and innovative sustainable materials came together to conquer extreme heat, torrential rain, and fierce competition. Hear firsthand how the Brunel Solar Team's winning mentality led to their eighth global win, and how circular fiber tire technology proved that sustainability and high performance can go hand-in-hand. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in
Patterson, Lori
Static Seal Test Fixture and ProcedureAS7982 (Current)11/13/2025
This SAE Aerospace Standard (AS) provides dimensions and procedures for a standardized test fixture used to evaluate the static performance of O-rings and other seal types in glands per AS4716 and AS5857.
AMS CE Elastomers Committee
Hardness Testing of Elastomeric O-RingsAIR4738B (Current)11/13/2025
This SAE Aerospace Information Report (AIR) provides a general description of methods for hardness testing of O-rings including factors which affect precision and comparison of results with those obtained in standard tests.
AMS CE Elastomers Committee
Silicone (PVMQ) Rubber Extreme-Low-Temperature Resistant 65 - 75AMS3337G (Current)11/10/2025
This specification covers a silicone (PVMQ) rubber in the form of sheet, strip, tubing, extrusions, and molded shapes.
AMS CE Elastomers Committee
Rubber, Fluorocarbon Elastomer (FKM) 70 to 80 Hardness, Low Temperature Sealing Tg -22 °F (-30 °C) For Elastomeric Shapes or Parts in Gas Turbine Engine Oil, Fuel and Hydraulic SystemsAMS3384A (Current)11/10/2025
This specification covers a high temperature, compression set and fluid resistant fluorocarbon (FKM) rubber in the form of sheet, strip, tubing, extrusions, and molded shapes for aeronautical and aerospace applications.
AMS CE Elastomers Committee
Optimizing the Structural Finite Element Method based Process to Evaluate the Sustainable Human Accidental Sliding Load of Automobile Airvent Knob Design Made with Thermoplastic PC - ABS2025-28-028911/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit finite element analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in non-prestressed condition. The research work proposes a FEM based analysis approach to evaluate the mechanical breakage load of airvent knob assembly for accidental sliding load. This process skips the assembly level snap insertion load case along with silicone rubber pad compression which could serve as the prerequisite simulation. This prerequisite simulation is computationally expensive and complex to solve due to polymer plasticity and silicone rubber elastomer hyper-elasticity and moving frictional contacts between parts. If the accidental sliding load case without considering pre-tension on snaps is simulated, the load causing mechanical failure in the FEM
Shah, Viren, Wani, Dishant, Miraje, Jitendra
3D Printed Injection Molding Tool: An Unique Approach for New Product Development2025-28-032111/06/2025
Automotive industry frequently uses 3D printed plastic proto parts during new product development phases as it bypasses the high tooling investment & development time at early part development stage. However, for some application, 3D printing technique & its limited material options are not fulfilling the required material properties in the part, resulting poor performance during product testing which may mislead the design engineer during validation process. To overcome this, we introduce a novel approach in constructing injection molding tool by 3D printing the core and cavity using Stereolithography (SLA). This enables production of parts with application-recommended material grades, facilitating traditional validation and increasing stakeholder confidence. This paper compares part quality from 3D printed molds against conventional metallic molds for a shifter gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life
Gandhi, Sorna Rajendran, Gunduboina, Chaitanya
The Effect of Differential Humidification and Membrane Thickness on PEMFC Operation2025-32-003911/03/2025
In the recent years, the urgency to decarbonize the mobility sector has highlighted the importance of the electrochemical hydrogen use in fuel cells to complement the battery-based electrification. Hydrogen is the greenest energy carrier, and low-temperature Polymer Electrolyte Membrane Fuel Cells (PEMFCs) are part of an ever-evolving scenario, with particularly promising use in high energy demand sectors. Hydrogen is the main player in decarbonisation scenarios, but there are many issues, including its production and storage. There are many categories of hydrogen; in these applications, the finest category of hydrogen, called green hydrogen, is required. To achieve completely green vehicle mobility, enormous technological advances are necessary. This paper presents a 3D-CFD study to analyse the behaviour of PEMFCs by examining the role of humidification, covering fully humidified (anode and cathode), anode-only, cathode-only, and fully dry operations. This is simulated for several
Scialpi, Leonardo, D'Adamo, Alessandro, Marra, Carmine
Development of Integral Forming for New “NMAX” YECVT Parts Using the Plate Forging Method2025-32-000511/03/2025
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Temperature Effect on Fatigue Performance of Thermoset and Thermoplastic Composites2025-32-000611/03/2025
The growing demand for lightweight, durable, and high-performance materials in industries such as aerospace, automotive, and energy has driven the development and evaluation of thermoset and thermoplastic composites. Within this framework the static and fatigue mechanical behavior of one thermoset material and two thermoplastic composites are investigated in the (-30° +120°C) temperature range, to simulate extreme environmental conditions. The results from the tensile tests show the different mechanical behavior of the investigated materials, while the cyclic test results highlight the significant impact of temperature on structural properties, offering useful insights for their application in temperature-sensitive environments. This research is partially funded by the Italian Ministry of Enterprises and Made in Italy (MIMIT) within the project ”New Generation of Modular Intelligent Oleo-dynamic Pumps with Axial Flux Electric Motors,” submitted under the ”Accordi per l’Innovazione
Chiocca, Andrea, Sgamma, Michele, Franceschini, Alessandro, Vestri, Alessio, mancini, Simone, Bucchi, Francesco, Frendo, Francesco, Squarcini, Raffaele
Nanofibers Yield Stronger, Tougher Carbon Fiber CompositesTBMG-5412111/01/2025
Researchers at the U.S. Department of Energy (DOE)’s Oak Ridge National Laboratory (ORNL) have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites — an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.
How AI Can Find the Next Groundbreaking PolymerTBMG-5412511/01/2025
Nylon, Teflon, Kevlar. These are just a few familiar polymers — large-molecule chemical compounds — that have changed the world. From Teflon-coated frying pans to 3D printing, polymers are vital to creating the systems that make the world function better.
Rubber: Fluorosilicone (FVMQ) High Temperature Fuel and Oil Resistant For Seals In Fuel Systems and Specific Engine Oil SystemsAMS7273D (Current)10/24/2025
This specification covers a fluorosilicone (FVMQ) rubber in the form of molded rings.
AMS CE Elastomers Committee
Rubber: Acrylonitrile-Butadiene Rubber (NBR) Fuel and Low Temperature Resistant 60 - 70 Type “A” Hardness For Seals in Fuel SystemsAMS7271K (Current)10/22/2025
This specification covers an acrylonitrile-butadiene rubber in the form of molded rings, compression seals, O-ring cord, and molded-in-place gaskets for aeronautical and aerospace applications.
AMS CE Elastomers Committee
Composite Materials Handbook Volume 3 - Revision HR-64010/16/2025
The third volume of this six-volume compendium provides methodologies and lessons learned for the design, analysis, manufacture, and field support of fiber-reinforced, polymeric-matrix composite structures. It also provides guidance on material and process specifications and procedures for using the data that is presented in Volume 2. The information provided is consistent with the guidance provided in Volume 1, and is an extensive compilation of the current knowledge and experiences of engineers and scientists from industry, government, and academia who are active in composites. The Composite Materials Handbook, referred to by industry groups as CMH-17, is a six-volume engineering reference tool that contains over 1,000 records of the latest test data for polymer matrix, metal matrix, ceramic matrix, and structural sandwich composites. CMH-17 provides information and guidance necessary to design and fabricate end items from composite materials. It includes properties of composite
CMH-17
Aerospace & Defense Technology: October 202525AERP1010/02/2025
Nadcap at 35: Still Defining Excellence in Aerospace and Defense Manufacturing High Performance Enclosure Systems for Aerospace and Defense Applications: Preparing for What’s Next Selecting the Best Plastic for Spacecraft Applications 2025 Rising Star Awards Aerospace and Defense Winner – Keshika Warnakula Managing Thermal Reliability at the Edge: The Critical Challenge DoD Isn’t Talking About Analyzing Aircraft Antenna Placement and Performance with Unified Modeling and Simulation U.S. Army Tests Innovative Autonomous Tactical Vehicle Prototype Researchers Discover New Materials That Could Enhance Fighter Jet Efficiency Could Metasurfaces Be The Next Quantum Information Processors?
Next-Generation Elastomer Seals: Enhancing Battery Safety and Sustainability in E-MobilityTBMG-5387610/01/2025
Conductive Polymer Improves Sensor-Based DevicesTBMG-5398510/01/2025
Scientists have produced a new, powerful electricity-conducting material that could improve wearable technologies, including medical devices. The new technique uses hyaluronic acid applied directly to a gold-plated surface to create a thinner, more durable film, or polymer, used to conduct electricity in devices like biosensors. It could lead to major improvements in the function, cost, and usability of devices like touchscreens and wearable biosensors.
At-Home Melanoma Testing with Skin Patch TestTBMG-5399310/01/2025
Melanoma testing could one day be done at home with a skin patch and test strip with two lines, similar to COVID-19 home tests, according to University of Michigan researchers. Developed with funding from the National Institutes of Health, the new silicone patch with star-shaped microneedles, called the ExoPatch, distinguished melanoma from healthy skin in mice.
Selecting the Best Plastic for Spacecraft ApplicationsTBMG-5396410/01/2025
Designing Resilient LSR Supply Chains Through Vertical IntegrationTBMG-5398810/01/2025
In today’s medtech landscape, innovation isn’t just about what a device does — it’s about how reliably and cost-effectively it gets to market. As devices grow smaller, smarter, and more user-centered, materials like liquid silicone rubber (LSR) play a bigger role in enabling performance, comfort, and compliance. From implantables to connected wearables, LSR is helping engineers meet growing design and usability demands. As demand for the material grows, so do the pressures on supply chains, including launch timelines, increased regulatory scrutiny, and rising technical complexity.
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