Browse Topic: Plastics

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The information in this document is intended to apply to commercial jet transport category airplanes that incorporate plastic (polycarbonate or acrylic) lenses on exterior light assemblies, or are being considered for such an application as opposed to glass lens designs. Exterior lighting applications include position light assemblies, anticollision light asemblies, and landing light assemblies. However, much of the material provided herein is general in nature and is directly applicable to many aircraft categories including, but not limited to, helicopters, general aviation aircraft, and military aircraft
A-20B Exterior Lighting Committee
Inspired by the paper-folding art of origami, North Carolina State University engineers have discovered a way to make a single plastic cubed structure transform into more than 1,000 configurations using only three active motors. The findings could pave the way for shape-shifting artificial systems that can take on multiple functions and even carry a load – like versatile robotic structures used in space, for example
Thermal management in electric vehicles plays a significant role, in keeping all the electronic components under the safe operating region for lower power dissipation, higher efficiency and this increases the component’s life. Based on the increase in range of e-vehicles, the power dissipation requirement had increased from OEMs. In addition, the compact size, weight, and limited cooling technique have increased the thermal management requirements in printed circuit boards (PCB). In a passive cooling technique, high thermally conductive metal with plastic overmould concept in PCB cover or housing will have a huge advantage in transferring the heat from e-components to keep within operating temperature conditions [1, 6]. The advantage of alumina or mica metal insert is that it has higher thermal conductivity and electrical resistivity, which helps to dissipate the heat at a higher level when it is locally in contact with hot spot regions of the PCB. This concept also helps to reduce the
Rajasekaran, Arun PrasadRajendran, RathinBadiger, Shashikanth
While 3D printing has exploded in popularity, many of the plastic materials these printers use to create objects cannot be easily recycled. While new sustainable materials are emerging for use in 3D printing, they remain difficult to adopt because 3D printer settings need to be adjusted for each material, a process generally done by hand
Researchers have found a way to bind engineered skin tissue to the complex forms of humanoid robots. This brings with it potential benefits to robotic platforms such as increased mobility, self-healing abilities, embedded sensing capabilities and an increasingly lifelike appearance. Taking inspiration from human skin ligaments, the team, led by Professor Shoji Takeuchi of the University of Tokyo, included special perforations in a robot face, which helped a layer of skin take hold. Their research could be useful in the cosmetics industry and to help train plastic surgeons
Unlike glass, which is infinitely recyclable, plastic recycling is challenging and expensive because of the material’s complex molecular structure designed for specific needs. New research from the lab of Giannis Mpoumpakis, Associate Professor of Chemical and Petroleum Engineering at the University of Pittsburgh, focuses on optimizing a promising technology called pyrolysis, which can chemically recycle waste plastics into more valuable chemicals
Electric trucks and off-highway vehicles weigh about 30% more than their gasoline- and diesel-powered counterparts. That's a challenge for OEMs who want to reduce vehicle weight to increase range but are bound by the limits of current battery technology. To reduce vehicle weight, OEMs can make design changes in other areas, such as by replacing steel with thermoformed plastics, aluminum alloys and composite materials. What manufacturers may overlook, however, is the weight savings that can be achieved with industrial rubber products. Rubber is already lightweight, but there are heavier-than-necessary elastomeric components used throughout vehicle interiors and exteriors, typically with metal or plastic fasteners
Wysong USA has been manufacturing industrial press brakes, hydraulic shears, and mechanical shears for sheet metal and plastics for nearly 120 years. Like many companies, their motto was “if it ain’t broke, don’t fix it,” so their product had remained essentially the same. But during a customer visit that motto clashed with another company saying, “the customer is always right.” This customer had replaced the dry clutch brake for an oil shear clutch brake that was more accurate. “The customer is always right” won, so Wysong updated their product line and increased accuracy while reducing costs, making it a win all around
The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of
Marconi, PedroAmarante, EvandroFerreira, CristianoBeal, ValterRibeiro Júnior, Armando
Recently, the environmental temperature of vehicles is changing due to the electrification of vehicles and improved internal combustion engine system to reduce carbon emissions. However, mechanical properties of plastic materials change very sensitively to environmental temperature changes, and mechanical properties decrease when exposed to high temperatures. Therefore, it is important to estimate lifespan estimation of plastic parts according to temperature changes. In this paper, reliability analysis process to estimate the maximum service temperature of plastic parts was developed using aging data of material properties, environmental condition data of automotive parts, and field driving condition data. Changes in the mechanical properties of plastic materials such as glass fiber reinforced polyamide materials were tested. The environmental exposure temperature of the vehicle and parts was measured, and the general driving pattern of the vehicle was analyzed. Weibull aging model and
Youn, Jee YoungChung, Min GyunAhn, Hyo Sang
To characterize the stress flow behavior of engineering plastic glass fiber reinforced polypropylene (PPGF) commonly used in automotive interior and exterior components, mechanical property is measured using a universal material testing machine and a servo-hydraulic tensile testing machine under quasi-static, high temperature, and high strain rate conditions. Stress versus strain curves of materials under different conditions are obtained. Based on the measured results, a new parameter identification method of the Johnson-Cook (J-C) constitutive model is proposed by considering the adiabatic temperature rise effect. Firstly, a material-level experiment method is carried out for glass fiber reinforced polypropylene (PPGF) materials, and the influence of wide strain rate range, and large temperature span on the material properties is studied from a macroscopic perspective. Then, the model parameters of the J-C constitutive model are identified based on the experimental data, and the
Zheng, Wei-JunLiu, Xiao-AngShangguan, Wen-BinZhang, QuGu, Chen-guang
A natural fiber based polymer composite has the advantage of being more environment-friendly from a life cycle standpoint when compared to composites reinforced with widely-used synthetic fibers. The former category of composites also poses reduced health risks during handling, formulation and usage. In the current study, jute polymer laminates are studied, with the polymeric resin being a general purpose polyester applied layer-by-layer on bi-directionally woven jute plies. Fabrication of flat laminates following the hand layup method combined with compression molding yields a jute polymer composite of higher initial stiffness and tensile strength, compared to commonly used plastics, coupled with consistency for engineering design applications. However, the weight-saving potential of a lightweight material such as the current jute-polyester composite can be further enhanced through improvement of its behavior under mechanical loading. A weakness of a natural fiber reinforced composite
Karthika, M RDeb, AnindyaArockiasamy, Madasamy
The tubing described in this document is for use in electrical interconnect systems for the protection and routing of wire bundle installations
AE-8C1 Connectors Committee
The world is on a “take-make-waste,” linear-growth economic trajectory where products are bought, used, and then discarded in direct progression with little to no consideration for recycling or reuse. This unsustainable path now requires an urgent call to action for all sectors in the global society: circularity is a must to restore the health of the planet and people. However, carbon-rich textile waste could potentially become a next-generation feedstock, and the mobility sector has the capacity to mobilize ecologically minded designs, supply chains, financing mechanisms, consumer education, cross-sector activation, and more to capitalize on this “new source of carbon.” Activating textile circularity will be one of the biggest business opportunities to drive top- and bottom-line growth for the mobility industry. Textile Circularity and the Sustainability Model of New Mobility provides context and insights on why textiles—a term that not only includes plant-based and animal-based
Lee-Jeffs, AnnSafi, Joanna
Researchers have been pursuing the development of robots so tiny that they can maneuver through blood vessels and deliver medications to certain points in the body. Now, scientists have succeeded in building such micromachines out of metal and plastic in which these two materials are interlocked as closely as links in a chain. This is possible thanks to a new manufacturing technique they have devised
Some people do not go the dentist for a fear of syringes, thereby risking a worsening of untreated tooth damage. However, some dental practices offer patients a gentle alternative — a device for computer-controlled, pain-free local anesthesia, which its developers fittingly call a magic wand: The Wand – STA System from Milestone Scientific. For the past 25 years, the U.S.-based company specializing in injection technology has been manufacturing the system’s single-use components from CYROLITE®- by Röhm — a high-quality, transparent, acrylic-based plastic especially for medical applications
This procurement specification covers inserts made from A286 alloy of the type identified under the Unified Numbering System as UNS S66286, solid film lubricated with a piastic self locking device, integrated locking keys to positively secure the insert against rotation when properly installed in threaded holes
E-25 General Standards for Aerospace and Propulsion Systems
Most motor mounts, even for EV applications, are made of metal alloys. It makes intuitive sense: It's a vibration-intensive mounting application that demands durability that matches the life of the vehicle itself. But there is another way. Now, a composite nylon-based motor mount on the Cadillac Lyriq has won the Society for Automotive Analysts' Innovation in Lightweighting Award. The mount is a collaboration between GM, anti-vibration parts maker DN Automotive and chemical company Celanese. It is made with Zytel PA NVH Gen 2, a new polyamide (PA 66). The results not only showed up in development data, but in the end product, which has reviewers raving about how quiet the Lyriq's cabin is - “crypt quiet,” according to Automotive News
Clonts, Chris
As a car OEM, we continuously strive to set the bar for competitors with every product. Consumer travel experiences are enhanced by increasing passenger cabin silence. There is only one steering system opening in the firewall panel, which is used for allowing intermediate shaft's fitment on the pinion shaft of the steering gear. The steering grommet is the sole component that covers the firewall cut-out without disrupting steering operations, which has a substantial impact on the NVH performance of the vehicle. It is typically used in cars to eliminate engine noise and dust entering to passenger compartment. The part is assembled inside the vehicle where the steering intermediate shaft passing through BIW firewall panel. We use a bearing, plastic bush, or direct rubber interference design in the steering grommet to accommodate the rotational input the driver provides to turn the automobile. However, occasionally noise may be produced due to uneven bearing or plastic bush loading or a
J, SadhishVijayarangan, DeepakS, SenthilKole, Shantinath
This SAE Recommended Practice determines whether plastic and glass-plastic safety glazing materials will successfully withstand exposure to simulated weathering conditions
Glazing Materials Standards Committee
Plastics, steel and aluminum technologies that reduce weight and emissions recognized with 2023 Altair Enlighten Awards. Toyota and its segment-first IsoDynamic Performance Seat were big winners in this year's Altair Enlighten Awards, honored during an awards ceremony at the 2023 CAR Management Briefing Seminars (MBS) in August. Debuting in the 2024 Tacoma TRD Pro, the performance seat's various lightweight structures took the top spot for both the Enabling Technology and the Module Lightweighting categories. Four other category winners, along with runners-up and honorable mentions, showcased how automotive and commercial-vehicle companies are applying advanced technologies and artificial intelligence to create a more sustainable future for the industry. “They demonstrate exceptional leadership in this area, but more importantly they demonstrate how these innovative solutions can be achieved by collaborating with the supply chain,” Richard Yen, Altair's senior VP for product and
Gehm, Ryan
In recent years, research interest in the 3D printing of metal patterns on plastic parts has grown exponentially, due to its high potential in the manufacturing of next-generation electronics. But fabricating such complex parts through conventional means is not easy. Now, researchers from Japan and Singapore have developed a new 3D-printing process for the fabrication of 3D metal–plastic composite structures with complex shapes
Structural automotive components are subjected to fatigue damage under cyclic stresses and strains. The fatigue damage initiates at stress levels lower than the elastic limit of the material and results in cracks. The Initial fatigue cracks are difficult to detect, such cracks can develop rapidly and cause sudden and brittle failure in structures. Many structural automotive components are fabricated involving weld induced local conditions such as geometry of weld toe and localized tensile residual stresses. These conditions are favorable for initiation of fatigue damage at weld toe. In current work, sever plastic deformation (SPD) which is based on high frequency impact treatment using ultrasound energy was applied on weld toe of representative weld joints. The effect of SPD on weld toe geometry modification, microstructure and residual stresses were evaluated. Microscopic and X-ray diffraction techniques were used to study the effects of SPD. It was observed that SPD can significantly
Chauhan, ShivDhadange, RaviPonkshe, ShripadrajShende, Deodatta
Side door latches in an automotive play a major role in occupants’ safety. The latches consist of both retention assembly and actuator assembly. The actuator assembly majorly consists of motor, gear & other components and these are protected through a Plastic Lower case and Housing. The Lower case (over-mold) with the Electrical Component Carrier - ECC (pre-mold) plays an important role in providing electrical power supply to the latch system. Since these parts are manufactured with terminal traces & plastics, upfront mold flow simulations help the product teams to evaluate the short fills, warpage, and other quality aspects in the critical areas of these components. In the part assembly station, the ECC (pre-mold) and the Lower case (over-mold) are connected to the Motor on one side and the Connector on the other. The proper alignment of the pre-mold pins is of great importance and the pre-mold must not be externally visible once the molding is complete. During the prototype build
LONKAR, VISHWAVINUTANAC, Rupesh KumarManjunath, ArunKumar, Naveen
Vehicle aesthetic appearance is critical factor in the perceived quality of a vehicle. Auto OEM focuses on the improvement of perceived quality. The perceived quality of a vehicle is improved by achieving a superior finish on the visible parts. Plastic parts used in visible areas are painted to achieve a superior finish & aesthetic. However, the painting process is very energy intensive, releases a lot of harmful VOCs into the environment, emits carbon di-oxide into the environment & is a very costly process. Also, painted parts pose a challenge for recycling at the end of life. For painting one square meter area, around 6.5 Kg of co2 is released. Additionally, the painting cost contributes to around 60 % of the part cost. As the emphasis has increased on sustainability & reducing the cost, we took the challenge to develop novel mold in color material to eliminate the painting process without compromising the aesthetic & functional requirements of part. The challenge was to develop the
jha, AshutoshHatwalne, Mrunal R.
A team of researchers at University of California, Riverside, has moved a step closer to finding a use for the hundreds of millions of tons of plastic waste produced every year that often winds up clogging streams and rivers and polluting our oceans
The molecules in our bodies are in constant communication. Some of these molecules provide a biochemical fingerprint that could indicate how a wound is healing, whether or not a cancer treatment is working, or whether a virus has invaded the body. If we could sense these signals in real time with high sensitivity, then we might be able to recognize health problems faster and even monitor disease as it progresses
A team of Cornell University researchers have laid the foundation for developing a new class of untethered soft robots that can achieve more complex motions with less reliance on explicit computation. By taking advantage of viscosity - the very thing that previously stymied the movement of soft robots - the new approach offloads control of a soft robot's cognitive capability from the “brain” onto the body using the robot's mechanical reflexes and ability to leverage its environment. A soft robot is made from soft, flexible materials, such as silicone or other elastomers, rather than rigid materials such as metal or plastic used in non-soft robots. Soft robots are designed to mimic the movement and flexibility of biological organisms
The current Indian biofuel policy focuses on the use of alcohol as a potential gasoline blending component to achieve a target of 20% alcohol in gasoline by 2025. The automotive vehicle fuel system uses a variety of metals and non-metals (elastomers and plastics). The fuel system is designed to run with a dedicated fuel, say gasoline or diesel. The use of alternative fuels, i.e., fuels that blend with straight gasoline or diesel, is increasing, and it is critical to understand the impact of these fuels on engine fuel system components. High octane fuels like ethanol and methanol are blended with gasoline to increase engine performance and reduce exhaust emissions, but the alcohols are hygroscopic and corrosive in nature. These fuels' permeation, swelling, and other effects cause changes in material properties. The test fuel is a gasoline-ethanol-methanol (GEM blend of A20 blend), which contains 5% ethanol, 15% methanol, and 80% gasoline. There is no data available on the use of A20 in
Chakradhar, Dr. MayaRamadhas, A SShanti, PrakashJustin, P RajArora, AjayMaheshwari, M
Diesel engines are known for their excellent low-end torque, better drivability, performance, and better fuel economy. The increase in customer demands pushes to deliver higher power and torque along with fuel economy. This requirement puts a great challenge on the overall weight of the engine. This paper explains the holistic approach followed along with optimizing the rocker arm cover to achieve the weight target without compromising on durability and cost in the commercial segment 2.5-liter Diesel Engine. This paper presents a complete overview of the design and development of Rocker Arm (RA) cover to meet Strength, Durability, NVH and Aesthetic in Commercial Engine where base design is in aluminum which is mounted on cylinder head with a separate breather system. From aluminum the base design of Rocker arm cover is optimized to sheet metal where in there is reduction of 43% in weight and cost saving of 13%. The proposed design is optimized to meet the durability, NVH and without
Yaser, K U Syed Taj
Innovative robotic rotational molding technology allows for the use of new materials in manufacturing parts and hard cases for military and aerospace applications. This is creating opportunities for new product geometries, tighter tolerances, and less waste than traditional plastic molding. There are thousands of applications within the aerospace and defense industries using plastic parts and storage containers. Today, the production of specialized parts and protective hard cases for military applications can call for unique materials to meet more stringent standards (flammability, high heat/cold tolerances, airtightness, watertightness, electromagnetic interference shielding, multi-layering, to name a few). Meeting these strict requirements can be challenging when using traditional molding processes such as rotational molding, thermoforming, blow molding, or injection molding
Excessive internal valve leakage is an inefficiency that worsens upstream system inefficiencies. Effective valve design is the solution. Electric vehicle thermal management requires OEMs and suppliers to control many variables that potentially create excessive heat. Designing thermal-management systems (TMS) to effectively control these variables is critical to overall EV performance. Internal leakage and other coolant-valve performance criteria are among the variables affecting EV performance, most notably driving range. Valve design is fundamental to a robust, thermally efficient and leak-free system, according to engineers at Robertshaw Controls, a specialist in plastic coolant-valve innovation and TMS design
Hokky, Steve
This SAE Standard establishes a uniform test procedure and performance requirements for personal watercraft floatation. This SAE Standard does not apply to outboard powered personal watercraft and jet powered surfboards
Personal Watercraft Committee
This test is designed to measure the thickness of textiles, plastics, and similar materials
Textile and Flexible Plastics Committee
Aryballe Technology's unique sensors-on-a-chip solution aims to end the subjectivity of the human nose while neutralizing vehicle cabin odors. Whether they're riding in an autonomous shuttle, a transit bus, a train or a rental car, passengers often face cabin air full of “mal odors” - bad smells - including cigarette and vape smoke, pungent food, blatant lack of personal hygiene and worse. Where the off-gassing of plastics and leather in new vehicles had been a minor issue in the past, the olfactory (science of smells) experience is increasingly a key differentiator in rider satisfaction as new mobility solutions emerge. Ensuring a neutral-smelling passenger space is a growing focus of fleet owners and managers, particularly as autonomy becomes established in the commercial-transportation sector. Looking to a future of driverless shuttles, OEMs in the field (i.e., Cruise Automation, Waymo, Navya, Transdev, EasyMile and a host of players in China) are investigating olfaction-based
Brooke, Lindsay
Researchers have designed a transparent polymer film that conducts electricity as effectively as other commonly used materials, while also being flexible and easy to use at an industrial scale. The resulting process could yield new kinds of flexible, transparent electronic devices such as wearable biosensors
This specification covers a two-part epoxy resin system in the form of a bisphenol "A" epoxy resin filled with fumed silica and carbon microspheres and a separate curing agent
AMS P17 Polymer Matrix Composites Committee
Halogen detector is an important halogen gas leakage detection instrument. In order to ensure that the upper and lower shells have the same quality, it is necessary to use one mold and two pieces in production. Compared with the conventional one-mold two-cavity process, it is easier to produce warpage and volume shrinkage. To solve this problem, a multi-objective injection molding process optimization method based on deep neural network (DNN) model based on stochastic weight average (SWA) method and multi-objective evolutionary algorithm based on decomposition (MOEA/D) was proposed. Melt temperature, mold temperature, injection pressure, holding pressure, holding time, and cooling time are the six parameters and important structure parameters (gate diameter) as design variables, warpage, and volume shrinkage rate as the optimization goal. The neural network model between variable and goal was established, and the MOEA/D algorithm was used for global optimization. The multi-objective
Wang, ChangjingFan, XiyingGuo, YonghuanLu, XiangningWang, DezhaoDing, Wenjie
For medical device manufacturers that work with different kinds of plastics (i.e., polycarbonate, polyethylene, and polypropylene), utilizing plasma treatments can create competitive advantages and transform specific parts into specialized, engineered components with 10 times the value
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