THE ENGINEERIST: Fail Fast, Succeed Faster

Editor’s Note: The Engineerist is a three-part blog series written by Michael Corr, founder of Los Angeles-based manufacturing consulting firm, DuroLabs. This is part two.

Certification testing is expensive, especially when your product fails.

I was managing an engineering team several years ago when we submitted a new product with an injection-molded enclosure to UL for certification testing. The tests included a mechanical stress test with some rather extreme impact forces. This product was a deviation to a predecessor and therefore had legacy requirements which constrained our design options. With the time pressure we had to get the product to market, the mechanical engineering team and I were hoping a few modest changes to the existing legacy injection mold would be sufficient to pass the new certification testing and go into production. They weren’t.

Logo Image: PR Newswire

Prototype Prep Before UL Testing
After a humbling blow to our egos and sizeable invoices from both the molder and UL, we took another approach. The ME team reviewed the points of failure of the plastic enclosure and came up with a few design improvements. But we didn’t want to risk failure again, and UL required testing parts fabricated from the actual production mold. It would be too expensive and risky if we were to modify the tool and fail again. Continue reading

Webinar: Designing for Selective Laser Sintering

This is the final part in our series of “Designing for 3D Printing” webinars. Just as we’ve looked at stereolithography and direct metal laser sintering in previous webinar, this presentation will provide insights into how to design for selective laser sintering (SLS), a discussion on material options, and recommended applications for SLS.

Post build

The presentation will include the following:

  • Comparison of SLS materials
  • Design guidelines for functional prototypes and production parts
  • Moldability considerations for effective development
  • Open Q&A session

TITLE: Designing for 3D Printing: Selective Laser Sintering
PRESENTER: Eric Van Roekel, SLS production manager
DATE: Thursday, October 27 at 1 p.m. CDT
REGISTER: Click here to sign up  

Can’t make it that day? You can still register and we’ll send you an on-demand version to watch when convenient. Also, feel free to forward this invite to your colleagues.

3D Printing Boosts Rocket Project for Engineering Students

University of Minnesota engineering students are readying a 3D-printed rocket engine for launch sometime later this year, with help from Proto Labs.

This cutaway view of the engine shows the cooling channel, which is one long tube that spirals down inside the wall.

David Deng, a senior aerospace engineering student at the U of M’s Twin Cities campus, is leading the extracurricular effort to design, build, and eventually fly a liquid-propellant rocket as project manager of LPRD Rocketry. The group’s name, pronounced “leopard,” is an acronym for Liquid Propellant Rocketry Design. The group includes aerospace engineering students and others studying electrical engineering, computer science, mechanical engineering, and materials science.

The primary design challenges the group faced included the small overall size of the engine itself, and the need to also somehow incorporate a cooling system inside the engine.

David Deng (right), and the University of Minnesota student group LPRD Rocketry (left).

“The manufacturing of [the rocket engine] is incredibly difficult using conventional methods, especially for a very small engine,” Deng said. “The struggle was how do we [add] a single cooling channel through this entire engine, coiling around the side of it? That’s where Proto Labs came in. 3D printing is essentially the only way to get regenerative cooling on an engine this small and have it be a single channel.”

READ CASE STUDY

EYE ON INNOVATION: Self-Driving Tractor Harvests Interest from Ag Industry

The latest innovation in tractors for the modern farm “features everything but the farmer,” muses a recent headline in a story from Bloomberg News about an autonomous tractor concept from CNH Industrial.

“As Detroit carmakers and Silicon Valley tech giants vie to bring driverless cars to U.S. roads, one of the world’s largest tractor makers is looking to do the same down on the farm,” Bloomberg reports.

This self-driving tractor, a Case IH Magnum prototype model from CNH Industrial, was revealed for the first time last month at a farm equipment show in Iowa.
Photo: Wall Street Journal

At a farm equipment show in Iowa in September, CNH Industrial (Case IH/New Holland) revealed its Autonomous Concept Vehicle, which drew strong interest from those in attendance.

The cabless, self-driving tractor—a Case IH Magnum prototype model—is equipped with cameras, radar, and GPS, enabling farmers to remotely monitor planting and harvesting via computer or tablet from their homes, barns, fields, or pickup trucks. A second concept model, the New Holland T8 NH, includes a cab, so that the tractor can be operated either by a driver or in autonomous mode.

Continue reading

VIDEO: Lockheed Martin Drone Takes Flight with help from Proto Labs

The drone market in the U.S. is expected to soar to an $82-billion industry in the next decade, the New York Times recently reported. With that robust market in mind, Lockheed Martin, the aerospace, defense, and technology giant, developed a small, fold-up, lightweight drone, the Indago Quadcopter UAV (unmanned aerial vehicle), turning to Proto Labs for quick-turn prototyping and low-volume production.

Proto Labs’ automated design for manufacturability (DFM) and quoting system was especially helpful in taking the Indago from 3D-printed prototypes to injection-molded parts, and getting finished parts delivered in days and weeks. The video tells the story: