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Manufacturing & Prototyping

Portsmouth Naval Shipyard Welds First Ever Metal 3D-Printed Submarine Component

Engineers recently completed inspection, testing, and shipboard installation of a welded, additively manufactured (AM) copper‑nickel flange for the USS...

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Manufacturing & Prototyping

Researchers Introduce New Digital Calibration Method for 'Born Qualified' Parts

The Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, is developing a comprehensive suite of capabilities to ensure that additively...

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Materials

Army Advances Additive Manufacturing From Experimental Tech to Enterprise Sustainment Tool

The U.S. Army’s adoption of additive manufacturing took another major step forward in March with the opening of a new “Additive Makerspace” at...

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Manned Systems

Developing a Digital Twin to Model Fatigue in 3D-Printed Spacecraft Parts

The rapid production of custom components for rockets and satellites is often essential to support design modifications, repairs, and operational needs in space travel....

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Mechanical & Fluid Systems

Gore Challenges Wet Sealing with Dry Sealant for Permanent Aircraft Structures

For decades, wet sealing has been accepted as a necessary constraint in aerostructure manufacturing, despite its impact on throughput, variability and necessary...

Briefs

Materials

EP40: Structural Epoxy Used for Steel Bonding in Marine Applications

Overall, the newly developed testing methodology using EP40 as the model adhesive was effective for evaluating the performance of marine adhesives. Read on to learn more.

Briefs

Materials

New 3D-Printing and Manufacturing Techniques Grant More Control Over Energetic Material Behavior

Because any small tweaks or environmental changes can dramatically alter how energetic materials function, Purdue University engineer Monique McClain is developing state-of-the-art tools and methods to control these materials’ behavior throughout the manufacturing process and down to the particle level. Read on to learn more.

Briefs

Power

New Protective Layer Boosts Lithium Metal Battery Performance

The coating toughens the surface of the electrolyte fivefold against fracturing from mechanical pressure. It also makes existing imperfections much less vulnerable to lithium burrowing inside, especially during fast recharging. Read on to learn more.

Briefs

Power

Anode-Free Battery Doubles Electric Vehicle Driving Range

A joint research team led by Professor Soojin Park and Dr. Dong-Yeob Han of the Department of Chemistry at POSTECH, together with Professor Nam-Soon Choi and Dr. Saehun Kim of KAIST, and Professor Tae Kyung Lee and researcher Junsu Son of Gyeongsang National University, has successfully achieved a volumetric energy density of 1270 Wh/L in an anode-free lithium metal battery. This value is nearly twice that of lithium-ion batteries currently used in electric vehicles, which typically deliver around 650 Wh/L. Read on to learn more.

Briefs

Energy

Supercapacitors That Rival Batteries

In a study published in Nature Communications, a team reveals a new kind of carbon-based material that allows supercapacitors to store as much energy as traditional lead-acid batteries, while delivering power far faster than conventional batteries can manage. Read on to learn more.

Briefs

Materials

Breakthrough in Carbon-Based Battery Materials Improves Safety, Durability, and Power

This research demonstrates a new way to make carbon-based battery materials much safer, longer lasting, and more powerful by fundamentally redesigning how fullerene molecules are connected. Read on to learn more.

Products

Energy

New Products

See the new products, including Littelfuse's TPSMB Asymmetrical Series TVS Diodes; Siemens' SICHARGE FLEX product family, its next-generation EV distributed charging system; Renesas Electronics Corporation's expansion of its software-defined vehicle solution offerings centered around the fifth generation (Gen 5) R-Car family; and much more.

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Materials

European Researchers Develop Self-Healing Composite Material for Spacecraft

Healable spacecraft structures could soon be possible thanks to cutting-edge composite technology. Swiss companies CompPair and CSEM, and Belgian company...

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Manufacturing & Prototyping

How Biomanufacturing Could Transform Defense Material Production

Biomanufacturing uses biological materials to create new materials. For example, bioengineered spider silk is lighter than carbon fiber and stronger than Kevlar — making it...

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Test & Measurement

Argonne AI Tools Power Safer, Faster Aerospace Inspections

Artificial intelligence (AI) is helping industry move faster, safer and smarter. A research collaboration among Spirit AeroSystems Inc., the U.S. Department of Energy’s (DOE’s)...

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Propulsion

Breakthroughs in Testing Solid-Fuel Ramjets Advance Research

Scientists at the U.S. Naval Research Laboratory are developing the next generation of solid-fuel ramjet (SFRJ) propulsion, addressing one of the field’s most persistent...

Technology Report

Manufacturing & Prototyping

Now Playing: MUSiC, the First Multi-user Silicon Carbide Fabrication Facility in the U.S.

The University of Arkansas opens the nation’s first multi-user silicon carbide fabrication lab.

Articles

Manufacturing & Prototyping

Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace

Achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. Read on to learn more.

Briefs

Materials

Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research

In collaboration with Auburn University’s Center for Polymers and Advanced Composites and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell — a next-generation 3D carbon fiber composites printer set to define the future of the nation’s hypersonic programs. Read on to learn more.

Articles

Aerospace

Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight

Together, microsecond pulsing, alloy-specific pulse shaping, core-and-ring beam modulation, and controlled oscillation provide far greater precision than CW welding. Read on to learn how.

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Manufacturing & Prototyping

Meeting the Demands of Defense Production and Sustainment Through Additive Manufacturing

When a chilled water pump failed aboard a U.S. guided missile destroyer, maintainers ran into an all-too-familiar problem. The six-blade cooling rotor...

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Manned Systems

How Airbus is Using w-DED to 3D Print Larger Titanium Airplane Parts

Airbus is using wire‑directed energy deposition (w‑DED) to 3D print titanium aircraft parts at much larger scales than earlier additive manufacturing methods allowed....

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Manned Systems

Can This Self-Healing Composite Make Airplane and Spacecraft Components Last for Centuries?

Researchers have created a self-healing composite that is tougher than materials currently used in aircraft wings, turbine blades and other...

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Manufacturing & Prototyping

European Researchers Leverage AI in Manufacturing Rocket Parts

Artificial Intelligence (AI), promises many benefits in all domains, and rocketry is no different. The European Space Agency’s Future Launchers Preparatory Program(FLPP) is...

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Materials

The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals

In an industry where failure is not an option and precision is paramount, aerospace manufacturers and suppliers are constantly seeking components and...

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Research Lab

New 3D-Printable Nanocomposite Prevents Overheating in Military Electronics

U.S. Army and university researchers collaborated to develop a 3D-printable material using tiny particles that conduct heat and can be used to more efficiently cool...

Webinars

Automotive

Advancements in Zinc Die Casting Technology & Alloys for Next-Generation Automotive Applications

Today’s automotive manufacturing demands progressively lighter, stronger, and more sustainable components, and zinc die casting processes and...

Webinars

Energy

Vehicle Test with R-444A: Better-Performing R-1234yf Direct Replacement for Hybrid & EV Heat Pump Systems

EV heat pumps present unique thermal management challenges. OEMs want to use existing R-1234yf systems as well as maintain low...

Articles

Manufacturing & Prototyping

SAE Books: 'Automated Fiber Placement' with Ramy Hari

Ramy Harik, a Fulbright alumnus and director of the Clemson Composites Center, is pushing the boundaries of manufacturing with his latest book, Automated Fiber Placement: Status,...