Designing waterproof enclosures involves understanding some key principles, and this guide is here to help. It will walk you through the necessary steps to develop a high-quality waterproof product that not only meets large-scale production requirements but also excels in functionality and water resistance, ensuring it performs exactly as required. <h2>What's an IP Rating?</h2>When we talk about making a waterproof enclosure for electronics, we're really talking about its IP rating. This rating tells you how good the product is at keeping stuff like dust and water out.<h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted"> </h3><h3>Decoding the IP Code</h3>The IP code has two numbers, in the format IPXX. The first number is about keeping out solids—anything from fingers to dust. It goes from 0 (not protected) to 6 (totally sealed off). The second number is for water. It starts at 0 (no protection) and goes up to 8 (can handle being under water for a while), and sometimes you'll see a 9K, which is extra tough, handling hot water. <h3>What the Ratings Mean</h3>These ratings are super important because they give you a quick idea of what your product can handle:IPX6: Can take strong jets of water from any side.IPX6K: Like IPX6 but even stronger against high pressure.IPX7: Can be underwater for 30 minutes at a depth of 1 meter.IPX8: Can go deeper than 1 meter—usually around 3 meters—and stay there for 30 minutes.IPX9K: This one's a big deal—it can take hot, high-pressure water from different angles.&nbsp;<h2>Starting with the Basics: Waterproof Industrial Design</h2>When we talk about starting with 'industrial design', we're referring to the initial concept—the 'make it pretty' phase. But don’t worry, our focus is on the 'make it work' aspect. It’s about ensuring that the design is not only aesthetically pleasing but also functional, especially when it comes to waterproof design.&nbsp;For this article, we’ll use a two-part case molded in ABS as an example. <h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Selecting Appropriate Materials in Waterproof Enclosure Projects</h3>For those of you looking into how to make a waterproof box for electronics, the material choice is critical. If you need more strength, you might lean towards an ABS/PC blend. But beware, this blend doesn't play well with oils or solvents—it can weaken the material and lead to damage. Any screws used need to be clean, as any oil on them can seep into the plastic over time, causing the parts to fail. <h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Optimizing Corner Design for Enhanced Waterproofing</h3>Sharp corners can be problematic. They're harder to seal and more prone to damage. A more gradual flow between faces, with rounded corners, can improve both the seal and the durability of the case.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc3NjIwNzMwLUNvcm5lcnMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 442px;" class="fr-fic fr-dib" alt="designing enclosure corners"><h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Effective Assembly Strategies for Enclosure Water Resistance</h3>When it comes to putting the case together, we want to avoid the unsightliness of exterior nuts and bolts. Using internal threaded inserts like brass or stainless steel is an option, especially for larger products or those that require regular servicing. However, these can be tricky to implement and can introduce their own problems.Instead, we'll be using M2 Plastite trilobular thread-forming screws with TORX heads - these drivers are more factory friendly. These screws create a strong hold without damaging the material and are ideal for a waterproof enclosure design aiming for higher IP ratings like IPX6K or IPX7. The use of washer heads can distribute the load, preventing the screws from digging into the case, which is essential for maintaining a good seal.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc3NjA3NTQ5LUFzc2VtYmx5LnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 464px;" class="fr-fic fr-dib" alt="screws design">For a less conspicuous finish, we can opt for chemical blackening of the screws. However, the shiny steel can also add a nice touch to the design.You might think M2 screws are small, and you could go up to M2.5 or M3, but the size increase doesn't significantly enhance strength and can make the case bulkier. For bigger products, M2 screws are usually sufficient, but you have the flexibility to go larger if the design allows for it.<h2 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..."> </h2><h2 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Advanced Sealing Techniques in Enclosure Design</h2>Sealing your waterproof enclosure is the crux of ensuring its effectiveness, and there are several ways to achieve this. However, not all methods are equal when you're looking to produce at scale. The Challenge with O-RingsWhile O-rings might seem like a go-to solution, they come with their own set of challenges. They can be tricky to assemble without causing twists or misplacements, and any minor error can compromise the waterproofing—especially when aiming for an IPX6 rating or higher. They might work for handcrafted, low-volume products, but they're not ideal for large-scale production. Custom Rubber Gaskets: A Step UpMoving to a custom rubber gasket that combines all sealing elements into one is a significant improvement. It <a href="https://jiga.io/resource-center/manufacturing/design-for-assembly-principles-applications-guidelines/" target="_blank" id="isPasted">simplifies assembly</a> and reduces the chance of misplaced seals. However, it's not without flaws. The gasket needs to be large enough to handle, which can result in a bulkier look that might not be desirable for every product. It's a decent choice for moderate production volumes but might not be the fastest to assemble. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc3NTc5NDMyLUdhc2tldC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 461px;" class="fr-fic fr-dib" alt="Industrial Design Waterproofing Gasket"> The Winning Strategy: OvermoldingFor mass-produced waterproof products, overmolding the seal is the standout method. It takes the burden off assembly workers since the seal is integrated into the product during manufacturing. This not only speeds up the process but also minimizes human error, as the seal placement is consistent and no longer reliant on manual dexterity.The upfront investment in an extra tool for overmolding might seem steep, but considering the cost of field failures—not to mention the potential damage to customer relationships—the investment pays off rapidly, especially if your product has a higher price point.As Henry Ford pointed out, the cost of not having the right tool can exceed the investment in the tool itself. By choosing overmolding, you're not just buying a tool; you're investing in the reliability and efficiency of your waterproof product's future. The Importance of Seal PressureSeal clamping is another crucial aspect of designing a waterproof enclosure for electronics. It's not just about keeping water out; it's also about handling internal pressure changes due to temperature variations. Handheld products often experience significant temperature shifts, which can cause the internal pressure to fluctuate. Dealing with Temperature-Induced Pressure Changes<ul id="isPasted"><li>Air Expulsion: When a product heats up and the internal pressure increases, it might expel air, which seems harmless initially.</li><li>Air Ingression: The real issue arises when the product cools down. This reverse pressure gradient can cause the product to suck in air. If this air is moist, it can lead to internal damage, either quickly or over time.</li><li>Desiccant Pouches: While these can delay moisture-related issues, they are not a permanent solution. Moisture trapped inside can still fog up display windows and corrode the electronics, especially when the product warms up.</li><li>Venting as a Solution: Venting with a moisture barrier can be effective, but it requires meticulous maintenance. The hydrophobic layer of the barrier must remain clean; otherwise, it can easily become ineffective. Moreover, rapid heating or cooling can overwhelm the barrier, leading to pressure spikes.</li></ul> A Comprehensive Approach to Seal ClampingGiven these challenges, a more robust approach to seal pressure is advisable. The goal is to ensure that the enclosure can't bulge between the fixings, which might compromise the seal. Adding extra screws is a cost-effective way to reinforce the seal, and with an overmolded seal, the additional holes pose minimal risk. Ideal Fixing DistributionThe original industrial design might have had a certain distribution of fixings, adequate for an IPX6 rating but not sufficient for higher standards like IPX6K or IPX7. Based on experience, a more effective layout would involve placing fixings no more than 35mm apart. This closer distribution of screws ensures a more consistent and reliable seal, crucial for achieving higher IP ratings. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc3NjU4MjA5LVNlYWxpbmcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 508px;" class="fr-fic fr-dib" alt="enclosure design fixings"> <h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Key Considerations for the Gasket</h3>The gasket is the linchpin of a waterproof design. Its effectiveness hinges on two critical factors: its correct placement without any faults, and high compression at potential leakage points. <h3 id="isPasted">Different Scenarios and Gasket Choices</h3>1. For a Single Product: If you're making just one item, and it's going to be hand-assembled, O-rings can be sufficient. They’re manageable for a one-off project.&nbsp;2. For a Moderate Volume Production: If you're aiming to produce about 100 units, and you have skilled assemblers, then a custom-molded rubber gasket is a viable option. It's more labor-intensive and requires careful inspection, but it's doable.3. For High-Volume Production: When the goal is to produce hundreds of units daily, with a fast-moving production line and less skilled labor, overmolding the gasket becomes essential. Without this, you risk facing a high percentage of seal-related failures.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzg1MDA4MTE3LU92ZXJtb2xkZWQgR2Fza2V0LnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 732px;" class="fr-fic fr-dib" alt="Overmolded Gasket">The Advantages of OvermoldingOvermolded gaskets offer <a href="https://www.plastikcity.co.uk/blog/advantages-disadvantages-of-injection-moulding/" target="_blank" id="isPasted">unparalleled precision and reliability</a>. This precision allows for exact compression, ensuring both the effectiveness and durability of the seal. This method is proven in mass production environments, where keeping the elements out is non-negotiable. Cost-Effectiveness and Quality AssuranceThe cost of the extra tooling for overmolding can vary widely, but the investment is justified when you consider the broader economic picture. For instance, if a product costs $50 to produce and a field failure incurs a cost of $200, a $3,000 tool would pay for itself after preventing just 15 failures.Moreover, this approach streamlines assembly and reduces the need for extensive quality assurance checks associated with less precise gasket solutions. Detailed Gasket FeaturesLooking closely at a well-designed, overmolded gasket, you'll notice features like ‘pinch points’—small, pointed ridges around screw holes and along the enclosure's perimeter. These ridges ensure consistent compression, accommodating the varying forces exerted by screws and the minor flexing of the case.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc1OTU0NzkwLUdhc2tldC1Db21wcmVzc2lvbi1GZWF0dXJlcy03Njh4NDc2LnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 728px;" class="fr-fic fr-dib" alt="Gasket Compression Features"><h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Gasket Placement and Control</h3>In waterproof enclosure design, especially for electronics, the placement and control of the gasket are crucial for ensuring a durable and effective seal. Let's delve into the specific design elements that make a significant difference. Gasket Size and Containment <ul id="isPasted"><li>Groove Dimensions: In the case we're examining, the groove in the bottom wall is 1.8mm wide and 1mm deep, with an overall wall thickness of 2.4mm. The resulting 0.5mm wide skirts provide essential containment, preventing the gasket from bulging under pressure.</li></ul><ul><li>Tooling Considerations: The groove's shallow depth means it doesn't require much draft; its parallel structure can be easily removed from the tooling due to its formation from the force side.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzg1MTQ1NDE5LUdyb292ZSBhbmQgc3RlcC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="Groove and step waterproof design"> Aesthetic and Functional Design Elements<ul id="isPasted"><li>Step at the Joint Line: There's a deliberate small step at the product's joint line. This not only facilitates cleaner tooling but also helps mask any imperfections in the component parting line, enhancing the product's overall appearance.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc4NjQwNDA0LWZlZWRlci5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="gasket feeder design"> Detailed Features for Effective SealingCase Top Features<ul id="isPasted"><li>Compression Ridges: A 90° pointed ridge on the screw post compresses each screw gasket, while a small skirt wraps over the gasket to prevent bulging and maintain pressure.</li><li>Double Row Ridge: Along the box's periphery, a double row ridge is used where compression forces are relatively lower.</li></ul> Screw Pillar Design<ul id="isPasted"><li>Screw Pillar Adaptation: The screw hole expands to the outside diameter of the thread for a depth of 1.5mm, creating an undamaged collar of plastic at the top of the pillar. This feature is critical for maintaining the integrity of the pillar, even if the thread causes some damage.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc4NTYxMDY1LW1hdGNoaW5nIGZlYXR1cmVzIG9uIHRoZSBjYXNlIHRvcC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="90° pointed ridge waterproof design"><h3 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Selecting the Right Screw</h3>The screw is a central element in the design of waterproof enclosures, especially when aiming for high IP ratings. A specialized screw can make a significant difference in both the assembly process and the long-term reliability of the product. Characteristics of the Ideal Screw<ul id="isPasted"><li>Head Type: T6 or T7 Torx heads are recommended. They provide excellent engagement and can be easily driven with hand tools or automated equipment.</li><li>Thread Type: A trilobe plastite M2 thread is suggested, based on our extensive experience. This is a thread-rolling type rather than thread-cutting, which is gentler on the material and forms a stronger bond.</li><li>Material and Durability: The screws are made of hardened 420 stainless steel, which is robust enough to prevent the head from being torqued off. This material choice ensures durability and longevity.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzAxNzc4NTQ1ODA5LVVudGl0bGVkICgxKS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="Screw design waterproof">Fine-Tuning Screw Implementation<ul id="isPasted"><li>Pillar Hole Sizing: Finding the ideal screw pillar hole size is essential. Typically, a diameter hole of about 1.4-1.55mm works well for an M2 nominal screw. However, this can vary based on the screw manufacturer and the specific polymer used in the molding.</li><li>Adjustments for Different Polymers: The hole size may need to be adjusted depending on the type of polymer used in the enclosure's construction. Different materials can react differently to the screw, affecting the overall integrity of the seal.</li></ul>&nbsp;&nbsp;<h2 data-elementor-setting-key="title" contenteditable="true" data-pen-placeholder="Type Here..." id="isPasted">Sealing the Deal: Key Takeaways</h2>Designing waterproof enclosures for electronics is a blend of choosing the right materials, like ABS, and paying attention to details such as IP ratings and overmolded gaskets for sealing. The selection of specialized screws is also crucial. This approach balances functionality with ease of manufacturing, ensuring that the final product is not only technically sound but also practical in real-world use.

Designing waterproof enclosures for electronics is a blend of choosing the right materials, like ABS, and paying attention to details.

Designing a Waterproof Enclosure: A Simple Guide

Backplane PCBs are interconnect systems that integrate various electronic modules, creating a unified and scalable system. As IC bandwidths skyrocket, the need for high-speed backplane buses has grown significantly. Yet, they’re challenging to design.These backplanes are crucial in sectors like defense, telecommunications, and data centers where high data transfer rates are essential. But herein lies the challenge: designers are met with intricate signal integrity concerns, including impedance control, lumped parasitics, and noise degradation.Wondering how to enhance the reliability of your high-speed backplane bus? This article has the expert design tips you need. With a reliable system bus in place, you can focus on component functionality, assured that everything will sync seamlessly at the hardware level.<h2></h2><h3>Design Considerations</h3>A high-speed backplane is a sophisticated interconnection system, tailored to support data transmission at exceptionally high rates. But as data rates soar into the multi-gigabit range, signal integrity issues like crosstalk, impedance mismatches, and insertion losses become pronounced. This makes designing high-speed backplanes a tricky task.Here’s a basic step-by-step for creating a high-speed backplane:Step-by-Step Guide For Your High-speed Backplane PCBA Design<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1698409299798-1698409299798.png" alt="Pcb electric circuit on the pc screen" class="fr-fic fr-dii"><ol><li>High-Level Design with Functional Block Diagrams: At this phase, the objective is to capture the big picture of the system: how different components or circuit packs interconnect, the number of signals involved, power requirements, etc.</li><li>Sketch a Preliminary Routing Outline: This involves a rough estimation of where tracks (connections) will go. It’s about understanding how tracks might be routed and identifying potential problems early on. Having a sense of the spatial layout can help in understanding the complexity of the design.</li><li>Make a Pin-list Summary: Create a spreadsheet listing all the pins for every circuit module. This helps in estimating the number of layers required, organizing signals, selecting appropriate high-speed backplane connectors, and more.</li><li>Select the Right Connectors: The connector is crucial. The choice can dictate design longevity and adaptability. Ensure it’s robust( since backplanes experience multiple insertions and removals), meets future high-speed requirements, and has the right pin configurations.</li><li>Define the Geometry for Differential Pairs: Properly configure your differential pairs. Having consistent spacing and identical length traces within the pair reduces EMI and crosstalk and upholds characteristic impedance.</li><li>Preliminary Stack-Up: This step involves deciding the arrangement of layers in a multi-stack high-speed backplane PCB.</li><li>Make a Detailed Route Plan: Building on the preliminary routing plan, this phase involves a more detailed look at how the actual routes will run, ensuring that signals have clear paths and minimizing the potential for interference.</li><li>Analyze Vertical Trace Space: Confirm there’s adequate room for traces to run vertically between connectors. This can influence your choice of connector or overall strategy.</li><li>Conduct a Signal Clarity Check: Here, verify that your signals will travel cleanly without unwanted distortions. Utilize simulations and tools to ensure the integrity of your transmitted data.</li></ol><h2></h2><h3>Challenges in High-Speed Backplane Design</h3>As the signal travels from its source to its destination via a high-speed backplane, several factors can compromise its integrity. Here’s a breakdown of the core challenges faced:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1698409299234-1698409299234.png" alt="Hs backplane design challenges" class="fr-fic fr-dii"> <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1698409299997-1698409299997.png" alt="Male laboratory worker in whitecoat studying" class="fr-fic fr-dii"><ol><li>Conductor Skin Effects &amp; Dielectric Losses: At high frequencies, signals prefer the outer “skin” of conductors rather than using its entire cross-section. This phenomenon is known as the “skin effect”. As the effective area of the conductor decreases, the resistance it offers to the signal increases, leading to signal loss. Also, the high-speed backplane PCB’s dielectrics are not perfect insulators and can absorb some of the signal’s energy.</li><li>Return Loss &amp; Impedance Discontinuities: The vias, connector pins, and differences in layer stacking on the backplane can introduce mismatches in impedance. When the signal hits these discontinuities, a part of it gets reflected back, diminishing the energy that reaches the endpoint.</li><li>Signal Stubs: Stubs can cause parts of the signal to get trapped or delayed, leading to signal degradation and potential interference. Stubs are commonly caused by poorly designed vias, un-terminated branches in the trace routing, unused connector pins, elongated component leads, and mismatched layer transitions in the high-speed backplane PCB.</li><li>Lumped Parasitics: Unintended resistances, capacitances, and inductances from components and board features can distort and degrade the signal.</li><li>Noise Degradation On high-speed backplanes, daughterboards have multiple transceivers with differential pairs running parallel on the PCBA. When too close, they can cause crosstalk.</li></ol><h2></h2><h3>Tips for Better Signal Integrity in a High-Speed Backplane</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1698409300042-1698409300042.png" alt="Large green pcb microcircuit board" class="fr-fic fr-dii">To address the aforementioned signal integrity concerns, consider the following board design strategies:<ol><li>Choose the Right Equalizer: High-speed backplane links do not have a simple attenuation curve. They have multiple fluctuations due to reflections, crosstalk, and specific frequency resonances. Pick the right equalizer to compensate for these imperfections.</li><li>Material and Component Evaluation: Pay attention to the choice of vias, stack-ups, and connector pins. These choices directly impact signal integrity. Always monitor the ‘eye-closure’ to gauge this effect.</li><li>Prioritize High-Resolution Measurements: Always measure the high-speed backplane’s passive components as well as the near-end eye and far-end eye between daughter boards in both the frequency and time domains. A higher resolution in measurements means better pinpointing of potential issues like crosstalk or unexpected impedance changes.</li><li>Use a Good Vector Network Analyzer (VNA): Ensure your VNA has an adequate frequency range, offers reliable time-domain performance, and provides a diverse set of de-embedding techniques.</li><li>Manage the distributed capacitance on the Backplane: Capacitance on a backplane affects signal speed and quality. Over half of this capacitance originates from the transceiver’s input/ output pins. To improve signal integrity, select low-capacitance ICs for transceivers, increase trace impedance, and minimize stub lengths.</li><li>Use a well-matched termination resistor: Place a termination resistor at the end of a signal trace to prevent reflections. Ensure its value matches the loaded impedance of the backplane trace for best signal integrity.</li><li>Optimize for low-power consumption: For better power efficiency, reduce the backplane’s capacitance by using tighter slot spaces, shorter stubs, and low-capacitance components. This allows for higher termination resistor values, drawing less current.</li><li>Incorporate Ground Pours for Enhanced Isolation: Use ground pours on your backplane PCB for better isolation and consistent impedance. This provides a stable ground reference, minimizing electromagnetic interference and ensuring strong signal integrity.</li><li>Transform Unused Signal Layers into Plane Layers: Convert unused signal layers in multi- layered backplane PCBs to plane layers, either ground or power. This boosts electromagnetic interference shielding, aids heat dissipation, and can function as decoupling capacitors, reducing power noise and stabilizing impedance.</li></ol><h2></h2><h3>Connector, Pinout, and Routing Best Practices</h3>A well-functioning high-speed backplane is heavily reliant on its connectors, pinouts, and routing techniques. Here are some best practices to consider:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1698409300588-1698409300588.png" alt="Best practices table" class="fr-fic fr-dii"> <h2></h2><h3>Comparison Between Common Backplane Standards</h3>Over the years, several standards have emerged, each tailored to specific application needs. Here’s a concise comparison of three prominent backplane standards: VME, CompactPCI, and VPX.VME (VMEbus): The Versa Module Europa bus is an open-source backplane standard started in the 1980s. It was made so parts from different companies could work together in one system. While reliable, its parallel bus architecture makes it slower compared to newer technologies, especially for data-heavy tasks.cPCI (CompactPCI): CompactPCI was introduced in the mid-1990s as an adaptation of the desktop PCI standard for industrial and embedded applications. It is particularly popular in telecom applications due to its high data rates and support for hot swapping.VPX : VPX was developed in response to the growing demand for higher data transfer rates, particularly in the defense and aerospace sectors. Unlike older standards such as VME and CompactPCI, VPX adopts a switched fabric architecture, which directly addresses the limitations of traditional bus-based systems. This architecture not only facilitates multi-gigabit per second transfers but also enhances scalability and reduces contention.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1698409300688-1698409300688.png" alt="Binary code numbers in blue abstract speed motion" class="fr-fic fr-dii"> <h2></h2><h3>Conclusion</h3>High-speed backplanes are pivotal for designs that need fast data transfer. Different industries use specific backplane standards; for instance, the defense sector often opts for the Sensor Open Systems Architecture (SOSA).However, crafting these backplanes is no easy task due to signal integrity challenges such as conductor skin effects, return loss, impedance discontinuities, signal stubs, and noise degradation. You need an expert design team and the right design tools in place, along with a reliable PCB manufacturer to get it right.<section id="isPasted"><h4>Have production challenges? Get help now.</h4><a href="https://www.macrofab.com/pcba/engineer-benefits/" target="_blank">CHECK OUT MACROFAB'S ENGINEER-FRIENDLY FEATURES</a></section><section><div data-bs-ride="carousel"><h5> </h5></div></section>

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In this episode, we unveil the astounding achievement of a student team that created an electric vehicle (EV) capable of shattering the 0-62mph speed record, leaving even the most capable state of the art supercars trailing behind.

Podcast: Student-Built EV Shatters 0-62mph Record, Leaving Supercars in the Rearview

This article was discussed in our <a data-saferedirecturl="https://www.google.com/url?q=https://www.wevolver.com/profile/the.next.byte&source=gmail&ust=1672821999265000&usg=AOvVaw3lLKdHdEN0YvCEsaHI7hx9" href="https://www.wevolver.com/profile/the.next.byte" rel="noopener noreferrer" target="_blank">Next Byte podcast</a>.&nbsp;<iframe height="200px" width="100%" frameborder="no" scrolling="no" seamless="" src="https://player.simplecast.com/5af262f5-0967-4c6a-8b58-6de660cf0e47?dark=false" class="fr-draggable" data-gtm-yt-inspected-6="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The full article will continue below.<hr>While lightning rarely strikes the same place twice, the <a href="https://www.amzracing.ch/en/world-record" target="_blank" rel="noopener noreferrer">Academic Motorsports Club Zurich (AMZ)</a> has somehow made it strike thrice. As they clinch the EV world acceleration record for the third time since 2014, one has to wonder: is it the seasoned giants of the automobile world or passionate students who are setting the benchmark for speed?Having already painted their legacy on the canvas of speed by breaking the same record in 2014 and 2016, this quest wasn&rsquo;t merely to reclaim their title. It was about stretching the boundaries of innovation, transforming academic prowess into tangible, ground-shaking technological feats. As Yann Bernard, head of motor development at AMZ, <a href="https://ethz.ch/en/news-and-events/eth-news/news/2023/09/from-zero-to-one-hundred-in-0-956-seconds.html" target="_blank" rel="noopener noreferrer">articulated</a>, their venture marries dedication with the thrill of tackling real-world challenges. <iframe width="640" height="360" src="https://www.youtube.com/embed/mvoFemftA34?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-6="true" id="70611535" title="New World Record – from 0 to 100 km/h in 0.956 seconds">&nbsp;</iframe> <h3>A world record, obliterated</h3>The vanguard students from ETH Zurich and Lucerne University of Applied Sciences and Arts, forming the spirited team at AMZ, have proven that when innovation meets ambition, records are not just broken &ndash; but obliterated.Their latest electric vehicle masterpiece, <a href="https://www.amzracing.ch/en/cars/2023%20WR" target="_blank" rel="noopener noreferrer">Mythen</a>, has left the world astounded, achieving a meteoric 0-62mph (0-100 km/h) acceleration world record for EVs in a staggering 0.956 seconds. To put this performance in perspective, it <a href="https://ethz.ch/en/news-and-events/eth-news/news/2023/09/from-zero-to-one-hundred-in-0-956-seconds.html" target="_blank" rel="noopener noreferrer">shattered</a> the previous record of 1.461 seconds, which was achieved by a team from the University of Stuttgart in 2022.This is not only the world record, but also <a href="https://www.amzracing.ch/en/world-record" target="_blank" rel="noopener noreferrer">the first time</a> that an electric vehicle has accomplished the feat below the one-second barrier. It&#39;s also pertinent to note that it only took Mythen&nbsp;about 40 feet, or just over 12 meters, to break this record. The AMZ team executed their record attempt at a racetrack but astoundingly,&nbsp;would have only needed about half the length of a regulation tennis court to reach 62mph. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0NjI0MjYzMTY0LUVUSF9BTVoyM18zNi5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 532px;" class="fr-fic fr-dib">Mythen in action (credit: ETH Zurich / Alessandro Della Bella)<h3>The secret sauce behind their success</h3>Some of the main technical factors driving <a href="https://www.amzracing.ch/en/cars/2023%20WR" target="_blank" rel="noopener noreferrer">Mythen</a>&#39;s immense success are outlined below:<ol><li>In-House Mastery: Mythen, a beacon of student innovation, was birthed entirely by the AMZ team &ndash; from the printed circuit boards to its chassis. This in-depth involvement at every stage ensured that each component was meticulously optimized for record-breaking performance. </li><li>Power to Weight Paradigm: At a mere 309 pounds (140 kilos), Mythen&#39;s lightweight carbon and aluminum honeycomb structure stands in stark contrast to its immense power. With its student-developed, four-wheel hub motors, it boasts a remarkable 326 horsepower (240 kW), giving it a power-to-weight ratio of over one horsepower per pound of weight. Juxtapose this with many supercars, which despite having more horsepower and added weight, don&#39;t come anywhere close to&nbsp;Mythen&#39;s 0-62mph time. </li><li>Aerodynamics &amp; Ground-Effect Synergy: Dario Messerli, head of aerodynamics at AMZ,&nbsp;<a href="https://ethz.ch/en/news-and-events/eth-news/news/2023/09/from-zero-to-one-hundred-in-0-956-seconds.html" target="_blank" rel="noopener noreferrer" id="isPasted">emphasized</a> the necessity of not just raw power, but its efficient transfer to the ground. One of the main technical challenges AMZ encountered is that during the 0-62mph speed window, a traditional wing (such as those often seen on high-speed vehicles like Formula One racecars) would not generate sufficient downforce to ensure efficient power transfer. The team&#39;s innovative solution? A vacuum mechanism, acting as a gargantuan suction pad, that ensures maximum traction, alongside an underbody that also leverages ground effects to maintain unparalleled stability during its explosive acceleration. </li><li>Battery Efficiency: Mythen&#39;s battery stands at roughly one-third the size of a standard Formula Student EV. This design choice is strategic, allowing unparalleled speed without the encumbrance of a bulky battery &ndash; further amplifying its acceleration prowess.</li></ol><h3> </h3><h3>Significance</h3>This isn&rsquo;t just a victory lap for the team at AMZ. Mythen&rsquo;s success is a herald of the boundless horizon of electric vehicles. As the world increasingly leans towards sustainable mobility, such feats highlight the untapped potential of EVs.Mythen&#39;s success also serves as a reminder to automobile giants: the next automotive marvel may not emerge from a sprawling corporate lab but from a buzzing university workshop, replete with passionate students and audacious dreams.

How a hand-built electric race car from Swiss university students shattered the 0-62mph (0-100km/h) acceleration record in a mere 0.956 seconds, outpacing the giants of the automotive world.

Student-Built EV Shatters 0-62mph Record, Leaving Supercars in the Rearview

<h2 id="isPasted">Introduction</h2>Modern hardware engineering teams are facing a productivity crisis. Research commissioned by Dassault Syst&egrave;mes shows that, on average, engineers spend just 51%[1]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> of their time on innovation and design work. It also shows that they are typically working with outdated information 20% <a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a>[1] of the time, meaning that engineers are able to dedicate just 41% of their time to innovative, productive work with up-to-date input data.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NjQ5NzI2LUVuZ2luZWVyVGltZVV0aWxpc2F0aW9uLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 302px;" class="fr-fic fr-dib">Derived from [1]. Drawing office challenges of this nature are adversely affecting both product quality and time-to-market for product businesses, with Autodesk research indicating that 35%[2]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> of engineers report missing due dates during the design process. These challenges are also recognised by engineering leaders, with more than 94% [3] of engineering executives shown to recognise the need for improved mechanical engineering productivity.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NjgwOTgxLURlc2lyZWRJbXByb3ZlbWVudC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib">Reproduced from [3]. <hr><h2 id="isPasted">The Cause</h2><h3>A Fragmented Approach to Information Management</h3>Dassault&#39;s research[1]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> permits further breakdown of engineer time demands. It shows that 25% of all &#39;non-value-added&#39; engineer time is consumed by simply searching for information, with significant time also spent collecting data for other stakeholders, and repeating work when information could not be found.Considering why this may be the case, an engineering practices and procedures survey[4]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> provides some indication, with results demonstrating that e-mail, meetings, and telephone remain the dominant mechanisms for communication and collaboration in contemporary engineering teams. These channels are private by design, with participants having to take active, post-hoc steps to share outcomes with team members. Important technical information shared via these routes is also frequently rendered undiscoverable; hidden from other team members, exempted from version control, and put beyond the ready reach of any new hire.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NzE0NDY1LUNvbGxhYm9yYXRpb25Ub29sLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">Drawn from the results of [4]. &#39;Issue Tracking System&#39; refers to software development-focused products: JIRA, GitHub, GitLab etc. <h3 id="isPasted">Design Review Procedures: A Persistent Threat</h3>Checking and approval procedures are a key component of engineering best practice. Many organisations run a stage-gate process, typically with at least two review stages, but often with more. In general, there are two broad categories of review and approval procedures involved in physical system design and development:<ol><li>A high-level concept review, typically completed earlier in the design process. This review assesses the design concept against broad objectives, and does not address minor design or manufacturing details.</li><li>A detailed checking and approval procedure for finalised drawings, completed prior to system components being formally released via an ECN or ECO procedure.</li></ol>The results of <a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank">[4]</a> tell a story of inadequate tooling, with in-person meetings and e-mailed screenshots dominating the approaches taken by modern engineering teams. In both cases, these methods offer very poor visibility&mdash;typically failing to capture topics discussed, decisions taken, and action items agreed.However, the latter approach is considered particularly pernicious: it places vast time demands on the engineer requesting review. They are obligated to manually select and annotate salient views of their design, then distribute these to a wider set of stakeholders. This set of stakeholders then returns the documents with their own annotations, and the engineer initiating the review must collate and address multiple possibly conflicting comments from disparate sources.&dagger; <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5NzQ1OTQ2LVJldmlld01ldGhvZG9sb2d5LnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">Drawn from the results of [4].&dagger;Though Anneal currently has no robust data to support a quantitative assessment of the impact of the screenshot and e-mail based design review process, it is a topic frequently encountered during customer conversations, with the typical procedure involving the assembly of a multiple page PowerPoint presentation of salient views which is then e-mailed to a number of reviewers for comment.<hr><h2 id="isPasted">The Cost</h2>The damaging consequences of poor visibility and discoverability of technical information are clear to see: engineers must spend more time looking for information, they must repeat previously completed tasks, and they must complete remedial rework in the wake of design progressing with out-of-date values. Dassault&#39;s research[1] provides values for the most frequently reported consequences of bottlenecks in collaboration and shortcomings in information discoverability that result in outdated information feeding into the design process.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0MDg5ODAyMzQ4LUNvc3QucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Recreated from [1]. Further considering the impact of outdated information in design, survey results indicate that more than half of engineering organisations[4]<a href="https://www.getanneal.com/engineering-productivity.html#ref" target="_blank"></a> have encountered problems arising from out-of-date values persisting through design iterations, with these ranging from time-pressured and costly late-stage rework of a given design, through to catastrophic failure of a large-scale product prototype.All considered, the prevailing approach to managing the design and development of complex hardware systems appears to be failing for many teams. Engineers are bogged down in non-technical workload, and their tools are not providing adequate support. With engineers spending just 41% of their time&mdash;two days per week&mdash;on productive, innovative work, individual companies are spending hundreds of thousands of dollars on misdirected engineering resource, and could be losing millions in the marketplace through degraded product quality, stretched development cycles, and delayed product introductions.<hr><h2 id="isPasted">The Solution</h2>For most teams, the best mitigation for this productivity crisis will require two things: modified behaviour, and modified tools.On behaviour, engineering teams must adopt more open, collaboration-centric mechanisms for communication. They should consider reducing task scope, mixing disciplines, and assigning ownership to all work. More importantly, they should prioritise seeding a writing culture, take steps to make engineering decision making readily interrogable, and champion visibility and transparency amongst their team.On tools, software should be sought or developed to support the behavioural change. Engineering teams should seek access to software that enables both real-time and asynchronous peer review of drawings, CAD files, and technical reports. They should seek software that allows engineering topics to be discussed in context, that allows them to view task progression and workload distribution across a project, and that allows them to leverage modern web application technology to accelerate product development and improve product quality&mdash;wherever the team is.<hr><ul><li>[1]: Reduce Non Value Added Work, Dassault Syst&egrave;mes &amp; Tech Clarity&nbsp;</li><li>[2]: Extending PDM Beyond Design Data Management, Autodesk &amp; Tech Clarity&nbsp;</li><li>[3]: The CAD Productivity Research Report, Siemens &amp; Lifecycle Insights&nbsp;</li><li>[4]: Engineering Practices &amp; Procedures Survey, Anneal</li></ul>

The average engineer spends just 41% of their time on productive, innovative work⏱️

The Engineering Productivity Crisis

<h2 dir="ltr" id="isPasted">Introduction</h2>3D printing requires knowledge from various engineering and design areas, including 3D design, materials science, and mechanical engineering. No matter the scale of your additive manufacturing project, having a deep understanding of these elements is essential for success. One way for engineers to expand their 3D printing knowledge is through engagement with online courses. In this article, we look at the <a href="https://bigrep.com/academy/" target="_blank" rel="noopener noreferrer">BigRep Academy</a>, an online 3D printing knowledge resource from the German-based 3D printing company Big Rep.<h2 dir="ltr">BigRep Academy</h2>The BigRep Academy is a valuable asset for engineers and designers throughout the 3D printing industry who are looking to expand their knowledge of large-format digital fabrication. 3D printing is an industry that is continuously evolving, so it is essential for engineers and designers to stay ahead of trends with the right technical knowledge.&nbsp;The BigRep Academy has an extensive repertoire of courses, tutorials, and insights, catered specifically for engineers and designers looking to expand their technical knowledge.&nbsp;<h2 dir="ltr">Basic Training (eLearning Platform):</h2>The BigRep Academy e-learning platform includes course materials that provide the necessary fundamental knowledge for efficient 3D printing. These fundamental courses include:&nbsp;<ul><li dir="ltr">Blade Basics:&nbsp;Find out how to get about and get the most of BigRep&rsquo;s potent slicing program, BLADE. This session will teach you everything you need to know, from preparing your model to optimizing your print settings to producing professional-quality prints. By learning about the various slicing parameters, infill patterns, and support structures, you&#39;ll be able to fine-tune the quality and efficiency of your prints.</li><li dir="ltr">Design for Additive Manufacturing: Explore the fundamentals of design used in additive manufacturing. Learn the basics of designing for 3D printing, such as taking into account the geometry, material qualities, and support structures of your creations. Using the skills and knowledge provided by this program, you will be able to develop designs that make full use of the diverse potential of additive manufacturing. You will learn how to optimize designs for strength, utility, and effective use of materials, which will enable you to build complex parts that were previously impossible to make using standard manufacturing methods. You will also learn how to optimize designs for optimal use of space.</li><li dir="ltr">Operating Your BigRep Printer:&nbsp;Gain complete self-assurance in your ability to operate your BigRep printer. This session covers key features such as setting up the machine, calibrating it, loading it with material, and successfully printing. You will acquire a comprehensive knowledge of the operations of the printer, such as how to manage the temperature, load filament, and level the bed. You will be able to get the most out of your equipment and produce results that are reliable and of a high standard if you are familiar with the peculiarities of its operation.</li><li dir="ltr">Troubleshooting:&nbsp;Utilizing their troubleshooting module, you can locate and fix typical mechanical faults as well as difficulties with the print quality. Learn how to diagnose problems with your printing process, such as layer adhesion, warping, or nozzle clogging, and adopt efficient solutions to maintain a smooth and uninterrupted printing process. You will develop skills in troubleshooting that will allow you to recognize potential issues and take necessary actions, so ensuring that your printing experience will go off without a hitch.</li></ul>Each module takes approximately 2 hours to complete. There is a test at the end of each training module, except for the introduction module. When participants pass the test, they receive a certificate.<h2 dir="ltr">Advanced Training</h2>Users who are interested in further improving their 3D printing abilities can take advantage of the advanced training choices provided by BigRep Academy, which is available in addition to their eLearning platform. These modules consist of the following:<ul><li dir="ltr">Blade Advanced:&nbsp;Improve your cutting prowess by learning more about the powerful tools available in the BLADE program. Gain an advantage in the 3D printing market by learning how to maximise print speed, material economy, and productivity. Adaptive layer height, variable infill density, and intelligent support generation are just a few of the cutting-edge techniques you&#39;ll learn about. You can save time and resources without sacrificing print quality by using these methods to fine-tune prints for specific needs.</li><li dir="ltr">Printer Maintenance:&nbsp;You can extend the life of your BigRep printer and keep it running well with regular maintenance. If you want to maintain your machine running smoothly and efficiently and cut down on downtime, this training package will show you the ropes. You&#39;ll gain an understanding of how to clean the print bed, lubricate moving parts, and inspect for signs of wear and tear, among other routine maintenance tasks. Maintaining your printer regularly will increase its lifespan and guarantee reliable operation.</li><li dir="ltr">Individual Training:&nbsp;BigRep recognizes that each customer has particular needs. BigRep can tailor training to meet your unique needs, whether those needs are related to completing a particular project or overcoming a particular difficulty. By tailoring your education to your unique needs, you can learn about the specifics of 3D printing that will have the most impact on your process.&nbsp;</li></ul><h2 dir="ltr">Why Choose BigRep Academy?</h2><a href="https://bigrep.com/academy/" target="_blank" rel="noopener noreferrer">The BigRep Academy</a> is currently available to all BiG Rep customers. It is a unique offering that provides specialized knowledge about large-format 3D printing. As a 3D printing company that covers printers, materials, and a service platform, the company has the depth of experience to elevate your designs through its knowledge sharing. Learn more about the academy <a href="https://bigrep.com/academy/" target="_blank" rel="noopener noreferrer">here</a>.&nbsp;

Deepen your 3D printing knowledge by exploring the BigRep Academy. Explore foundational and advanced techniques through courses such as Design for Additive Manufacturing and 3D Printing Troubleshooting. 


Expanding Professional  3D Printing Knowledge Through Online Learning Academy

Additive manufacturing offers several unique and important advantages, such as speed, design freedom, and affordability in low volumes. However, one of the major obstacles to the widespread adoption of the manufacturing process is part strength.Because the 3D printing process constructs parts one layer at a time, it can produce weaknesses throughout the part, as well as specific defects like layer lines and deformations. But how serious is this limitation? How strong are 3D printed parts compared to molded parts? And is the process only suitable for flimsy prototypes or cannot be used for more important applications?This article asks the question “How strong are 3D printed parts” with a particular focus on FDM 3D printing, looking at how users can improve their 3D printed part strength without turning to other processes.&nbsp;<h2 dir="ltr">How Strong Are FDM 3D Printed Parts?</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1OTEyNjA5MTczLTNkX3ByaW50ZXJfY3JlYXRpbmdfYmx1ZV9vYmplY3QuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">FDM parts are not as strong as some other plastic partsFused Deposition Modeling (FDM), also known as Fused Filament Fabrication (FFF), produces parts with varying strength based on material choice, print settings, and design. This process involves depositing molten thermoplastic layer by layer, creating unique mechanical properties. &nbsp;Material selection is crucial. PLA is strong but brittle, making it suitable for rigid, non-load-bearing applications. ABS offers better impact resistance but is less stiff. PETG balances flexibility and toughness, while advanced materials like nylon, polycarbonate, and carbon-fiber-reinforced filaments provide exceptional strength and durability. Industrial-grade filaments like PEEK and ULTEM are used in automotive and aerospace due to their superior mechanical properties and heat resistance.[1] &nbsp;Despite these strengths, FDM parts have inherent weaknesses. The most notable is anisotropy—parts are strongest along the horizontal plane but weakest between layers, where delamination can occur. Poor adhesion between layers reduces tensile and shear strength, making proper print settings essential. &nbsp;Print orientation, infill density, wall thickness, and post-processing methods like annealing can mitigate these weaknesses. Structural design improvements such as fillets at stress points also enhance durability. &nbsp;<h2 dir="ltr">Other 3D Printing Technologies</h2>The table below looks at how alternative 3D printing technologies compare to FDM in terms of part strength. While vat photopolymerization 3D printers are often comparable in price to extrusion printers, other technologies can be significantly more expensive.<div dir="ltr" align="left"><table><tbody><tr><td>Technology</td><td>Typical Part Strength</td><td>Cost</td></tr><tr><td>FDM (Fused Deposition Modeling)</td><td>Moderate; strong along layers, weaker between layers</td><td>Low to Medium</td></tr><tr><td>Vat Photopolymerization (SLA/DLP)</td><td>High surface detail, brittle unless using engineering resins</td><td>Low to Medium</td></tr><tr><td>SLS (Selective Laser Sintering)</td><td>High; durable, isotropic parts with good mechanical properties</td><td>High</td></tr><tr><td>Material Jetting</td><td>Moderate to high; brittle unless reinforced</td><td>High to Very High</td></tr><tr><td>Metal (e.g., DMLS, SLM)</td><td>Very high; comparable to traditionally manufactured metal parts</td><td>Very High</td></tr></tbody></table></div><h2 dir="ltr">Are 3D Printed Parts as Strong as Molded Parts?</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1OTEyNjIxMDAyLWJvdHRsZV9tb2xkX2Rlc2lnbi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="molding">Holding typically produces strong plastic partsFDM 3D printed parts are generally not as strong as injection molded parts due to differences in how they are made. Injection molding produces solid, homogeneous parts with consistent mechanical properties, while FDM creates objects layer by layer, introducing potential weak points between layers.FDM parts are strongest along the horizontal plane but are prone to delamination when stressed along the vertical axis.[2] In contrast, injection molded parts have uniform strength throughout. Material selection also plays a role; while FDM can print strong materials like nylon and carbon-fiber composites, injection molding supports a wider range of high-strength polymers.However, with optimized print settings, high-performance filaments, and post-processing techniques, FDM parts can approach the strength of injection molded parts in some applications.<h2 dir="ltr">The Strongest 3D Printing Materials</h2>Material selection plays an important role in achieving strong 3D printed parts. Here we look at the strongest affordable 3D printing filaments and also the strongest engineering filaments, which are more expensive and can only be used on premium machines.<h3 dir="ltr">Strong Consumer-Level Materials</h3><ul><li dir="ltr">PETG is strong, impact-resistant, and easy to print, making it ideal for functional parts with good flexibility and chemical resistance.</li><li dir="ltr">PLA+ (Enhanced PLA) is more durable and less brittle than regular PLA, while retaining ease of printing and affordability.</li><li dir="ltr">Nylon (Polyamide) is tough, wear-resistant, and strong, though it requires a heated bed and controlled environment for best results.</li><li dir="ltr">ABS is durable and impact-resistant, suitable for mechanical parts, though it requires good ventilation due to odor and warping risks.</li><li dir="ltr">Polycarbonate (PC Blend) is extremely strong and heat-resistant, with affordable blends offering easier printing on standard FDM printers.</li></ul><h3 dir="ltr">Strong Engineering Materials</h3><ul><li dir="ltr">PEEK is an ultra-strong, high-temperature-resistant material often used in aerospace and medical applications but requires specialized printers.</li><li dir="ltr">ULTEM (PEI) offers exceptional strength, heat resistance, and chemical stability, ideal for demanding industrial applications.</li><li dir="ltr">Carbon-fiber-reinforced filaments, like nylon or PETG composites, provide lightweight yet rigid parts suitable for structural use.</li><li dir="ltr">Polycarbonate (pure) delivers high strength, toughness, and heat resistance, ideal for engineering-grade parts but demands precise print settings.</li><li dir="ltr">Nylon 12CF (Carbon-Fiber Nylon 12) combines the toughness of nylon with the rigidity of carbon fiber, excellent for high-stress applications.</li></ul>Recommended reading: <a href="https://www.wevolver.com/article/peek-3d-printer" target="_blank">PEEK 3D Printing: Unlocking the Potential of High-Performance Polymers</a><h2 dir="ltr">How to Make 3D Printed Parts Stronger</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1OTEyNjI5OTEyLTNkX3ByaW50ZWRfZ3JpZF9wYXR0ZXJucy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib" alt="infill">Adjusting infill pattern and density is one way to improve 3D printed part strength<h3 dir="ltr">Part Design</h3>Create strong 3D printed parts with thoughtful CAD design focused on minimizing stress points and distributing loads effectively. Avoid sharp corners, which concentrate stress and can lead to cracking. Instead, use fillets or chamfers to create smoother transitions. Reinforce key areas with ribs, gussets, or thicker sections to increase structural integrity without significantly adding weight.Consider load paths and how forces will act on the part. Use organic, curved shapes when possible, as they better handle distributed forces. Design for symmetry and balanced geometry to prevent warping and mechanical failure.<h3 dir="ltr">Infill Patterns</h3>Infill patterns play a critical role in determining the strength of 3D printed parts. For maximum mechanical strength, high-strength infill patterns like cubic and gyroid are commonly used.&nbsp;The basic grid pattern provides adequate strength along both axes due to its crisscross structure, making it ideal for load-bearing parts. However, the cubic pattern offers similar strength while being more material-efficient. <a href="https://www.wevolver.com/article/gyroid-infill">Gyroid infill</a> stands out for its continuous, wavy structure, providing isotropic strength while reducing weight. &nbsp;For flexible materials like TPU, one of the best infill patterns is the concentric pattern. Its circular layers mimic natural structures, allowing for uniform flexibility and resistance to tearing. This pattern evenly distributes stresses, making it ideal for wearable or impact-resistant parts.<h3 dir="ltr">Other 3D Printer Settings</h3>Print orientation greatly affects strength. Align parts so critical features face the strongest print axis, parallel to the print bed. Additionally, slower print speeds improve layer bonding by allowing better material adhesion. Higher nozzle temperatures enhance interlayer strength but should stay within material limits to prevent stringing or overheating.Increasing wall thickness and enabling more perimeter shells boosts part durability. Use a lower layer height for finer bonding, though this extends print time. Adjusting the cooling fan speed—lower or off for materials like ABS—helps prevent weak layer adhesion. Correct bed leveling and proper extrusion settings also ensure consistent, strong prints.<h3 dir="ltr">Post-Processing Techniques</h3>Post-processing can significantly enhance the strength of 3D printed parts. Annealing is a common method where parts are heated in an oven to relieve internal stresses and improve layer adhesion. For materials like PLA, annealing at around 80-100°C can increase heat resistance and tensile strength, though it may cause slight warping. Longer annealing times are particularly effective on carbon fiber-reinforced filaments.[3]Coatings like epoxy resin or polyurethane create a protective outer layer, boosting impact resistance, waterproofing, and surface finish. Applying fiberglass or carbon-fiber wraps can reinforce critical areas.That being said, post-processing for part strength is more critical for non-extrusion processes. For instance, vat photopolymerization generally requires post-curing for stronger parts, while most metal printing technologies require extensive heat treatment to produce high-quality parts.Recommended reading: <a href="https://www.wevolver.com/article/the-ultimate-guide-to-3d-printing-post-processing-techniques" target="_blank">The Ultimate Guide to 3D Printing Post-Processing Techniques</a><h2 dir="ltr">How to Calculate the Strength of a Printed Object</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzM1OTEyNjM5NTUyLXRlbnNpbGVfdGVzdF9zYW1wbGUuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib" alt="tensile">Standardized tensile strength testing can determine the pulling resistance of printed partsTesting the strength of 3D printed parts involves several key methods, each targeting specific mechanical properties like tensile, impact, and flexural strength. These tests ensure that printed components meet performance requirements for real-world applications.<h3 dir="ltr">Tensile Strength Testing&nbsp;</h3>Tensile strength measures a material’s resistance to being pulled apart. Standardized test specimens, typically shaped like dog bones, are printed according to ASTM D638 or ISO 527 standards. The test involves placing the specimen in a tensile testing machine, where controlled pulling force is applied until failure occurs. The maximum stress endured before breaking indicates tensile strength.&nbsp;Consider factors like print orientation, layer height, and material type, as tensile strength is often weakest along the Z-axis due to layer adhesion. Comparing results from different orientations can highlight how print settings affect structural integrity.<h3 dir="ltr">Impact Strength Testing</h3>Impact strength tests measure a material’s ability to absorb energy during sudden impacts. A common method is the Charpy or Izod impact test, where a notched test specimen is struck by a swinging pendulum. The energy absorbed during fracture indicates the material's toughness.For 3D printed parts, ensure consistent print settings and part orientation to obtain accurate results. Tough materials like nylon, PETG, and polycarbonate usually excel in these tests, while PLA tends to be brittle. Adding notches simulates real-world stress concentrators, making the test more representative.<h3 dir="ltr">Flexural Strength Testing &nbsp;</h3>Flexural strength indicates a material’s resistance to bending forces. The three-point bending test is commonly used, where a printed specimen is supported at two ends while a force is applied at the center until it breaks. ASTM D790 provides standard guidelines for this test.&nbsp;Flexural testing highlights how well a material handles compressive and tensile forces simultaneously. For FDM parts, print orientation matters: parts printed with layers aligned along the bending axis perform better. Materials like ABS and carbon-fiber composites offer high flexural strength, making them suitable for load-bearing applications.Recommended reading: <a href="https://www.wevolver.com/article/3d-printing-problems" target="_blank">How to Solve Common 3D Printing Problems</a><h2 dir="ltr">Conclusion</h2>On the whole, the strength of 3D printed parts depends on factors like printing technology, material selection, design, and process settings. While FDM parts are inherently weaker along layer lines due to anisotropic properties, careful design, proper orientation, and use of advanced materials like fiber-reinforced filaments can significantly boost strength. Post-processing methods such as annealing and coating further enhance durability.&nbsp;Ultimately, 3D printed parts can be remarkably strong when engineered and manufactured correctly, rivaling traditional manufacturing methods in many applications from prototyping to end-use production.<h2 dir="ltr">Frequently Asked Questions</h2>What factors determine the strength of 3D printed parts?Part strength depends on factors such as the material used, print orientation, layer adhesion, infill pattern, and wall thickness. Post-processing techniques like annealing or applying protective coatings can further enhance strength.Which 3D printing technology produces the strongest parts?Metal 3D printing (including processes like DMLS/SLM) produces the strongest parts, followed by industrial processes like SLS for plastics due to its isotropic properties. FDM can also create strong parts with the right machinery, materials, and print settings.How can I increase the strength of FDM 3D printed parts?Use strong filaments like fiber-reinforced nylon, optimize print orientation, use a strong infill pattern, and increase wall thickness. Post-processing methods like epoxy coating or annealing can also improve strength.How are 3D printed parts tested for strength?Common tests include tensile testing (pulling force), impact testing (sudden force resistance), and flexural testing (bending resistance). These tests follow ASTM or ISO standards for consistent, accurate results.<h2 dir="ltr">References</h2>[1] Kafi A, Wu H, Langston J, Atak O, Kim H, Kim S, Fahy WP, Reber R, Misasi J, Bateman S, Koo JH. <a href="https://onlinelibrary.wiley.com/doi/abs/10.1002/app.49117" target="_blank">Evaluation of additively manufactured ultraperformance polymers to use as thermal protection systems for spacecraft</a>. Journal of Applied Polymer Science. 2020 Oct 5;137(37):49117.[2] Ahn SH, Baek C, Lee S, Ahn IS. <a href="https://www.worldscientific.com/doi/abs/10.1142/S0217979203019241" target="_blank">Anisotropic tensile failure model of rapid prototyping parts-fused deposition modeling (FDM)</a>. International Journal of Modern Physics B. 2003 Apr 10;17(08n09):1510-6.[3] Stojković JR, Turudija R, Vitković N, Górski F, Păcurar A, Pleşa A, Ianoşi-Andreeva-Dimitrova A, Păcurar R. <a href="https://www.mdpi.com/1996-1944/16/13/4574" target="_blank">An experimental study on the impact of layer height and annealing parameters on the tensile strength and dimensional accuracy of FDM 3D printed parts</a>. Materials. 2023 Jun 25;16(13):4574.

How strong are 3D printed parts compared to injection molded parts?

Part strength is sometimes seen as a weakness of 3D printing. But how strong are 3D printed parts really, especially compared to injection molding?

How Strong Are 3D Printed Parts? A Comprehensive Analysis

<h2 id="isPasted">Some Historical Perspective</h2>The relationship between physical engineering and the programmable computer is as old as the computer itself. The reality is that, for most of us, crunching lots of numbers by hand is frustrating, time-consuming, and error-prone.The British government of the 1820s agreed, opting to fund the early development of Charles Babbage&#39;s difference engines. These were visually striking machines: large mechanical computers, some capable of solving 7th order polynomials, that were intended to dramatically reduce the cost of production of tabulated trigonometric and logarithmic functions &mdash; the kind that were incredibly useful to scientists, engineers and navigators in the immediate aftermath of the Industrial Revolution.Fast forward to 1945, and we see the first glimpse of modernity: ENIAC, the world&#39;s first programmable, electronic, general-purpose digital computer. If you&#39;re curious as to what was it designed for, the answer is the computation of artillery and mortar firing tables; a task that involves exactly the kind of Newtonian mechanics calculations that will be familiar to any undergraduate mechanical or aerospace engineering student (see: Mayevski&#39;s <a href="https://books.google.co.uk/books/about/Trait%C3%A9_de_balistique_ext%C3%A9rieure.html?id=jE_zAAAAMAAJ&redir_esc=y" target="_blank">Trait&eacute; de balistique ext&eacute;rierure&nbsp;</a>, or the US Army Ballistic Research Laboratories&#39; <a href="https://asset-pdf.scinapse.io/prod/77299953/77299953.pdf" target="_blank">The Production of Firing Tables for Cannon Artillery</a>).Just a decade or so after ENIAC, IBM drew up its first specifications for a new programming language, The IBM Mathematical Formula Translating System, familiar to many of us as FORTRAN. Developed expressly for science and engineering, FORTRAN is a true titan of the scientific computing world. If you&#39;ve ever fired up MATLAB, analysed a load-case with an <a href="https://en.wikipedia.org/wiki/Finite_element_method" target="_blank">FEA</a> package, or run some new geometry in <a href="https://en.wikipedia.org/wiki/Computational_fluid_dynamics" target="_blank">CFD</a> &mdash; then it&#39;s almost certain that FORTRAN is involved in that stack somewhere, even six or seven decades on.<hr><h2 id="isPasted">Why Software Matters For Hardware</h2>The advantages of using digital computers in the physical engineering disciplines are both marked and multifarious, and I hope somewhat obvious.At a low level, these advantages can be quite straightforward. They include things like providing engineers with the ability to perform large numbers of calculations with little to no risk of human error. Think of something like repeated matrix multiplication, perhaps as part of a kinematics problem. How confident would you be in getting every step of that calculation right, without accidentally picking up a value one row down or one column across from where you intended? Thankfully, with the help of a few lines of FORTRAN, MATLAB, or Python, the computer can perform these calculations on your behalf, perhaps billions of times, without the threat of inconsistency or human error. At least... <a href="https://en.wikipedia.org/wiki/Pentium_FDIV_bug" target="_blank">almost all of the time.</a>At a higher level, however, these advantages are even more pronounced. They are the culmination of decades of work across several disciplines; the output of engineers, scientists and mathematicians who have designed, implemented, and shared computational techniques that address a myriad of challenging problems &mdash; from solving partial differential equations at scale, enabling modern FEA and CFD, through to the development of boundary representation solid modelling techniques that enable modern CAD systems. The convergence of these technologies has revolutionised engineering; accelerating development cycles, reducing the need for physical testing, and helping the world&#39;s engineers improve the quality and performance of everything from ships to spacecraft.As an illustration, think of the draughting process. For many engineering professionals who started their careers prior to the 1990s, draughting work would have still involved a drawing board, pens, and paper, cellulose, and/or linen. In the event of a mistake, the draughtsperson would have had to break out the scalpel or Tipp-Ex to &#39;erase&#39; the error, or issue an entirely separate drawing amendment to be paired with the original documents. With modern CAD systems, minor drawing modifications completed prior to release go completely unnoticed, and subsequent amendments can be as simple as a quick tweak and a brief change order &mdash; no redrawing of anything, no folder of amendments.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg1NTI3MDQ5MjY0LUhXRHJhd2luZ09mZmljZS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"><figcaption id="isPasted">The Harland &amp; Wolff Drawing Office, Belfast, at some point during the 1960s or 1970s. My father served part of his apprenticeship in this room a decade or two later. Maritime Belfast/National Museums Northern Ireland</figcaption>Better yet, imagine the difference in resource requirement and development cycle times for something like a turbocharger. If every minor tweak to blade or housing geometry requires an entire manufacture, assembly, and balancing routine before the new design makes it to the gas stand, every iteration will fall weeks behind and cost significantly more to explore than its simulation-driven counterpart &mdash; where a design change could make it to CFD in a matter of minutes. This is before we even consider the introduction of something like mathematical optimisation into this loop, where the responsible engineer could define their objective function, their variables, and their constraints, and conceivably let the computer play tunes with the geometry, feed that into the simulation, interrogate the results, then rinse and repeat until it reaches an optimum. Ultimately, well correlated models, <a href="https://en.wikipedia.org/wiki/All_models_are_wrong" id="isPasted" target="_blank">even if wrong</a>, are incredibly useful.<hr><h2 id="isPasted">Why Hardware Matters for Everyone</h2>So computers are wonderful tools, and so are the niche software packages we run on them, but so what? Well, I believe we now find ourselves at a critical point in both the trajectory of engineering as a discipline, and in its utility as a mechanism for improving our lives as a species. We have a lot of *very* active engineering fields right now, with a lot of important problems to address &mdash; and in the end, at some point, somebody has to actually make stuff to make things better.For example, it seems to me that we are standing but a few feet forward of the starting line in a new, privately funded space race. We have seen SpaceX engineers repeatedly achieve nothing short of a triumph of control engineering: reversing a rocket onto a barge in the ocean, opening the door to reuse, and as a result, both dramatically reduced space access costs and dramatically increased launch cadence. We have companies like SpinLaunch working to yield orbital access mechanisms that help escape <a href="https://www.nasa.gov/mission_pages/station/expeditions/expedition30/tryanny.html" target="_blank">the tyranny of the rocket equation&nbsp;</a>.We have a burgeoning paradigm shift in personal transport, with electric cars, scooters, and e-bikes encroaching further and further on the internal combustion engine&#39;s long-established territory.We have additive manufacturing evolving into a serious, cost-competitive manufacturing technique that can achieve geometries beyond the reach of traditional subtractive approaches, and we have generative design technology helping engineers produce mathematically optimised, often organic-looking solutions to pressing design problems. To see the power of these two in concert, just look at <a href="https://www.czinger.com/" target="_blank">Czinger</a> and <a href="https://www.divergent3d.com/" target="_blank">Divergent</a>.And, of course, we have ever more compelling incentives to overhaul the majority of our civilisation&#39;s energy infrastructure, pushing us to diversify the means by which we generate electricity, fostering the development of improved wind, solar, and &mdash; I hope &mdash; nuclear technologies.In short, we&#39;ve got a lot of real-world engineering to tackle, and plenty of hardware to build.<hr><h2 id="isPasted">Software is Eating the World</h2>Ultimately, it strikes me that the way in which we develop the physical systems around us is changing, and not all our tools yet accommodate this.Despite the arrival of an entire range of engineering software systems in the latter part of the last century, these were typically specialised products, often designed to form improved but effectively like-for-like replacements of an existing way of accomplishing a given task, whether that was replacing the draughtsman and his drawing board with a CAD workstation, or replacing a complex, <a href="https://twitter.com/CalumDouglas1/status/1550594001874698246" target="_blank">stiffness-altering oil pressure measurement apparatus&nbsp;</a>around a bearing with a CFD case.As a result, we find ourselves at a point where, as a profession, we&#39;re equipped with some extremely impressive tools; tools that can help us build the shorter iterative loops that are required to yield accelerated system development.However, it feels like we&#39;re still using these revolutionary tools, developing the technology that is critical to our species&#39; future, inside an operational framework that was designed for slide rules, drawing boards, and row after row of draughtsmen packing a tobacco smoke filled drawing office.Our systems are heavily siloed, our teams often fragmented. We struggle to collaborate across teams, sites, and time zones. We have vast and unstructured knowledge bases that are full of effectively undiscoverable data, put beyond the reach of those who don&#39;t know exactly where to look. And we struggle for visibility &mdash; of tasks, responsibilities, upcoming changes, and most importantly, of our data.Even the big players recognise this. Dassault push <a href="https://discover.3ds.com/reduce-non-value-added-work" target="_blank">research</a> that shows engineers spend 34% of their time performing &#39;non-value-added&#39; work; dominated by the amount of time spent just looking for stuff, trawling through network drives and cluttered inboxes. This same research shows that engineers are typically working with outdated information 20% of the time &mdash; imagine a full day a week, every week, for every member of your team, just being thrown away because of bad input data. This pattern has to change.In fact, for newer hardware companies, I think some things have *already* changed. <a href="https://a16z.com/2011/08/20/why-software-is-eating-the-world" target="_blank">Software is eating the world&nbsp;</a>applies not only to the electronic control of fuel injectors and ignition coils, but to the adoption of software-like management practices, with a focus on short design-build-test loops. I may hate the confusing, jargon-heavy nomenclature of &#39;agile&#39; methodology, but there is some method in the madness.<hr><h2 id="isPasted">Better, More Collaborative Software for Engineering Teams</h2>The future that I see is one where we not only have specialised tools for specific parts of the engineering cycle, but we have a central, engineering specific hub; an operating system that ties these things together.We want to see the world&#39;s physical engineering teams build better products faster; to achieve shorter development cycles, to iterate faster, and to better leverage their internal knowledge &mdash; so that they can achieve their goals, whether that&#39;s kinetic launch, faster cars, or greener energy.We think this will be brought about by transforming how hardware teams communicate, collaborate, and manage technical knowledge. That means better, more connected software; software that focuses on resolving the productivity-killing shortfalls in current engineering process. We think hardware teams should have technical communication mechanisms that are fast, painless, and traceable; that allow new hires to find the information they need, without requiring someone else to go rooting through their inbox for half an hour. We think engineers should be able to see what colleagues are working on, how these items are prioritised, and what&#39;s coming next. We think engineers should be able to annotate drawings, share calculations and schematics, and offer opinions on proposed solutions &mdash; all in real-time, wherever they are, with all that data stored and indexed for easy discoverability down the line.&nbsp;Above all, we think engineers should have a single source of truth to work with; a repository of version-controlled design values, simulation outputs, and performance targets &mdash; whether those are scalar values, or n-dimensional maps.In the end, what we want to see is engineering teams moving beyond the pain of e-mail ping-pong with spreadsheets and presentations, to stop scrawling performance differentiating IP over paper drawings that are destined for the shredder, and to start letting the computers handle the busywork.

Betty Jean Jennings and Fran Bilas at the main ENIAC control panel. Moore School of Electrical Engineering. U.S. Army, ARL Technical Library Archives

The recent history of our physical engineering disciplines is intertwined with computing. The future is too. 

The Future of Hardware is... Better Software

<h2 id="isPasted">Quick Wins</h2>We&#39;ll be looking at three items here that should be broadly universal across any Mechanical Engineering function, and should also be applicable to other disciplines. Our objective is to highlight some minor changes in workflow that can offer a significant benefit for your team. Taking these in order...<hr><h2 id="isPasted">1. Drawings: Datum Tables</h2>This is something I started doing several years ago to combat my own frustration with trying to read other people&#39;s drawings, and I was always surprised that it wasn&#39;t a standard practice in any of the design departments I&#39;ve worked in.Picture the scene: one of your colleagues has just finished off the drawings for a new cylinder head, and they pass them to you for peer review. If your brain works anything like mine, the first things you want to check are all the major datum features. However, when a drawing pack runs to six or seven substantial pages, this turns into a less entertaining, more time-consuming, monochrome version of Where&#39;s Wally? &mdash; which isn&#39;t really what we&#39;re after.For me, the fruit doesn&#39;t hang much lower. Work up a table&dagger; that lists datum features in alphabetical order, list their sheet, list their grid reference, then place the table somewhere easy to find on the drawing. Anyone else lifting the drawings will be able to dive right into reading the important bits, without having to scour the thing for ten minutes before they start actually thinking about the task at hand. This can as simple as Table 1.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MjI1NDYxMjE1LVRhYmxlSW1hZ2UucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Table 1 &dagger;If you&#39;re so inclined, I also imagine that it should be possible to implement automatic table assembly with a little bit of code. From memory, when I last explored this with CATIA v5 macros, I couldn&#39;t find any reference to datum objects in the object model documentation.<hr><h2 id="isPasted">2. Excel: Named Ranges</h2>As the sort of engineer whose professional home lies in writing code to analyse, simulate, and control physical systems, this point is much closer to my heart. With a few notable use-case exceptions, such as its easily accessed optimisation tools, I basically hate Excel. I consider it to be like the adjustable spanner of the software world: it might work for the task at hand, but it&#39;s still the wrong tool for just about every job.I believe that Excel inadvertently pushes people to construct terribly organised models and analyses that are often borderline unintelligible, and that building a clean solution in Excel requires the adoption of some very considered practice that you would basically get by accident if you did this work in any one of MATLAB, Python, Julia, Fortran etc. &mdash; the list goes on.More specifically, when I&#39;m forced to unpick somebody else&#39;s Excel-based model or analysis, there is one overwhelmingly common piece of practice that makes me want to tear my hair out: an overflowing formula bar, brimming with unnecessary parentheses and mysterious references to <code>!Sheet2&nbsp;</code>and <code>$C$907</code>. Let&#39;s take a real-world example of how unnecessarily messy this can get, even for relatively simple cases, then we&#39;ll move onto cleaning things up.<h3>The Problem</h3>The simple example case I&#39;m going to give here will be familiar to anyone who&#39;s ever designed an engine, a gas strut, or a (hydro)pneumatic suspension system: computing gas pressure in a cylinder of known volume. We&#39;re going to use the <a href="https://en.wikipedia.org/wiki/Van_der_Waals_equation" target="_blank">Van der Waals equation of state,&nbsp;</a>owing to the fact that the ideal gas law is pretty rubbish at approximating the behaviour we&#39;d typically see in any of these systems. The Van der Waal&#39;s equation of state is given by:<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MTY3MzEzOTIyLUVxMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">For simplicity, we&#39;ll take the case for n moles of gas, so this becomes:&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MTY3MzQ0NzcxLUVxMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Where:<ul><li>P denotes pressure.</li><li>V denotes volume.</li><li>n denotes moles of gas.</li><li>R&nbsp;denotes gas constant.</li><li>T denotes gas temperature.</li><li>a denotes Van der Waals constant for intermolecular interaction.</li><li>b denotes Van der Waals constant for real gas molecule volume.</li></ul>In our example scenario, we can pretend that we&#39;re solving for pressure, with all other values known, so we can quickly rearrange as follows:&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MTY3Mzk1NTExLUVxMzQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Equation shuffling out of the way, let&#39;s pluck some values from the air and get these plugged into a spreadsheet to see what we&#39;re dealing with. The values we&#39;re going with assume a 10cc volume, 20&deg;C, and enough pure nitrogen fill to generate approximately 86barA.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MjIxMjQ5NDg2LVNjcmVlbnNob3QgMjAyMy0wNS0xNiAxMDA5MTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">The typical quick spreadsheet setup leaves us with something that looks like this:&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MTY3NTAxNDA0LTIyMDUxOS0zUXVpY2tXaW5zLU5vTmFtZWRSYW5nZS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 730px;" class="fr-fic fr-dib">In my view, this isn&#39;t the end of the world; all the referenced cells are close by, and I can pick apart the formula quickly &mdash; but you can already see that extension of this sort of pattern to something more complex will start to cause serious headaches. By the time you&#39;re working with something which has parameters spanning sheets and substantially more complex formulas in play, this method is a nightmare.&nbsp;<h3 id="isPasted">The Solution</h3>Thankfully, a better way forward here is entirely quick and painless: <a href="https://support.microsoft.com/en-us/office/define-and-use-names-in-formulas-4d0f13ac-53b7-422e-afd2-abd7ff379c64" target="_blank">named ranges.&nbsp;</a>Named ranges effectively allow us to assign variable names of our choosing to these parameters, while also allowing us to configure the scope of the variables, i.e., whether they are visible only on a given worksheet, or whether they&#39;re global across the workbook.Setting a named range on a single value is as easy as clicking the cell in the top-left corner that currently shows cell address, overwriting it with an appropriate value, and hitting enter. There are plenty of other websites that explain how to use the &#39;Name Manager&#39; tools and get the most out of named range usage, but I&#39;ll just show you how much cleaner things look once you&#39;ve converted cell addresses to named ranges:<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg0MTY3NTI3MDI2LTIyMDUxOS0zUXVpY2tXaW5zLU5hbWVkUmFuZ2UucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">At least to my mind, this is an immediate and significant improvement. Compared with how it was previously, it is now substantially more straightforward to compare the formula with our target equation above. Any misplaced brackets or indices that might otherwise cause some serious pain to review or debug can now be caught much more readily, and you can move forward with increased confidence that your spready is trustworthy.<hr><h2 id="isPasted">3. Files: Naming Convention</h2>Finally then, the best (and shortest) tip: file naming convention. As far as I&#39;m concerned, there is precisely one correct way to name the sort of files generated by most engineering operations, and that way is as follows:<ul><li><code>YYMMDD-FileName.ext</code></li></ul>For example, the file in our named range scenario might be called something like <code>220519-NamedRangeExample.xlsx</code>.By placing the date at the start of the filename, and by following the <a href="https://en.wikipedia.org/wiki/ISO_8601" target="_blank">ISO8601</a> date component order, lexicographical sorts will yield files in chronological order, irrelevant of when they were copied to the particular directory.Then, by adopting dashes instead of spaces, underscores, or whatever else you might fancy for separation of sections of the file name, you&#39;re making the decision up-front that you simply want to avoid any funnies with respect to how filenames are handled.For example, any files appearing at a web URL will have spaces substituted for <code>%20</code>, which isn&#39;t exactly readable, and underscores can cause issues with both certain platforms and certain indexing systems.&nbsp;

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