Are you an APSX-PIM desktop injection molding machine owner eager to embark on the journey of custom mold design? Crafting your own molds unlocks a realm of possibilities, from rapid prototyping to small-scale production. However, mastering the custom mold design process requires meticulous planning and a keen understanding of your machine's capabilities. In this guide, we'll walk you through the major steps of custom mold design, tailored specifically for APSX-PIM users.Understanding the Basics of Custom Mold Design:Define Your Requirements: Start by clearly defining your project requirements. What are you molding? What are the desired dimensions, materials, and surface finishes? Understanding these aspects will guide your mold design process.Design Conceptualization: Design out your mold design concept, considering factors like parting lines, gating, and ejector pin placement. Utilize CAD software for precise modeling and visualization.Mold Material Selection: With APSX-PIM's air cooling feature in mind, opt for aluminum as your mold material. Its durability and efficient heat dissipation make it ideal for long-term use with the machine.Utilize Blank Mold Templates:&nbsp;Take advantage of the blank mold templates available on the APSX-PIM website. These templates provide a solid foundation for your mold design, saving time and ensuring compatibility with the machine.Tips and Tricks for APSX-PIM Users:Simplify Your Mold Design: Eliminate cosmetic features to streamline your mold design. By keeping it simple, you enhance manufacturability and reduce production costs. Remember, APSX-PIM excels in quick and cost-effective iterations compared to larger industrial machines.No Water Cooling Channels Needed: Since APSX-PIM features air cooling, there's no need for water cooling channels in your mold design. This simplifies the design process and eliminates the complexities associated with water cooling systems.Optimize for Rapid Iterations: APSX-PIM's compact size and quick setup allow for rapid iterations of mold designs. Take advantage of this by designing molds that facilitate fast iteration and testing of new product designs.Precision and Efficiency:&nbsp;APSX-PIM offers precise control over injection parameters. Design your molds with tight tolerances to ensure consistent part quality. Focus on optimizing cycle times and minimizing part warpage for efficient production runs.Conclusion:Custom mold design for APSX-PIM opens up a world of possibilities for desktop-scale injection molding. By understanding the major steps of the design process and leveraging tips and tricks tailored for APSX-PIM users, you can maximize the capabilities of your machine. Whether you're prototyping new products or producing small batches, mastering custom mold design will propel you towards success in the realm of injection molding.#injectionmolding #apsxpim #molddesign #CADCAM

Are you an APSX-PIM desktop injection molding machine owner eager to embark on the journey of custom mold design? Crafting your own molds unlocks a realm of possibilities, from rapid prototyping to small-scale production. 

Mastering Custom Mold Design for APSX-PIM: A Simple Guide

Designing parts for CNC machining may seem straightforward—raw materials is removed from a solid block to create the desired shape. However, there are many ways your designs can encounter issues may arise from parts that are not designed with manufacturability in mind.We conclude some of the most critical issues, that our engineering experts frequently meet in quote requests. Avoiding the issues will help you improve your part design, shorten lead time, and even perhaps save some costs along the way.&nbsp;<h2 dir="ltr">Avoid the Sharp Internal Corners</h2>Not all features are achievable, a typical example is an internal angle of 90°. See Figure-1. This is because all current CNC milling tools have a cylindrical shape, which creates a rounded edge instead of a straight or sharp angle when cutting along the edges of the machined cavity. If a straight angle must be retained, the usual approach is to use EDM (electrical discharge machining), which is a more expensive manufacturing process than CNC machining.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909572420-1712909572420.png" width="602" height="157" id="isPasted" class="fr-fic fr-dii"><h2 dir="ltr" id="isPasted">Avoid Designing Thin, Tall Walls</h2>When designing for CNC machining, it is important to avoid designing excessively thin or tall walls. While thin walls may be necessary for certain projects, it is important to note that studies have shown that wall thickness is proportional to the stiffness of the material, which can impact the achievable accuracy due to vibrations during machining. The standard minimum thickness for walls is 0.8 mm for metals and 1.5 mm for plastics. See Figure-2, tall walls may result in issues such as undesirable surfaces, difficulty in meeting part tolerances, and the risk of chipping, bending, or breaking. A good rule of thumb for walls is a width-to-height ratio of 3:1.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909612525-1712909612525.png" width="602" height="179" id="isPasted" class="fr-fic fr-dii"><h2 dir="ltr">Avoid Parts with Unnecessary Tight Tolerances</h2>Although CNC machining can tolerate some of the tightest tolerances in manufacturing process, it doesn't mean that every part needs to have the strictest tolerances. In fact, using tight tolerances only when absolutely necessary can greatly reduce costs. As precision requirements increase, more precision manufacturing processes are needed, leading to lower production efficiency and higher costs.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909593141-1712909593141.png" width="602" height="212" class="fr-fic fr-dii">But sometimes, the flawless assembly can be achieved through creating reasonable gaps, simplifying assembly relationships, and using positioning features. In addition, it is also important to maintain same tolerancing as this would reduce machining time. See an example in Figure-3.<h2 dir="ltr">Avoid the Small and Deep Holes, and the Curved Holes</h2>The small, deep holes should be avoided as they can cause drill breakage and make chip removal difficult. The ratio of hole depth to diameter should not exceed 3, and one method to avoid deep holes is to use stepped holes. Blind holes require an additional 25% of hole depth for chip storage. Additionally, the curved holes cannot be machined using CNC methods. However, if this feature is required in your design, Electrical Discharge Machining (EDM) can be used to achieve, with the raised production cost along the way.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909593562-1712909593562.png" width="602" height="355" class="fr-fic fr-dii"><h2 dir="ltr">Avoid the Deep Cavity</h2>There is a certain proportional limit to the machining depth of CNC cutting tools, and the best machining performance is achieved when the cavity depth is 2-3 times the diameter of the tool. Of course, it is possible to machine deeper cavities, up to a maximum of 4 times the tool diameter, but this will increase costs, especially when using multi-axis CNC machine tools. For example, a milling cutter with a diameter of 12mm can safely machine a cavity with a maximum depth of 25mm, not exceeding 48mm. See Figure-5.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909593090-1712909593090.png" width="598" height="361" class="fr-fic fr-dii"><h2 dir="ltr">Summing it Up</h2>Of course, no one single design tip can address every practical design issues. For additional assistance, feel free to CONTACT US, and you can get the in-depth and customized design analysis. To get your next design project started today, simply Upload a 3D CAD model now.

Optimize part design to reduce CNC machining time and cost

5 Mistakes to Avoid When Designing Machined Parts

When it comes to finishing options for aluminium parts, the choices can be baffling. Two standout methods, powder coating and anodizing, often find themselves at the centre of the debate. But what exactly sets them apart?Whether in the automotive industry, aviation, or just curious, understanding these methods will equip you with the knowledge to choose your specific needs.<h2 data-counter-attr="value0">What is Powder Coating?</h2>Powder coating is a finishing technique where a dry, free-flowing powder is applied to a surface, typically aluminium, with a spray gun. The powder adheres to the metal surface through electrostatic application before being cured under heat, forming a tough, uniform layer.<h3 data-counter-attr="value1">Benefits and Key Features</h3><ul><li>Durability: A powder coat creates a hard finish that’s more resistant to scratching, chipping, and corrosion than traditional paints</li><li>Variety: Many colours and textures are available, offering great versatility</li><li>Cost-effective: Though the initial setup may be expensive, the long-term benefits make it cost-efficient</li><li>Environmentally friendly: This process emits few <a href="https://www.epa.gov/indoor-air-quality-iaq/what-are-volatile-organic-compounds-vocs#:~:text=Volatile%2520organic%2520compounds%2520are%2520compounds,paints%252C%2520pharmaceuticals%252C%2520and%2520refrigerants." target="_blank" rel="noreferrer noopener">volatile organic compounds (VOCs)</a>, making it a greener choice</li></ul><h3 data-counter-attr="value2">Common Applications</h3><ul><li>Used for coating wheels, bumpers, and other parts for enhanced aesthetics and protection</li><li>Found in appliances and gadgets for a sleek, durable finish</li><li>It is ideal for coating window frames, railings, and other building elements</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909242472-CNC-machined-and-powder-coated-part-768x513.jpg" style="width: 100%px;" class="fr-fic fr-dib">CNC machined and powder coated part<h2 data-counter-attr="value3" id="isPasted">What is Anodizing?</h2>Anodizing is an electrolytic process that forms a protective oxide layer on the surface of aluminium. A robust, corrosion-resistant layer is created by submerging the aluminium in an acid electrolytic bath and passing an electric current through it. This natural oxide layer is not merely a coating but is integrated with the underlying aluminium, providing a strong bond.<h3 data-counter-attr="value4">Benefits and Key Features</h3><ul><li>Strength and durability: Unlike other coatings, anodized aluminium doesn’t peel or chip, offering lasting protection</li><li>Aesthetic flexibility: Anodizing allows for colouring and decorative finishes, providing a broad palette of options</li><li>Enhanced adhesion: The process allows for better adhesion for paints and glues.</li><li>Non-toxic: The process uses non-hazardous materials and is generally considered more environmentally friendly</li></ul><h3 data-counter-attr="value5">Common Applications</h3><ul><li>Anodizing is vital in aviation, where weight and durability are key considerations</li><li>Used in surgical instruments and other medical devices due to its resistance to wear and biological contamination</li><li>Kitchen utensils and cookware often utilise anodizing for a smooth, non-reactive surface</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909260643-Sheet-Metal-Aluminium-anodising-768x512.jpg" style="width: 100%px;" class="fr-fic fr-dib">Sheet metal aluminium anodizing<h2 data-counter-attr="value6" id="isPasted">Powder Coating and Anodizing Comparison</h2><h3 data-counter-attr="value7">Cost</h3>When evaluating cost, several factors come into play. Powder coating often has higher initial equipment and setup costs. Still, it can be more cost-effective in the long run, particularly for large-scale projects.On the other hand, anodizing typically has lower entry costs but may be more expensive for custom colours and finishes. Ultimately, the price will depend on the specific requirements and scale of the project.<h3 data-counter-attr="value8">Durability</h3>Durability is a vital consideration in choosing a surface treatment. Powder coating provides a robust surface that’s resistant to chipping and scratching. Its uniform coating ensures all-around protection.Anodizing, however, takes it further by integrating the protective layer into the aluminium. This results in a finish that doesn’t peel or chip, offering long-term resilience. Both methods are highly durable, but anodizing may provide a slight edge regarding wear resistance.<h3 data-counter-attr="value9">Corrosion Resistance</h3>Both powder coating and anodizing offer substantial protection in terms of corrosion resistance. A powder coat forms a sealed, continuous layer that prevents oxidation and corrosion.By creating a thick oxide layer, anodizing also offers robust corrosion resistance. While both methods are highly effective, anodizing’s integrated oxide layer might provide more consistent and long-lasting protection against corrosion, especially in aggressive environments.<h3 data-counter-attr="value10">Comparison Table</h3><table id="isPasted"><thead><tr><th>Characteristics</th><th>Anodizing</th><th>Powder Coating</th></tr></thead><tbody><tr><td>Type</td><td>Electrochemical process</td><td>Electrostatic process</td></tr><tr><td>Cost</td><td>High</td><td>Moderate</td></tr><tr><td>Durability</td><td>Excellent</td><td>Good</td></tr><tr><td>Corrosion Resistance</td><td>Excellent</td><td>Good</td></tr><tr><td>Colour Options</td><td>Limited colours</td><td>Wide range of colours</td></tr><tr><td>Surface Finish</td><td>Matte or satin texture</td><td>Glossy, matt, or satin textures</td></tr><tr><td>Colour Fading Resistance</td><td>Poor</td><td>Excellent</td></tr><tr><td>Eco-friendliness</td><td>Good</td><td>Excellent</td></tr></tbody></table><h2 data-counter-attr="value11" id="isPasted">Application-Specific Considerations</h2><h3 data-counter-attr="value12">Architectural Applications</h3>When it comes to architectural applications, both powder coating and anodizing have their merits. Powder coating’s wide range of colours and textures makes it versatile for adding an aesthetic touch to window frames, railings, and other architectural elements.&nbsp;On the other hand, anodizing offers a unique advantage with its corrosion-resistant properties. This makes it particularly suitable for structures in coastal areas where the salty air can accelerate corrosion.&nbsp;Anodizing might lead in this context, providing enhanced protection against the elements.<h3 data-counter-attr="value13">Consumer Electronics</h3>In the realm of consumer electronics, the coating process shines. Its sleek and attractive finish enhances the aesthetics of gadgets. At the same time, its scratch-resistant nature ensures that everyday wear and tear don’t mar its appearance.The versatility in colours and textures allows manufacturers to match the finish with the product’s design. While robust, anodizing might not offer the same array of customisation options as powder coating, making powder coating the preferred choice for consumer electronics.<h3 data-counter-attr="value14">Automotive Industry</h3>In the automotive industry, both powder coating and anodizing find their niches. Powder coating’s durability makes it popular for coating wheels, bumpers, and other metal products that withstand harsh road conditions.&nbsp;On the other hand, anodizing’s corrosion resistance makes it valuable in areas where vehicles might be exposed to corrosive elements, such as road salt. The choice here might depend on whether durability or corrosion resistance is the higher priority.<h3 data-counter-attr="value15">Aviation and Aerospace Applications</h3>For aviation and aerospace applications, the corrosion-resistant properties of anodized aluminium shine. In an industry where weight, durability, and corrosion resistance are paramount, anodizing’s ability to provide all three qualities makes it a top choice.&nbsp;The protective oxide layer helps extend the lifespan of crucial components, ensuring the safety and performance of aircraft.&nbsp;The unique demands of aviation and aerospace applications often make anodizing the preferred option.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1712909300406-Powder-coating-vs-anodising-1-768x513.png" style="width: 100%px;" class="fr-fic fr-dib">Powder coating (left) vs anodizing (right)<h2 data-counter-attr="value16" id="isPasted">How to Choose Between Powder Coating and Anodizing?</h2>A thoughtful evaluation of multiple factors becomes crucial when deciding whether to opt for powder coating or anodizing for aluminium finishing. In this intricate selection process, aesthetics, environment, and function are pivotal considerations.<h3 data-counter-attr="value17">Aesthetics</h3>One must assess the desired visual appeal of the finished product. A powder coat can have various colours and textures, catering to diverse design preferences.&nbsp;On the other hand, anodizing’s colour options, though limited, provide a more lasting and integrated appearance. The choice hinges on balancing immediate visual impact and long-term colour retention.<h3 data-counter-attr="value18">Environment</h3>The surrounding environment significantly impacts the durability and longevity of the chosen finish. Suppose the aluminium parts are expected to endure corrosive atmospheres or extreme weather conditions. In that case, anodizing’s inherent corrosion resistance offers a distinct advantage.Powder coating’s robustness remains undeniable, yet its vulnerability to chipping might necessitate an extra layer of protection in harsh environments.<h3 data-counter-attr="value19">Function</h3>The function of the aluminium component must dictate the choice of finish. If the part is exposed to mechanical stresses or potential abrasion, powder coating’s scratch-resistant nature could be instrumental.&nbsp;Meanwhile, if corrosion prevention is paramount, anodizing’s integrated oxide layer becomes indispensable.<h3 data-counter-attr="value20">Expert Opinion</h3>In this intricate decision-making process, the role of experts cannot be overstated. Engaging with professionals who possess comprehensive knowledge of both finishing methods is essential.&nbsp;These experts can evaluate the unique demands of each project, ensuring that the selected finish aligns optimally with its intended application.<h2 data-counter-attr="value21">Conclusion</h2>The choice between powder coating and anodizing in aluminium finishes transcends mere aesthetics. It’s a decision that directly impacts durability, corrosion resistance, and overall functionality.As we’ve navigated the intricacies of these processes, the significance of informed decision-making has become clear. Powder coatings and anodizing present distinct advantages, each catering to specific requirements.Powder coating offers a broad spectrum of colours and robust protection against scratching, making it a strong contender. On the other hand, anodizing embeds corrosion resistance into the very structure of the aluminium, ensuring a longer lifespan.In the dynamic landscape of surface treatment, Xometry emerges as a versatile and reliable service provider, offering powder coating and anodizing solutions. With a commitment to precision and excellence, Xometry caters to a diverse range of industries, fulfilling the nuanced requirements of each project.

In a world where quality and durability are paramount, selecting the right finish for an aluminium surface is more than a mere aesthetic choice. This article aims to clear the fog by providing a head-to-head comparison of powder coating and anodising processes.

Powder Coating vs. Anodizing for Aluminium

<h2 id="isPasted">Introduction&nbsp;</h2>Your design choices play a major role in ensuring the quality and reliability of your end product. The key to making good choices is building adaptability and expertise to first understand how your choices will affect the design and how it can be manufactured.This expertise as a PCBA designer will make you stand out in the competitive electronics industry.This e-Book will provide you with the design skills to develop exceptional PCBAs that not only meet but surpass their intended objectives while adhering to tight deadlines and budget constraints. Besides covering the essentials of PCBA design, this invaluable resource will also give you an insight into more advanced approaches and best practices to help even the most experienced designers achieve success. &nbsp; We will cover• Designing for Manufacturability: Discover techniques for optimizing your designs tosimplify manufacturing processes and reduce cost•&nbsp;Designing for Reliability: Understand how to create robust PCBAs that withstandchallenging environments and perform consistently over time• Designing for Testability: Learn to incorporate built-in testing methods to streamlineproduction and improve fault detection.• Designing for Compliance: Explore strategies to ensure your designs adhere to industryregulations and standards.• Designing for EMC Compliance: Uncover the principles behind electromagneticcompatibility and learn how to minimize interference in your PCBA designs.• Designing for PCBA Lifespan: Gain insights on maximizing the longevity and performance of your PCBAs through strategic design choices.Embrace the challenge and embark on this technological journey. You're only one step away from unlocking your full potential in the dynamic world of electrical engineering. Start reading today.<h2>Section One: &nbsp;Designing for Manufacturability: Design Techniques and Best Practices</h2>Design complexity is a daily reality for most PCBA designers, making their jobs increasingly difficult and challenging. This complexity extends beyond design, leading to intricate manufacturing hurdles.Selecting a contract manufacturer that aligns with your design needs is crucial, as every product is unique and quality hinges on a compatible factory. A mismatch can result in manufacturing issues that can persist long after product shipment, causing unfulfilled warranty expectations, financial strain, or even loss of market share.Design is a crucial element in the manufacturing and assembly process, and implementing effective strategies can make all the difference. While "design for manufacturability" (DFM) is a known concept, it is sometimes underappreciated or underutilized by electrical engineers.&nbsp;Design for Manufacturability (DFM) is a proactive approach to designing products that can be consistently manufactured by the designated supply chain with minimal defects. A DFM approach combines best practices with a keen awareness of supply chain limitations, and it can improve the efficiency and quality of manufacturing.By embracing DFM in the design process, electrical engineers can sidestep common problems like high production costs, low yields, extended lead times, and component shortages that tend to surface when DFM is neglected.The purpose of this section is to provide electrical engineers with a deeper understanding of PCBA design guidelines and DFM best practices.&nbsp;<h2 dir="ltr">Best Practices for PCBA Design</h2>To create high-quality, cost-effective, and easily manufactured PCBAs, it's essential to adhere to certain design guidelines that are critical for manufacturability. These include<h3 dir="ltr">Component Placement and Selection</h3>Choosing the right components for your PCBA is crucial for long-term reliability and performance. When selecting components, be sure to:<ul><li dir="ltr">Opt for standard components: Avoid unique or rare components, which may lead to higher costs, limited supplier competition, and increased supply chain disruptions. Standard components are more cost-effective, have a proven track record, and have shorter lead times for better on-time product delivery.</li><li dir="ltr">Conduct a Bill of Materials (BOM) analysis:&nbsp;A streamlined BOM can help reduce manufacturing costs. Fewer parts result in less purchasing activity, lower inventory needs, simplified inspections, and easier testing protocols. Careful creation and review of the BOM are essential to achieve this.</li><li dir="ltr">Use multi-functional parts: Choose components that serve multiple purposes, such as a cover or base plate that also functions as a heat sink.&nbsp;</li><li dir="ltr">Account for Moisture Sensitivity Level (MSL):&nbsp;Identify the MSL for all components and ensure the exposure time on the production floor is controlled. This helps prevent moisture-induced damage to sensitive components.</li></ul><h3 dir="ltr">Improve PCBA Design with Lean Processes</h3>As you tackle your PCBA design, remember to prioritize efficiency. Remove any unnecessary steps or elements that don't contribute to your product's overall quality or function. By simplifying the supply, fabrication, and assembly processes, you'll not only increase accuracy and speed but also make your PCBA easier to manufacture.&nbsp;<ul><li dir="ltr">Use consistent traces: Use consistent trace widths and avoid overly complex routing patterns to facilitate a smooth and easy manufacturing and inspection process</li><li dir="ltr">Optimize component placement:&nbsp; Choose careful component placement to minimize trace lengths and reduce the chance of signal interference</li><li dir="ltr">Collaborate with manufacturers:&nbsp; Engage in early and ongoing communication with your CM to ensure design compatibility and address potential issues to improve and enhance manufacturability.&nbsp;</li></ul><h3 dir="ltr">Optimize Trace Routing and Layout</h3>Some key aspects to consider while optimizing trace routing and layout are:<ul><li dir="ltr">Trace Widths and Spaces:&nbsp;Choose trace widths and spaces according to the guidelines provided by IPC-2221 to ensure the efficient distribution of electrical signals and reduce signal interference.</li><li dir="ltr">Layer Stackup:&nbsp;Design a balanced layer stack-up that promotes efficient signal routing and thermal management, considering factors such as signal integrity and power distribution.</li><li dir="ltr">Routing Techniques:&nbsp;Implement appropriate routing techniques, such as using differential pairs, controlled impedance traces, and avoiding 90-degree angles, to maintain signal integrity and reduce the possibility of electromagnetic interference (EMI).</li><li dir="ltr">Ground and Power Planes: Design solid ground and power planes to provide adequate electrical and thermal performance while minimizing noise and crosstalk.</li><li dir="ltr">Design for Signal Integrity: Consider factors such as trace impedance, trace length matching, and proper termination to ensure the signals maintain integrity throughout the circuit.</li></ul><h3 dir="ltr">Implement Design for Manufacturing (DFM) &amp; Design for Test (DFT)</h3>The DFM process focuses on designing products to be easily and cost-effectively manufactured. By considering factors such as materials, component placement, and fabrication techniques, DFM aims to minimize production costs, reduce the risk of manufacturing defects, and increase the overall efficiency of the manufacturing process. &nbsp;DFT on the other hand, ensures the PCBA can be tested and diagnosed efficiently. This process involves designing the board to be easily accessible for testing equipment, incorporating test points, and providing the necessary documentation for test engineers. &nbsp;Consider:&nbsp;<ul><li dir="ltr">Utilize Design Rules Check (DRC): Employ DRC to verify design compliance with industry standards, evaluating parameters like trace widths, spacing, hole sizes, and component placement to ensure successful fabrication.</li><li dir="ltr">Detect and Address Design Issues Early: Using DRC and DFT tools helps identify potential design violations or testability problems early, allowing designers to resolve them before manufacturing</li></ul>Implementing these tools can help detect potential design violations or testability issues early in the process, enabling designers to address them before the manufacturing stage, ultimately saving time and reducing costs.MacroFab's DFM Check:After an order is placed, MacroFab runs an extensive DFM check to ensure the highest quality PCBAs. This analysis includes evaluating the design's manufacturability and identifying potential issues impacting the production process. &nbsp;By utilizing MacroFab's proactive approach, customers can avoid costly rework and achieve faster time to market.&nbsp;<h2 dir="ltr">Challenges in PCBA Manufacturability</h2>The field of circuit board assembly has evolved significantly since its inception, leading to the development of advanced technologies and assembly methods that enable the creation of innovative electronic devices. However, these advancements have also brought about certain challenges when it comes to manufacturing PCBAs.So, what kind of challenges are we talking about? Let's explore some of the common issues that arise with popular PCBA design choices.Join thousands of engineers who have unlocked their full potential! Download the complete MacroFab's Engineering Essentials guide (over 70 pages) and gain the insights trusted by leading professionals in the industry.<a href="https://www.macrofab.com/documents/pcba-design-handbook-2023/" target="_blank" rel="noopener noreferrer">Download now</a>

To excel in the fast-paced electronics industry, you need not just adaptability, but a cultivated expertise to discern the far-reaching impact of your design decisions. This eBook is your key to building such expertise.

Engineering Design Essentials: The PCBA Design Handbook

Are you an EE looking for a new podcast?  Here's a list of MacroFab Circuit Break episodes to get you started. 

The Perfect Binge! Top 8 Circuit Break Episodes for New Listeners

Applications for <a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">3D printing</a> are expanding rapidly in response to new materials, technologies and secondary processes announced seemingly daily. We now see additive manufacturing being used for not only prototyping, but also production parts to reduce assemblies and fabricate complex geometries.<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">Injection moulding</a> continues as the workhorse that produces parts globally, without much fanfare. Perfected over decades, moulding remains the go-to service for cost-effective parts at quantities from 50 to over a million.A future where 3D printing replaces injection moulding may be far off, but today the two work beautifully in tandem. While 3D printing is often touted as a go-to service for prototyping, costs are typically prohibitive when scaling up to production volumes, which is where injection moulding can come in.Deciding which service is the right route for you? Let’s start with a look at cost drivers with both manufacturing services.Post processing workBuild time and post-processing are two main cost drivers. Determining ways to streamline your design or do without unnecessary finishes cuts down significantly on expenses.&nbsp;<img border="0" width="394" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDc0LTE3MTI2Njk2NDk0NzQuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="DMLS post processing" class="fr-fic fr-dii">3D Printing&nbsp;Build time: Far and away the most significant cost driver for 3D printing, a longer build time means a more expensive part. Take a solid cube, for example. While a simple part, printing the condensed cube layer by layer would take more time than if the cube’s interior used a cross-linked design, which requires less material and subsequently less machine time. Any necessary support structures during the printing process also increases machine time and cost.Material cost: Depending on the technology, 3D printing materials can add expense. While direct metal laser sintering (DMLS) recycles all unused powder, a process like selective laser sintering (SLS) uses a powder-based polymer process that does not allow for recycling, driving up cost.Post-processing: Required with nearly all 3D-printed parts, these processes strengthen parts, improve cosmetic appearance and more, but also require manual work that can be time consuming. Each 3D printing service also comes with necessary post-processing, so researching what is required on the front end will help determine cost. Injection MouldingPart complexity: Several design factors can lead to a more complex part with injection moulding. <a href="https://www.protolabs.com/en-gb/automated-design-analysis/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" target="_blank">Design for manufacturability</a> (DFM) analysis is critical to identify modifications that reduce cost. For example, a small part doesn’t automatically translate to a smaller mould size. If your part design requires an undercut or side action, mould base size (and cost) increases significantly. If a cam or insert is required, your overall mould size can increase by £1,000-£2,000 per component. Design TimeFor engineers under increasing pressure to bring products to market, time is money. Quick iteration is key to shorten the timeline to perfect your design and move from concept to final part. That’s why we see our customers start with 3D printing during the prototyping process before moving to injection moulding once a part is ready for production volumes.Product iteration with 3D printing is faster and less expensive compared to injection moulding. If you identify a design flaw once a part is 3D printed, the CAD file can be easily tweaked and uploaded with another iteration printed and sent your way in days. Injection moulding requires significant expense with each design change due to the reworking of the mould. Furthermore, injection moulding usually requires more upfront design work since creating a mould can be a complex process with many factors to consider.<img border="0" width="461" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDgzLTE3MTI2Njk2NDk0ODMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Worker inspecting moulded part." class="fr-fic fr-dii">&nbsp;Set Up and ToolingSet up and tooling costs are another area where 3D printing is the clear winner, as it does not require investment in either. Injection moulding on the other hand comes with tooling costs and often a set-up fee with each run of moulded parts. As we discussed earlier, DFM analysis will help reduce tooling costs, but a mould may still bring thousands in up-front expense. Piece-Part PriceNow here’s an opportunity for injection moulding to shine. Piece-part price for injection moulding is going to be significantly lower compared to 3D printing once we reach a high volume of parts. While we have discussed the cost of tooling at length, each part that comes off that mould will be more cost-effective once you reach quantities that rationalise the initial investment.Fortunately, our applications engineers are well-versed in helping our customers determine if piece-part price cost savings justify the initial upfront costs of injection moulding.<img border="0" width="408" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5NjQ5NDkzLTE3MTI2Njk2NDk0OTMuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Black vapor smooth 3D printed parts." class="fr-fic fr-dii">Post-processingRegardless of technology, nearly all 3D-printed parts will require some level of post-processing. Mandatory processes after a part is printed include removing support structures or excess resin, depending on the technology you choose. The emergence of post-processing options, such as <a href="https://www.protolabs.com/en-gb/services/3d-printing/enhanced-surface-quality-for-sls-and-mjf-parts/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-comparing-3dp-and-im-cost-dt-0424" title="Enhanced Surface Quality for SLS and MJF parts" target="_blank">vapour smoothing</a>, improving strength and aesthetics have been critical in expanding the applications of additive manufacturing, but each comes with an additional expense.Injection moulding on the other hand comes with more than 100 thermoplastic and thermoset materials that eject from the mould with high-quality finishes fit for production. Finishing process are available to texture a mould, add threaded inserts, laser engraving and more, but aren’t necessary for the durability and finish of the part. Prototyping vs. On-Demand ManufacturingInjection moulding is still a viable option at the prototyping stage. When prototyping at Protolabs, we use a single-cavity aluminium mould that can produce hundreds of parts and can be typically delivered in a week or less. Our customers often choose prototyping with injection moulding if they need to complete design or material iterations, as well as assess cost or manufacturability trade-offs.Once past the prototyping stage, our customers often move to on-demand manufacturing, producing injection moulded parts at Protolabs speeds. Using a steel mould, part quantities are virtually unlimited. On-demand injection moulding with us allows you to meet inventory needs with no minimum order quantities, and offers supply chain flexibility through bridge tooling, just-in-time production, or dual-sourcing strategies. Subscribe for monthly design tips <a href="https://explore.protolabs.com/design-tips-registration/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0424&utm_content=wevolver-design-tip-subscribe-banner-0424" target="_blank" rel="noopener noreferrer">here.</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNjY5Njc2NTYwLTE3MTI2Njk2NzY1NjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib">

Explore key components such as build time, material cost, and part complexity, which can add or reduce cost to your part.

Comparing the Cost between Injection Moulding and 3D Printing

Since its founding nearly 25 years ago, welding specialist<a href="https://www.elektrolas.com/en/" target="_blank">&nbsp;Elektrolas</a> has evolved from a company that supplies and maintains welding equipment to one that also offers training and quality management services and, most recently, welding automation services. In parallel to this expansion, the Dutch company has also evolved in terms of the technologies it uses. Notably, it has embraced the use of 3D printing (specifically,<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s5/" target="_blank">&nbsp;UltiMaker’s S5 ProBundle</a>), which has enabled it to improve automated welding setups and streamline operations.<h2 dir="ltr">The road to 3D printing adoption</h2>Like many companies familiar with more conventional production techniques, Elektrolas did not immediately recognize the benefits of integrating 3D printing into its processes. It took Thije van Delft, Technical Manager at Elektrolas, to invest in the technology himself and test out how it could be used in a welding context.He says: “I had done some tests in school using 3D printers, and I asked the company owner [Joost van den Hooven] if I could buy one. He said it wasn’t possible, so I said ‘I will buy one myself’ and purchased a very simple 3D printer for a couple hundred euros and started with that. We did some tests and after some time, Joost was convinced”. From there, Elektrolas consulted with the engineering students participating in traineeships at the company (who were familiar with 3D printing through their studies) about which 3D printer hardware they should invest in. After much deliberation, UltiMaker’s S5 ProBundle was chosen.<h2 dir="ltr">Unlocking new applications</h2>The UltiMaker 3D printer has played an important role at the company, particularly as Elektrolas has ramped up its automation department (spearheaded by van Delft), supplying robotic and cobot welding systems to customers in the Netherlands and beyond. To date, the company has sold and installed dozens of cobot welding systems, which empower its customers to accelerate their lead times and achieve consistent quality, all while mitigating labor shortages in the welding sector.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjMzMTE3NjI2LWluc2lkZXdlbGQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Thije van Delft with the UltiMaker S5 ProBundle, and the cobot welding rig in the back.3D printing has come into play in the production of clamps, which are installed on welding cobots to keep things running smoothly and to ensure the freedom of movement of the robotic arm. Van Delft explains: “We have a holder and an arm clamp that attach the torch hose to the robot. This is made up of two parts: one part that clamps to the robot and one part that attaches to the hose. These are fixed with a fixing pin. If you wanted to make that using milling or other conventional processes, it would not be possible.”<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2NzgwMjQ1LWxvdyBpbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">The complex form of the clamp makes it perfect to be 3D printed at a cost and timeframe impossible to replicate in other manufacturing methods. Image credit: Elektrolas.The company has also found it possible to quickly iterate replacement parts for the 3D printed clamps. Made from Tough PLA, it does happen that the clamps break sometimes. “In this case it’s very easy to print a new one and send it the next day to the customer,” van Delft says. “The customer simply sends a picture of what part is broken, we start the printer, and the next day we can send it via DHL to the customer.” This, of course, has the obvious benefit of eliminating the need for large inventories of spare clamps, since they can be printed on demand.Elektrolas has also turned to 3D printing in the production of temporary holders that attach hand welding torches to robotic or cobot systems. In this case, UltiMaker’s solution enabled Elektrolas to meet the needs of one of its customers who wanted to integrate a manual welding torch in an automated system. “We called the supplier of this welding torch, but the automatic version had a delivery time of 10-12 weeks,” van Delft recalls. By designing and 3D printing a holder to attach the welding torch to the robot, Elektrolas was able to offer its customer a stopgap solution while they waited for the final part from the welding torch supplier. This enabled them to keep their automated welding production up and running rather than being setback by system downtimes.<h2 dir="ltr">Why the UltiMaker’s S5 ProBundle?</h2>While both UltiMaker and Elektrolas are based out of the Netherlands, the local appeal was only part of the equation when the welding company started looking for a 3D printing solution to adopt three years ago. UltiMaker’s S5 ProBundle is a professional-grade solution that combines UltiMaker’s reliable dual-extrusion technology with advanced features like automated material management, superior air filtration, and humidity control for filament. The 3D printer also has a sizable print volume (330 x 240 x 300 mm), which was an important factor for Elektrolas as the company often prints large components.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2ODQ0NTY0LWRlZXAgLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Multiple prints can be completed simultaneously in the S5’s large print bed.&nbsp;Ease of use and print quality were also top of mind for van Delft and his team. The UltiMaker S5 ProBundle delivered on both fronts. Elektrolas has achieved consistency from print to print thanks to the ability to save setup and print settings in Cura. As van Delft explains, he and his team are able to design the parts they need in SolidWorks and print them on demand with the touch of a button. This is also thanks to the work of their trainee students, who have pre-programmed print settings, and UltiMaker’s intuitive user interface, which enables one-button printing. “If, for example, a client wants to weld with some special machine but there is no welding torch on the robot, we can take a normal welding torch and sketch a holder in SolidWorks and then print it.” Using this approach, test parts can be delivered the next day.In terms of printing materials, Elektrolas is primarily working with<a href="https://ultimaker.com/materials/s-series-tough-pla/" target="_blank">&nbsp;UltiMaker Tough PLA</a>, a technical PLA filament that offers good toughness (similar to ABS), as well as minimal warping and excellent printability at an affordable cost. While not the most robust material in UltiMaker’s portfolio, Tough PLA does meet the needs of the welding company for the clamps and holders. Even the material’s weaknesses have proven to be a benefit. “I have twice received a request for a new 3D printed clamp because the operator of the robot made a mistake and broke the clamp when the torch hit some corner when the robot was moving,” van Delft elaborates. “Here it is good that the clamp breaks, because it protects the torch from breaking. The clamp is not expensive and easy to replace, the torch is not.”<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyMjM2OTA5Mjg1LWxvdyByZXMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">The 3D printed clamps enable the welding hoses to be safely secured. By printing in Tough PLA, the clamps are robust but also quick and affordable to replace when needed.Elektrolas also benefits from other features that come with the S5 ProBundle, including Air Manager, an enclosure that provides closed inside-out airflow and filters up to 95% of ultrafine particles (UFPs) generated in the printing process, and the S5 Material Station. This piece of equipment stores and protects up to six spools of filament and offers end-of-filament detection and automatic spool switching, which facilitates lights-out printing. “If you have a big print, it is maybe 35-45 hours of printing,” van Delft adds. “Since we have big prints, the material station can change the PLA by itself and keep the print going until it’s ready the next day.”For 3D printer maintenance and technical support, Elektrolas turns to <a href="https://www.makerpoint.nl/nl-nl/" target="_blank">MakerPoint</a>, a Dutch supplier of 3D printing systems and maintenance provider based in Arnhem, Best, and Harlingen.<h2 dir="ltr">Intuitive 3D printing for traditional manufacturing</h2>Elektrolas is one of many businesses in the traditional manufacturing sphere that has reaped the benefits of UltiMaker’s professional 3D printing solutions. For example,<a href="https://www.wevolver.com/article/eriks-leveraging-3d-printing-to-improve-manufacturing-processes" target="_blank">&nbsp;industrial supplier ERIKS BV</a> relies on UltiMaker systems for a range of applications, including prototyping, tooling, customized jigs and fixtures, and replacement parts. You can find more<a href="https://www.wevolver.com/profile/team.ultimaker" target="_blank">&nbsp;UltiMaker client stories here</a>.

Dutch welding solutions specialist Elektrolas uses the UltiMaker 
S5 ProBundle to minimize machine downtimes and facilitate cobot welding for its customers.


How UltiMaker 3D Printing Supports Automated Welding

What’s the extent of impact of electric vehicle on drivetrain system? Electric Vehicle is driving significant change in drivetrain design for electric vehicles, with the use of different kinds of automatic transmissions and integrated units to optimize efficiency. Despite differences in operating principles, there are similarities. Explore the impact and challenges of drivetrain design and find how RPWORLD comes in to accelerate the design iteration.<h2 dir="ltr">What’s the Impact of EV on Drivetrain Design</h2>Electric Vehicle is driving significant change in the way manufacturers approach drivetrain design, as compared to the development process for traditional combustion engine vehicles. This change is reflected in the use of different kinds of automatic transmissions, such as 2-stage spur gear drives, integrated stepped planetary gear drives, or continuously variable transmissions (CVT), to optimize efficiency in state-of-the-art electric vehicles, whereas previously 6-speed manual or 8-speed automatic transmissions were standard in the automotive world.One notable difference is that electric motors, power electronics, and drivetrains can share a single housing, which reduces the overall number of components in the powertrain and lowers the system's weight. In battery electric vehicles (BEVs), this integrated unit may directly power a combined electric axle drive, while various transmission configurations are possible in hybrid vehicles, depending on how the manufacturer intends the electric motor and combustion engine to interact with each other.<h2 dir="ltr">Challenges in Component Design for Electric Vehicle Drivetrains</h2>Despite the differences in operating principles between electric vehicle drivetrains and their combustion engine counterparts, there are many similarities in the design and manufacturing processes required at the component level. Key components such as straight gears, helical gears, and housings are common to both types of drivetrains. However, specializing such components for electric vehicle drivetrains presents challenges in dealing with the higher torque and speed of rotations that can be achieved with electric motors.<ul><li><h3 dir="ltr">Special considerations for precision manufacturing</h3></li></ul>The precision manufacturing of transmission components like straight and helical gears or planetary gear drive systems requires tighter tolerances for electric vehicle components. The surface finish of gears also gains new importance as the noise emission of the drivetrain is critical in electric vehicles due to the silent electric motor.<ul><li dir="ltr"><h3>Shift in drivetrain design</h3></li></ul>Electric Vehicle is driving a significant shift in drivetrain design for state-of-the-art electric vehicles, leading to the use of different kinds of automatic transmissions and integrated units that reduce the overall number of components and weight of the system. Despite differences in operating principles, there are many similarities in the design and manufacturing processes required at the component level. Specializing components for electric vehicle drivetrains requires dealing with higher torque and speed of rotations and tighter tolerances, as well as placing greater importance on surface finish to reduce noise emission from the silent electric motor.<h2 dir="ltr">Customized Drivetrain Components to Meet Your Specific Needs</h2>At RPWORLD, we understand that every vehicle's drivetrain requirement is different, and that's why we offer customized drivetrain components with tight tolerance and high efficiency to meet your specific needs. Our 20-years’ experience in manufacturing allows you to turn your design into reality fast and accelerate your iteration and prototyping verification.RPWORLD is a customized manufacturing supplier, offering CNC Machining, Injection Molding, Sheet Metal Fabrication, Surface Treatment and more.

Photo by ThisisEngineering RAEng on Unsplash

Explore the impact and challenges of drivetrain design and find how RPWORLD comes in to accelerate the design iteration.

Customized Drivetrain Components: Meeting the Challenges of EV Design

Black anodizing refers to the process of anodizing an aluminium part and then dying it black using a suitable dye. This must not be confused with black oxide coating which is unsuitable for aluminium parts. Anodized aluminium has improved wear and corrosion resistance, while black anodized parts have the additional benefits of being light absorbent as well as being able to effectively radiate heat. This article will describe what black anodizing is, how it works, as well as the various pros and cons.<h2 data-counter-attr="value0">What is Black Anodizing?</h2>Black anodizing refers to the electrochemical process of blackening an aluminium part by first performing standard anodizing to create a semi-porous aluminium oxide layer. The oxide layer is then dyed black using one of three dyeing techniques: organic dyes, inorganic dye, or electrolytic dyeing using metal salts.&nbsp;The metals that can be black anodized are aluminium, magnesium, and titanium. Aluminium, however, is the most common material used for black anodizing. It must be noted that not all grades of aluminium can be black anodized. Only aluminium series 5, 6, and 7 can be anodized.<h2 data-counter-attr="value1">How Does Black Anodizing Work?</h2>Black anodizing works by first anodizing the part using the standard anodizing process with either a type II or type III anodizing process. A minimum anodized coating thickness of 25 microns or more is recommended for optimal colourfastness. Once anodized, the part will have a semi-porous surface structure. These pores are utilised to hold the black dye.&nbsp;There are three types of dyeing techniques, as described below:<ol><li>Organic pigments: These dyes are dissolved in warm water and then placed into the dye bath. The part is placed into the dye bath and the dye fills in the semi-porous surface of the anodic layer. Typically, black dyeing requires additional dyeing time compared to lighter colours. Organic-dyed parts are not recommended for outdoor usage.</li><li>Inorganic pigments: These pigments are not soluble in water. Inorganic pigments produce coatings with excellent light fastness. For black anodizing, parts can be produced with inorganic salts of cobalt sulfide.</li><li>Electrolytic dyeing: After normal anodizing, parts are placed in another electrolysis bath with a solution containing heavy metal salts. The anodic layer acts as the cathode, and a stainless steel electrode is placed in the acid electrolyte bath. The metal salts are then deposited into the bottom of the pores. Nickel, cobalt, and tin salts are used to produce different colours, a proprietary process that produces parts with exceptional colourfastness.</li></ol>After dyeing, the pores on the anodic layer must be sealed to prevent colour leaching. Sealing is typically done via hydration of the coating, which closes the pores off by reaction with the anodic layer. Wherever there is a pore, AI2O3H2O is formed; this is less abrasion-resistant than the normal aluminium oxide surface. Alternatively, chemical sealing can be put into effect, for example by using nickel acetate or dichromate sealing.<iframe width="640" height="360" src="https://www.youtube.com/embed/LBLV1CPBRRk?&amp;wmode=opaque&amp;enablejsapi=1&amp;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"></iframe>The time required to black anodize a part depends on the desired anodic layer thickness, the dyeing method, and the post-dye sealing technique. In general, it takes five minutes to anodize 2.5 microns. So to anodize the minimum recommended black anodized thickness of 25 microns will take around an hour. The dyeing process can take up to 20 minutes. However, these time frames also depend on the cleaning and rinsing processes.<h2 data-counter-attr="value2">Applications of Black Anodizing</h2>Black anodized aluminium has all the benefits of standard anodized aluminium with the additional benefits afforded by the black colouring. The black anodized aluminium is used in applications where the black coating is beneficial. Here are some applications examples:&nbsp;<ul><li>Satellite components that rely on the black anodic coating to&nbsp;</li><li>efficiently radiate heat back into space</li><li>Optical equipment that relies on the ability of black coatings to absorb any stray reflective light</li><li>Architectural trimmings in which the deep black colours are aesthetically pleasing while also having excellent colourfastness, and the surface finish provides improved abrasion resistance.</li></ul>An anodized coating can last between 10 and 20 years depending on the application, the thickness of the coating, and whether or not the relevant sealing steps were performed after anodizing. When metal salts are used for dyeing, the colour will not fade. However organic dyes will fade over time.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711444501200-Stack-of-black-anodised-aluminium-extrusion-bars.jpeg" style="width: 100%px;" class="fr-fic fr-dib">Stack of black anodized aluminium extrusion bars<h2 data-counter-attr="value3" id="isPasted">Benefits of Black Anodizing Finish</h2>The benefits of black anodizing include increased wear resistance and corrosion resistance. This finish ensures that anodized aluminium parts will not be prone to rust. Rust is typically used to describe the formation of a destructive flaking oxide layer on ferrous metals. When an oxide layer forms on aluminium, it adheres to the metal surface and prevents further oxidation of the base material.However, black anodizing has a few additional specific benefits described below:<ul><li>Heat emissivity: Aluminium components are often dyed black to increase their emissivity; applications can include heat sinks as well as satellite components.</li><li>No outgassing: Black anodized parts, if properly sealed after dyeing, do not undergo outgassing when exposed to a vacuum. This lack of outgassing helps protect sensitive equipment, especially sensitive space-based equipment.&nbsp;</li><li>Colour fastness: Black anodized parts, especially if dyed with inorganic or metal salts, have excellent colourfastness, which means they will typically maintain their colour when exposed to UV (ultraviolet) light.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711444547421-A-black-anodised-flashlight.jpeg" style="width: 100%px;" class="fr-fic fr-dib">A black anodized flashlight<h2 data-counter-attr="value4" id="isPasted">Limitations of Black Anodizing</h2>While black anodizing stands as a robust finishing process with notable advantages, it is important to acknowledge its inherent limitations. Navigating beyond its sleek black aesthetic and corrosion-resistant properties, certain constraints shape the boundaries of its applicability.<ul><li>Surface cracking: When exposed to thermal cycling, black anodized parts will form cracks in the anodic coating. These cracks are mainly due to the difference in thermal expansion rates of the substrate and the coating.&nbsp;</li><li>Limited materials: Not all aluminium series can be black anodized. In general, the most commonly anodized aluminium series are 5, 6, and 7, with series 6 being the most commonly anodized.</li><li>Colour fading: If organic dyes are used, black anodized parts will lose their colour as these dyes are unsuitable for UV light exposure.</li></ul><h2 data-counter-attr="value5">Summary</h2>In conclusion, black anodizing emerges as a versatile and essential process in the manufacturing landscape. Its dual advantages of enhanced corrosion resistance and an appealing black finish make it a preferred choice in industries ranging from aerospace to robotics.Xometry provides a wide range of manufacturing capabilities and other value-added services for all of your prototyping and production needs.

Explore black anodising, a key finish in manufacturing, and gain insights into the detailed process from pre-treatment to sealing. Understand its practical applications in industries such as aerospace and robotics, known for its durability and corrosion resistance in components.

Everything You Need to Know About Black Anodizing

The global surge in thermoplastics demand has led to increased production and plastic waste, surpassing annual production levels, necessitating the development of sustainable recycling methods and practices throughout the product life cycle to mitigate environmental impacts.

Engineering Thermoplastics Guide. Chapter 6. Sustainability and Recycling of Engineering Thermoplastics

As we look to the skies, we’re on the brink of a significant transformation. By 2036, the International Air Transport Association (IATA) suggests an annual flight tally of 7.8 billion passengers. As more people fly, the need for high-performance aircraft grows, and so does the challenge of creating robust avionic electronics.Avionic electronics operate in demanding conditions. They must withstand intense vibrations without any circuit board malfunctions. Traditional hydraulic and pneumatic systems in aircraft are not only weighty but also have notable reliability concerns. The intricacies of aircraft manufacturing lead to supply chain complications, extended prototype development periods, and greater waste. Additionally, there’s a rising call for predictive maintenance to reduce aircraft downtime.It’s fascinating to watch forward-thinking companies harness the latest trends in avionic electronics to overcome challenges. What sets the modern generation of aircraft apart are breakthroughs in sensor technology, such as engine vibration diagnostics, smart skins, and structural health monitoring.The utilization of virtual reality for aircraft diagnostics and advances in propulsion technology are also noteworthy. Powering onboard sensors with energy harvesting represents another transformative step.But it’s not all smooth flying. Avionics, like many established heavy industries, is often hesitant to fully adopt emerging tech trends. And they have good reasons: regulatory hurdles, compatibility concerns, the necessity of new investments, and the aim to maximize value from recently incorporated technologies—especially given the long life cycle of aircraft.Throughout this article, we’ll explore four cutting-edge trends in avionic electronics and shed light on the challenges they present.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711029254524-1711029254524.png" alt="Sensor technologies" class="fr-fic fr-dii"><h2><ol><li>Sensor Technologies for Enhanced Aircraft Safety and Performance</li></ol></h2>Modern aircraft are equipped with thousands of sensors, serving as critical components for improved safety, efficiency, reliability, and passenger comfort. These sensors not only monitor and diagnose various aircraft systems in real-time but also set the stage for proactive interventions and optimizations.Key trends in sensor technology currently shaping the future of aviation include:<ul><li>Engine Vibration Diagnostics: Enables early detection of engine anomalies, preventing potential malfunctions. As initially reported by <a href="https://www.militaryaerospace.com/test/article/14292200/engine-vibration-jet-aircraft-passenger-safety" target="_blank">Military Aerospace Electronics</a>, officials from the U.S. Federal Aviation Administration (FAA) Airport Safety Research have embarked on a two-year project. The aim is to use jet aircraft engine vibration monitoring to track both regular and irregular engine vibration levels during development phases, certification testing, and while in airline service.</li><li>Structural Health Monitoring (SHM): Environmental stress can compromise the durability of avionic electronics. SHM plays a pivotal role in safeguarding the integrity of avionic structures. Recent trends in SHM have seen an uptick in the use of more refined and sensitive sensors. These advanced sensors excel at pinpointing fatigue damage, concealed cracks in difficult-to-access areas, disbonded joints, and a host of other structural issues common in aging aircraft.</li><li>Smart Skins: Smart skins aim to provide a sensory layer on the external surface of an aircraft to detect changes, damages, or stress, similar to how biological skin detects stimuli. With advances in <a href="https://www.macrofab.com/blog/use-rigid-flex-pcb-assembly/" target="_blank">flexible electronics</a> and smaller sensors from nanotechnology and micro-fabrication, smart skins are now more reliable. They’re increasingly used on modern aircraft to enhance safety and performance.</li><li>Cutting-Edge Trends in Powering Sensors: Using energy harvesting, aircraft capture electricity from vibrations with embedded piezoelectric transducers. Aircraft naturally vibrate due to engines, aerodynamics, and air conditions, and so energy harvesting using piezoelectric can power onboard sensors, enhancing aviation sustainability.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711029254597-1711029254597.png" alt="Improved engine diagnostics" class="fr-fic fr-dii">Improved engine diagnostics, SHM, and smart skins, when paired with data analytics are optimizing maintenance in the aviation sector, significantly reducing the estimated $62 billion annual cost due to aircraft-on-ground time. These technologies enable immediate repair actions as soon as aircraft land, minimizing downtime.Highlighting this advancement, <a href="https://www.honeywell.com/us/en/press/2017/06/honeywells-connected-aircraft-maintenance-offering-to-reduce-flight-delays-and-cancellations-for-cathay-pacific" target="_blank">Honeywell and Cathay Pacific</a> have partnered to deploy Honeywell’s GoDirect Connected Aircraft maintenance system for their Airbus A330 fleet. This program, leveraging comprehensive diagnostic information, connectivity, and data analytics, has been shown to decrease system failures by up to 35 percent, reducing aircraft downtime and minimizing flight disruptions.<h2>2. Thermal Features Protecting Aircraft Electronics from Overheating</h2>Electronics produce heat, and <a href="https://www.macrofab.com/blog/improve-heat-dissipation-compact-pcba-designs/" target="_blank">managing this heat effectively</a> is vital for the reliability and longevity of aircraft systems.One of the foremost trends in cooling power electronics and semiconductor devices in aircraft is a shift from using air-cooled methods to liquid-cooled or two-phase flow solutions. These methods offer superior heat transfer density, which helps the electronics stay within safe temperature ranges and thereby reduce the risk of component failures.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711029254631-1711029254631.png" alt="Protect overheating thermal features" class="fr-fic fr-dii">Concurrently, there’s a renewed interest in air-cooled systems, especially air-cooled heat sinks integrated with advanced materials like Annealed Pyrolytic Graphite and Aluminum Graphite. These provide lighter thermal management systems than their liquid-based counterparts.Additionally, tools such as thermoelastic stress analysis are used in identifying crack locations in fastened aircraft joints.<h2>3. Increased Aircraft Electrification</h2>Global efforts to reduce pollution have spurred the push for greener, more sustainable aviation through aircraft electrification.This shift starts with replacing hydraulic and pneumatic systems with electrical alternatives, resulting in weight savings, improved fuel efficiency, and a reduced environmental footprint.The primary objective is to transition from fossil fuel-powered propulsion to cleaner, quieter electrical propulsion systems. Yet, this change presents challenges, given the bulky motors and the low energy density typical of electric systems. To address these issues, there’s active research into cutting-edge solutions like axial flux motors and superconducting technology. These innovations aim to reduce motor weight and size.Consequently, we’re currently witnessing a rise in more electric-powered aircraft (MEA), where only the propulsion remains fuel-driven, while other subsystems are electric.Hybrid electric aircraft (HEA) are expected to follow soon, blending conventional jet engines with electrical power. At the forefront of this transformation are industry giants like <a href="https://www.airbus.com/en/newsroom/press-releases/2017-11-airbus-rolls-royce-and-siemens-team-up-for-electric-future" target="_blank">Airbus, Rolls-Royce, and Siemens</a>, who have teamed up to pioneer a flight demonstrator for commercial hybrid-electric propulsion.Ultimately, the vision is the emergence of all-electric aircraft (AEA) or full-electric aircraft (FEA), which are entirely devoid of combustion engines.<h2>4. Diagnosing Aircraft Electronics with Virtual Reality (VR)</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1711029254707-1711029254707.png" alt="Aerospace virtual reality" class="fr-fic fr-dii">The VR Diagnostic System offers a virtual environment where technicians can navigate through a life-size, 3D representation of an aircraft’s electronic system. With immersive visuals and interactive elements, it provides a hands-on experience without ever touching the actual hardware.Technicians can view components from all angles, zoom in for detailed inspections, or even view inside components. Since this method is non-intrusive, it mitigates the risk of inflicting damage to delicate electronics or inadvertently triggering malfunctions during assessments.Additionally, it significantly saves time by eliminating the need for traditional paper manuals, enabling maintenance staff to quickly access relevant data on handheld devices.Beyond diagnostics, VR is being used as an excellent training medium. Novice technicians practice troubleshooting in the virtual environment, refining their skills without the risk of causing harm to actual aircraft components.<h2>Conclusion</h2>Modern aircraft are leveraging advanced sensor technologies for enhanced engine and structural health monitoring, as well as the implementation of smart skins. The vast array of diagnostic data gathered from these sensors is increasingly integrated with data analytics, enhancing inspection and maintenance processes.Additionally, the advent of Aircraft Maintenance Virtual Reality (AMVR) systems has revolutionized how aircraft are modeled during maintenance and inspection. VR systems also serve as invaluable training tools for novice technicians. Integrated thermal management systems and materials have also made significant strides in the avionic industry.<section><h4 id="isPasted">Visiting the Houston Area?</h4>Come Tour MacroFab’s ITAR-Compliant Facility<a href="https://www.macrofab.com/tour-macrofabs-itar-compliant-facility/" target="_blank">SCHEDULE YOUR TOUR NOW</a><section><h5> </h5></section></section>

The world is witnessing a rise in more electric aircraft (MEA) where only the propulsion remains fuel-driven and other subsystems are electric rather than hydraulic or pneumatic. Find out what this change means for EEs. 

Four Cutting-Edge Trends in Avionic Electronics You Should Know

At A GlanceChallengeInjection moulding 210 parts in 5 weeks for the battery pack cooling system for a fully electric super sports car prototypeSolutionHutchinson relied on Protolabs to obtain three different components within the required time and with the prescribed quality. The speed of interaction between Hutchinson and Protolabs, combined with experience in the automotive sector, allowed for the production of 210 parts in less than 5 weeks from the first contact.OutcomeThe iteration speed of Protolabs and Hutchinson led to perfect parts being delivered on time, ready to be tested and installed on the supercar prototype, reducing validation and testing times.<hr> In June 2023, 138,937 new cars were registered in Italy. Of these, just under 10% were electric cars: 7,539 plug-in hybrids and 6,159 fully electric vehicles. Adding the remarkable figure of 48,937 new electric hybrids, electric and hybrid cars together accounted for almost 45% of new registrations. &nbsp; <a href="https://www.hutchinson.com/en" target="_blank">Hutchinson</a>, a Total Group subsidiary, is a French multinational with 38,000 employees across more than 100 industrial sites in 25 countries, specialising in designing and manufacturing polymer-based products and systems for fluid management. Located in Rivoli, near Turin, is the global centre of competence for automotive fuel systems, typically for diesel or gasoline vehicles. However, in electric cars, such a system is non-existent. Instead, a similarly crucial component for the proper functioning of electric cars is the battery pack temperature stabilisation system, a critical node for vehicle safety. &nbsp; In 2025, Italy will introduce a fully electric supercar, and work on prototype development has already begun, thanks to the collaboration between <a href="https://www.protolabs.com/en-gb/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=wevolver-hutchinson-cs-0324" target="_blank" rel="noopener noreferrer">Protolabs</a> and Hutchinson.Designing a supercar means thinking big, and Engineer Valter Mondini, Project Manager, understands that no detail can be left to chance in a project of such significance. Hutchinson was brought in to find the best solution for cooling the battery pack. For a car to be defined as a supercar, it must deliver exceptional performance in speed and range, the latter being determined by a battery pack as extensive as possible while minimising space for other elements.The main technological challenge was minimising the space the hydraulic system used to cool the battery pack took. This involved replacing the&nbsp;<a href="https://www.protolabs.com/en-gb/materials/?utm_source=eureka&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=eureka-spotlight-hutchinson-cs-0124" target="_blank" title="Materials">material</a> used to make the tubes. Initially, the tubes were made of rubber that contained water and glycol, but Protolabs replaced the material with extruded plastic, ensuring the same mechanical performance. Each piece had to be flawless to guarantee a seal of up to 4 Bar. It was crucial to avoid any moulding imperfections, such as burrs, as they could mark the tube during the cold fitting phase and compromise the hydraulic system's seal.<img border="0" width="359" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwOTM3MTk2MTMyLTE3MTA5MzcxOTYxMzIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Protolabs and Hutchinson collaborate on the first Italian electric supercar" class="fr-fic fr-dii" style="width: 451px;">"Protolabs is among Hutchinson's accredited suppliers and collaborates on projects where the speed of iteration and the quality of the products obtained are unparalleled. They accepted the challenge. The timelines were extremely tight: we needed to produce four different&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=wevolver-hutchinson-cs-0324" target="_blank" title="Injection Moulding" rel="noopener noreferrer">injection-moulded</a> components in the specified material, with particularly tight tolerances given the importance of the battery cooling hydraulic system. Given the project's significance," explains Engineer Mondini of Hutchinson, we could not afford any mistakes.<blockquote>"Protolabs is among Hutchinson's accredited suppliers and collaborates on projects where the speed of iteration and the quality of the products obtained are unparalleled. They accepted the challenge." V. Mondini, Project Manager &amp; Engineer at Hutchinson</blockquote>&nbsp;"Upon receiving the initial request from Hutchinson," explains Stefano Mosca, Senior Account Manager at Protolabs in Italy, "we immediately involved our injection moulding centre of excellence in Eschenlohe, which is particularly accustomed to responding to requests from the automotive sector. We were already familiar with the sector's required standards and knew that when we are involved in a project, it is primarily for the speed and quality assurance of the parts we produce. In 5 weeks, we validated the project, produced the moulds, chose the filler percentage of both Nylon and PPS together with the customer, injected moulded the parts, and shipped them."The project is a fine example of international collaboration. The development project for these components was undertaken in Italy, developed in France, produced in Germany, tested in Italy, and a portion of the parts was shipped from Protolabs to Poland to be mounted on some prototypes— a fitting example of how an international supercar, which will be sold worldwide, is born.<img border="0" width="295" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwOTM3MTk2MTM5LTE3MTA5MzcxOTYxMzkuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="A close-up of several pipesDescription automatically generated" class="fr-fic fr-dii" style="width: 370px;">&nbsp;&nbsp;About Hutchinson:Hutchinson designs and manufactures smart solutions for a world on the move and contributes to future mobility on land, in the air and at sea. With expertise in fluid transfer, sealing, anti-vibration systems and materials &amp; structures, Hutchinson is a global leader in&nbsp;developing innovative solutions for sustainable mobility.To find out more, visit the&nbsp;<a href="https://www.hutchinson.com/en/accueil" target="_blank">Hutchinson</a> website.

Designing components for a super car means thinking big, delivering exceptional performance, and executing a flawless design.  Learn how Hutchinson worked with Protolabs to injection mould a battery pack cooling system in just 5 weeks.



Protolabs and Hutchinson collaborate on the first Italian electric supercar

The TechBlick Innovations Festival, happening online on April 25, 2024, is a curated event for engineers, researchers, entrepreneurs, and inventors, focusing on advancements in additive, printed, 3D, and wearable electronics, among other topics.&nbsp;It features networking opportunities and an immersive virtual exhibition. Attendees can expect talks from leading global speakers representing companies like SPGPrints, ACI Materials, and Akoneer, covering topics such as scaling printed electronics from lab to production, transformative conductive inks, and semiconductor packaging innovations. For more details, <a href="https://wevlv.co/techblick24eventdetails" target="_blank" rel="noopener noreferrer">visit the event page</a><a href="https://www.techblick.com/event/spring_innovations_festival" target="_blank" rel="noopener noreferrer"></a><a href="https://www.techblick.com/event/spring_innovations_festival" target="_blank" rel="noopener noreferrer">.</a>The last Innovation event had over 700+ participants [not registrants]! Do not miss this opportunity! There are simultaneous events throughout the day, including presentations from Neibling, NanoPrintek, TracXon, Kimoto, and more.&nbsp;The cutting-edge virtual environment enables you to meet other participants, attend events, and discover new technologies.&nbsp;<a href="https://wevlv.co/techblick_innovation_24" target="_blank" rel="noopener noreferrer" class="button-main-action">Register now!</a><h2 dir="ltr" id="isPasted">Speaker Highlights</h2>The event features a wide range of speakers covering all aspects of the additive and flexible electronics sector. Following are some of the highlights of notable speakers and their topics from Track 1 and Track 2:<h3 dir="ltr">Highlights from Track 1</h3>Innovating with TFT technology in both optoelectronic and biological ways — Partner and Co-CEO of LinkZill,Yixing Yang, will speak about TFT semiconductor technology and its applications in various fields of optoelectronics and life sciences such as large-area bio-sensing, novel display, high-throughput DNA synthesis, and in-vitro diagnostics (IVD).Scalable, customizable, multimodal electrode platform for biosensors and sensors — Healthcare Marketing Director of Linxens,&nbsp;Christelle Robellin, will speak about the latest advancements in Point-of-Care Diagnostics enabled by Linden’s innovative manufacturing process. She will cover recent developments in electrode design, surface coating, microfluidics, and connectivity, highlighting their applications in continuous monitoring of glucose, wound healing, water quality, and sports performance.Advances in wash testing of conductive inks for wearable electronics — Business Development Manager of Nagase ChemteX America Corporation (NCU),Alan Brown, will address the significant challenges faced by conductive inks when applied in wearable applications, with a particular focus on washability—the most formidable obstacle among them.&nbsp;Beyond paper: Inkjet printing is the future in drops — Manager of Sales and Services of Suss MicroTec,&nbsp;Peter de Vrieze, will discuss groundbreaking technologies aimed at advancing the field of printed electronics. De Vrieze will spotlight the latest advancements in analysis tools, ranging from cutting-edge dropwatching technologies to intelligent inspection tools.<h3 dir="ltr">Highlights from Track 2</h3>Demonstration of flexible and printed electronics production using INO PE Line A7 — representing INO Sales US,Nivas Vehar will demonstrate the production process of flexible and printed electronics through three-color screen printing, showcasing zero scrap and exceptional efficiency. After the demonstration, attendees can engage in a Q&amp;A session to explore the complexities of this cutting-edge process.Going maskless for semiconductor packaging with SSAIL — CCO of AkoneerTadas Kildusis, will introduce SSAIL technology, enabling direct copper deposition onto organic and dielectric materials. He'll discuss its applications in RDL, fanouts, and heterogeneous integration, emphasizing high adhesion for reliability in automotive and defense.Laser Patterning of sputtered coatings for high-volume production of flexible devices — Mechanical Engineer at Intellivation LLC,Matthew Kleyn, will discuss advanced roll-to-roll (R2R) solutions using vacuum coatings and laser patterning to meet the demand for high-volume flexible devices across industries. He'll emphasize optimized process controls and the importance of modularity and scalability for high-volume production.High Pressure Forming (HPF) for In-Mold Electronics (IME) processes — Director Sales &amp; Marketing at Niebling GmBH,Udo Weustenhagen, will speak about the importance of precise 3D substrate forming for In-Mold Electronics (IME). He will cover the alignment of conductor tracks, electronic components, and graphics within injection tool cavities. Weustenhagen will introduce the high-pressure forming process, highlighting its benefits over traditional methods, including lower temperatures and clever automation for series production.For the full list of speakers and presentation times, <a href="https://www.techblick.com/event/spring_innovations_festival" target="_blank">visit the event page.</a>

Engineers, researchers, entrepreneurs, inventors, and end users are invited to join TechBlick Innovations Festival, exploring additive, printed, 3D, and wearable electronics on 25 April 2024 online.

TechBlick Innovations Festival

Helmet made with KyronTEX®, a continuous carbon fiber-reinforced thermoplastic composite. Source: Mitsubishi Chemical Group

Composites are materials composed of a matrix and reinforcement, offering unique advantages and properties derived from both components.

Engineering Thermoplastics Guide. Chapter 5. Thermoplastic Composites and Their Applications

This episode of Circuit Break features James Lewis, the Bald Engineer, in a discussion on his ambitious Mega IIe project. Lewis dives into the technical details of constructing a functional computer around the Apple II GS's Mega II chip.<h3 data-sourcepos="5:1-5:240"><iframe width="100%" height="180" frameborder="no" scrolling="no" seamless="" src="https://share.transistor.fm/e/a2988ef3" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;</iframe> The conversation explores:</h3><ul data-sourcepos="9:1-14:0"><li data-sourcepos="9:1-9:121">Apple II Architecture and Nostalgia: Examining the open design and historical significance of the Apple II series.</li><li data-sourcepos="10:1-10:217">Mega IIe Project Breakdown: A detailed look at the project's evolution, including initial concepts, technical challenges like integrating modern microcontrollers (RP2040), and solutions for component shortages.</li><li data-sourcepos="11:1-11:264">Debugging and Design Decisions: The discussion covers debugging challenges encountered during integration and the rationale behind the project's shift from a simple breakout board to a modular backplane system and eventually a single-board computer format.</li><li data-sourcepos="12:1-12:145">Video Signal Processing: Lewis dives into the complexities of converting the Mega II chip's RGB output for modern digital video displays.</li><li data-sourcepos="13:1-14:0">Future Directions: The episode concludes with Lewis reflecting on the learnings from the project's extended development and potential future endeavors.</li></ul>This episode offers valuable insights for engineers interested in vintage computing, hardware design, and the unique challenges of integrating legacy components with modern technologies.Parker and Stephen also announce <a href="https://www.macrofab.com/events/macrofab-food-device-design-derby-challenge/" target="_blank" rel="noopener noreferrer">an exciting new contest</a> with over $5,000 in cash prizes, themed trophies, and free prototyping from MacroFab, but the deadline to submit is coming up fast! Thanks to Mouser Electronics for sponsoring the contest prizes.&nbsp;<hr><h3>About the Hosts</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwNDIwNjE5NzgzLTE3MTA0MjA2MTk3ODMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Parker dillmann" class="fr-fic fr-dii">Parker Dillman from MacroFab's CircuitBreak&nbsp;<h5>&nbsp; Parker Dillmann</h5>Parker is an Electrical Engineer with backgrounds in Embedded System Design and Digital Signal Processing. He got his start in 2005 by hacking Nintendo consoles into portable gaming units. The following year he designed and produced an Atari 2600 video mod to allow the Atari to display a crisp, RF fuzz free picture on newer TVs. Over a thousand Atari video mods where produced by Parker from 2006 to 2011 and the mod is still made by other enthusiasts in the Atari community.In 2006, Parker enrolled at The University of Texas at Austin as a Petroleum Engineer. After realizing electronics was his passion he switched majors in 2007 to Electrical and Computer Engineering. Following his previous background in making the Atari 2600 video mod, Parker decided to take more board layout classes and circuit design classes. Other areas of study include robotics, microcontroller theory and design, FPGA development with VHDL and Verilog, and image and signal processing with DSPs. In 2010, Parker won a Ti sponsored Launchpad programming and design contest that was held by the IEEE CS chapter at the University. Parker graduated with a BS in Electrical and Computer Engineering in the Spring of 2012.In the Summer of 2012, Parker was hired on as an Electrical Engineer at Dynamic Perception to design and prototype new electronic products. Here, Parker learned about full product development cycles and honed his board layout skills. Seeing the difficulties in managing operations and FCC/CE compliance testing, Parker thought there had to be a better way for small electronic companies to get their product out in customer's hands.Parker also runs the blog, longhornengineer.com, where he posts his personal projects, technical guides, and appnotes about board layout design and components.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1710945957606-stephen-kraig.jpg" alt="Stephen Kraig" class="fr-fic fr-dii" style="width: 758px;">Stephen Kraig from MacroFab's CircuitBreak&nbsp;<h5>&nbsp; Stephen Kraig</h5>Stephen Kraig is a component engineer working in the aerospace industry. He has applied his electrical engineering knowledge in a variety of contexts previously, including oil and gas, contract manufacturing, audio electronic repair, and synthesizer design. A graduate of Texas A&amp;M, Stephen has lived his adult life in the Houston, TX, and Denver, CO, areas.Stephen has never said no to a project. From building guitar amps (starting when he was 17) to designing and building his own CNC table to fine-tuning the mineral composition of the water he uses to brew beer, he thrives on testing, experimentation, and problem-solving. Tune into the podcast to learn more about the wacky stuff Stephen gets up to.

Parker and Stephen chat with James Lewis (aka the Bald Engineer) about constructing a functional computer based on the Apple II GS's Mega II chip, and also announce a contest sponsored by Mouser! 

Circuit Break Podcast 420: The Mega IIe: A Vintage Computing Adventure with James Lewis

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