SendCutSend x HardwareFYI Design Competition🥇
We’re teaming up with SendCutSend to find the best organization tool designed from sheet metal, and we're offering $1,500 worth of prizes! 🏆
To enter, design something cool in CAD that meets our DFM requirements and submit your files (DXF or STEP). If you win, we'll also bring your design to life and make it for you!
- Applications are open now through August 16th. Check out the application page for more information and examples.
Interesting Links 🏭
- This thread highlights the remarkable progress in aviation fuel efficiency, with modern aircraft surpassing the efficiency of cars and reaching up to 100 mpg per passenger! The significant improvement is attributed to increased bypass ratios in engines, improved aerodynamics, digital flight control systems, and use of lightweight materials like titanium and composites (thus decreasing the use of aluminum alloys illustrated above). These all enable modern aircraft like the Boeing 787 to carry 50% more weight, fly 50% further, and accommodate 100 more passengers while consuming 50% less fuel per hour compared to the 1960s-era Boeing 707.
- A study from the University of Oxford found that SpaceX’s platform strategy (developing standardized, reusable components and processes that can be adapted for multiple projects) was 10X cheaper and 2X faster than NASA’s bespoke strategy when compared over 200+ missions. Interesting to note: NASA's projects have historically experienced cost overruns averaging 45%, whereas SpaceX's platform strategy has minimized these overruns to just 1.1%
- Disney Imagineering recently published a research paper on the design of bipedal robot capable of expressive, artist-directed movements. They demonstrated that it is possible to build dynamic legged robots where the kinematics and the mechanical design are driven by a creative target rather than by functional requirements. The robot uses quasi-direct drive actuators with peak torques of 34 N-m and maximum velocities of 20 rad/s for the hip and knee joint, an impressive torque-to-speed ratio (the MIT Cheetah 1 actuator had 58 N-m peak torque but only 6.9 rad/s max speed, while being heavier). This combination allows for both high force output and relatively fast movement, which is crucial for dynamic robotic applications like legged locomotion.
- Looking for the best tips on designing printed circuit board (PCB) test fixtures? FixturFab recently released an extremely comprehensive overview on how to conduct mass production testing of PCBs. The video covers types of test fixtures engineers should implement during product development phases (prototyping, EVT, DVT, PVT, and mass production), common instrumentation & software options, firmware upload methods, and much more.
- High-volume low-speed (HVLS) fans are a type of mechanical fan greater than 7 feet in diameter, often found in industrial settings. This article discusses the physics of fans using basic principles like forced convective cooling, and more interesting the phenomenon of perceived cooling we experience as air passes through! Fans operate through forced convective heat transfer which carries heat away from the body’s surface, but also accelerates evaporative cooling at the skin and creates the wind chill effect. The wind chill effect makes us feel colder due to the moving air, even when the air temperature remains unchanged, by increasing the rate of heat loss from exposed skin.
- A how-to guide on ultrasonic bonding, which is a key nanofabrication technique that combines heat, ultrasonic energy, and pressure to create robust electrical connections for semiconductor devices. The most common method, wedge bonding, relies on applying the correct amount of ultrasonic power for the appropriate duration to form a proper connection.
Electrical overstress (EOS) and electrostatic discharge (ESD) is the top cause of semiconductor failure. Daniel Beeker, Principal Engineer at NXP, put together an incredibly thorough presentation on PCB Design Techniques to Improve ESD Robustness. Some tips include flooding unused space with ground, stitching ground islands and planes together, and avoid splitting ground planes.
Startup News 🚀
- Roboze announced a collaboration with Hitachi Rail, where production of spare train parts will be manufactured using advanced materials like ULTEM™ 9085 and Carbon PEEK on Roboze’s ARGO 500 solution. Hitachi Rail can now replace traditionally machined metal parts with their industrial 3D printing technology, significantly reducing costs and delivery times. Read the full press release here.
- For more details on super polymers and composite materials, Roboze's whitepaper discusses the strength of Carbon PEEK—a super-polymer that is 30% carbon fiber by weight and has greater tensile strength than certain aluminum alloys.
- SoundHealth has raised a $7M seed round to develop a medical wearable device aimed at alleviating nasal congestion through targeted acoustic vibration. This device employs acoustic resonance therapy instead of traditional, drug-based treatments. The seed round was led by Moai Capital and J4 Ventures.
- Nearfield Instruments has raised a $146M Series C round to scale its 3D nanometrology technology. The Netherlands-based startup designs semiconductor metrology equipment and has already deployed its technology in advanced high-volume semiconductor fabs. The funding round was led by Walden Catalyst and Temasek.
- Max Space has announced that their inflatable space technology will debut on a SpaceX test flight in 2026. Max Space habitats are made from mylar isotensoids, an array of tubular tendons that are inflated and held in tension. The structure (each cord is rated to 17,000 pounds!) allows the habitat to be ‘skinned’ with various materials needed for radiation shielding, micrometeor protection, and more. While details on their fundraising are sparse, both founders have notable previous successes in the space industry.
- Mytra has raised $78M in funding during a stealth incubation phase phase to develop a robotic platform that automates the movement and storage of materials in warehouses. Launching from stealth last week, Mytra announced a $50M Series B led by Greenoaks, with participation from Eclipse and 515 Ventures.
- SirenOpt has raised a $6.6M Seed round to develop their novel manufacturing inspection process cold atmospheric plasma (CAP), a non-destructive inspection method capable of determining multiple material properties like thickness, density, conductivity, chemical composition, and more. SirenOpt was originally founded in 2022 as a spin-out from UC Berkeley’s Chemical Engineering Department. The seed round was led by Voyager Ventures and Tomorrow VC.
