ENGINEERING

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Battery Pack

OEMs are changing the way they make batteries. Improvements to energy density are one key consideration but also the sustainability of the materials used. Many materials involved have questionable mining practices or volatile supply chains. One such material is Cobalt, which in addition to being very expensive, has its supply and mining confined mostly to China and the Democratic Republic of Congo. As a result, OEMs are trending towards higher nickel cathode chemistries like NMC 622 or NMC 811 in some new models.   

Up until 2018, the Chinese electric automotive market was predominately using LFP cathodes. This has now transitioned such that as of 2019 only 3 % of cars utilised LFP batteries. However, Tesla has now introduced the LFP Model 3 made in China which could upset this trend. Additionally, LFP is used extensively for markets like Chinese electric buses. Despite the reduction in market share of materials like cobalt, the rapidly increasing market for electric vehicles will drive demand for cobalt and many other materials drastically higher over the next 10 years.   Materials forecast for battery cells include aluminium, carbon black, casings, cobalt, copper, graphite, iron, lithium, manganese, nickel, silicon and polyvinylidene fluoride (PVDF).   

Battery Pack Materials  

Whilst the energy density improvements of Li-ion cells might be the most prominent battery improvements in the public eye, we are also seeing an increase in pack-level energy density at a greater rate than just cell-level improvements. Manufacturers are improving their battery designs, the mass of materials being used around the cells is steadily being reduced, allowing for a lighter battery pack or more cells to be used for the same mass. The choice of materials for several pack components also affects these improvements. More interest is being paid to composite enclosures for light-weighting, fire-retardant materials, thermal interface materials and much more. The thermal management strategy also impacts these choices, with increased energy density and consumer demand for fast charging, the thermal management must be more effective, but also present a smaller and lighter package. Several materials see a decrease in utilisation per vehicle, but this is often overshadowed by the rapidly growing market for EVs.   Battery pack materials forecasted include aluminium, copper, thermal management materials, thermal interface materials, steel, glass fibre reinforced polymers, carbon fibre reinforced polymers, inter-cell insulation, compression foams and housings and pack fire-retardant materials. 

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The Aerospace Industry and Additive Manufacturing: Maximizing the Benefits of 3D Printing

The aerospace industry is known for its embrace of new technologies, and 3D printing, also known as additive manufacturing, is no exception. In recent years, the aerospace industry has applied this advanced technology to a variety of uses, resulting in many benefits including faster production, lower costs, and increased design flexibility.

One of the most significant applications of 3D printing in the aerospace industry is in the production of components. By 3D printing complex geometries and intricate designs that would be challenging to produce using traditional methods, the aerospace industry has reduced the time required for many parts. The use of 3D printing also enables more efficient use of materials, lowering costs and increasing the competitiveness of aerospace companies.

Prototyping is another area where 3D printing has made a big impact in the aerospace industry. The ability to quickly produce prototypes of new designs and components allows companies to test and refine their products faster than with traditional methods. This has resulted in a significant acceleration of product development and enables aerospace companies to bring new and innovative products to market faster.

The aerospace industry is also using 3D printing to produce custom tooling and jigs. Quick production of these tools and jigs has reduced the time and costs associated with traditional manufacturing methods, helping aerospace companies remain competitive and efficient.

3D printing is also used in the aerospace industry to create custom parts and components for aircraft. On-demand production of these parts eliminates the need for large stocks of inventory and improves the efficiency of maintenance and repair operations.

The aerospace industry is utilizing 3D printing in a variety of ways, capitalizing on its benefits such as faster production, lower costs, and increased design flexibility. The industry continues to push the limits of what is possible and remains a leader in technological and engineering advancements.

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 Medical Industry Embraces CAD and Advanced Manufacturing for Implants

The integration of computer-aided design (CAD) and advanced manufacturing has revolutionized the medical industry. The use of CAD and 3D printing has led to the production of custom-made implants, prosthetics, and orthopedic devices with increased precision, accuracy, and speed, resulting in better patient outcomes.

One application of CAD in the medical field is in the design of custom implants. With CAD software, a digital model of a patient's anatomy can be created and used to design a custom implant that fits perfectly and minimizes complications. Advanced manufacturing techniques, such as 3D printing and rapid prototyping, also allow for the creation of complex implants in a shorter amount of time.

The medical industry is also utilizing new materials for implants, including biodegradable and bioactive materials. Biodegradable materials dissolve after serving their purpose, reducing the risks of long-term implant use. Bioactive materials, such as hydroxyapatite, can interact with tissues and bones, promoting healing and integration.

The use of CAD and advanced manufacturing techniques in the medical industry continues to drive innovation and improve patient care. The development of custom-made implants, biodegradable materials, and bioactive materials are just a few examples of the ways in which these technologies are changing the field of medicine.

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 The consumer market is tackling challenges of risk management and product development, as well as challenges in regulatory affairs, through a combination of approaches. Some of these include:

1. Due diligence: Consumer product companies are conducting thorough due diligence on the products and suppliers to ensure that the products are safe and meet regulatory standards.
2. Collaboration with regulators: Companies are working  closely with regulatory agencies to understand and comply with current regulations, and to stay informed about changes in regulations.
3. Investment in R&D: Companies are investing in research and development to improve their products and processes, and to reduce the risk of product defects or safety issues.
4. Risk management strategies: Companies are implementing comprehensive risk management strategies, such as product testing and evaluation, to minimize the risk of product recalls and safety issues.
5. Compliance and quality assurance programs: Companies are developing and implementing compliance and quality assurance programs to ensure that products meet regulatory requirements and standards.
6. Product liability insurance: Companies are purchasing product liability insurance to provide financial protection in the event of a product recall or safety issue.

Overall, the consumer market is taking a proactive approach to risk management and product development, and is working closely with regulatory agencies and engineering consulting firms to ensure that products are safe and compliant with regulations.

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