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Article
A precision shaft can be machined perfectly, inspected within tolerance, sent for heat treatment, and come back unusable. The shaft may bow, or a bearing journal may lose roundness or move outside tolerance. Reverse the order and a different problem appears. Machining after hardening can increase cycle time, cost, and tool wear or breakage. In […]
Article
Here’s a common mistake: an engineer designs a structural bracket using FDM 3D printing, runs FEA with the tensile strength from the material datasheet, and predicts a comfortable factor of safety. The printed part fails at a fraction of the predicted load. The material and analysis were correct, but the FEA assumed isotropic material properties […]
Article
Flame-retardant requirements show up in power supply housings, electrical connectors, and industrial control panels. They also turn up in products like a battery pack on a mobile robot, a diagnostic device housing, or a solar inverter enclosure. Any product with a battery, power electronics, or components near line voltage is a candidate for a flammability […]
Article
Choosing sheet metal for manufacture in aerospace isn’t just a matter of selecting the strongest or lightest alloy. For instance, a stronger material that suits machined components may crack during bending, while one that forms easily may lack the fatigue strength for vibration-loaded structures. An apparently suitable alloy may fail in salt spray, elevated temperatures, […]
Article
When a manufacturing customer requests a material certificate, they’re really asking multiple questions at once: was this material tested, did it meet the standard, and is this the actual material used to make my part? These questions need a clear, documented answer. In practice, the gap between them is where things go wrong. Material traceability—the […]
Article
Engineering for Vacuum, Thermal Extremes, and Reliability Aerospace materials and finishes for spacecraft must be selected to withstand vacuum, radiation, thermal cycling, and outgassing. These conditions introduce failure modes such as cold welding, material degradation, and contamination of sensitive components, requiring material and surface finish selection to be evaluated together to ensure reliable performance in […]
Article
Material strength is a primary design factor directly linked to product performance. High-strength materials allow for smaller parts, thinner walls, higher load-bearing capacity, and greater resistance to deformation. More strongly bonded materials also withstand extreme operating conditions better without deformation or failure. Material selection for CNC machining, though, is rarely as simple as selecting the […]
Article
Overmolding is widely used to combine materials with different properties—such as rigid substrates and soft-touch elastomers—into a single component. Common examples include tool grips, seals, and consumer products like toothbrushes. However, successful overmolding depends heavily on material compatibility. Poor adhesion between materials can lead to delamination and part failure, making proper material selection and interface […]
Article
Medical device materials must meet strict requirements for biocompatibility, sterilization compatibility, traceability, and regulatory documentation. Engineers selecting materials for medical device development must balance mechanical performance, manufacturability, cost, and regulatory compliance across the entire development lifecycle—from early prototypes to full-scale production. Medical devices range from simple disposables to complex multi-material systems. This guide explains common […]
Article
Environmental resistance describes a material’s ability to withstand chemical exposure, corrosion, UV radiation, moisture, and elevated temperatures without degrading. When selecting plastics or metals for CNC machining, injection molding, or sheet metal fabrication, engineers must evaluate long-term durability under real-world operating conditions. This guide ranks common engineering materials by overall environmental durability, corrosion resistance, and […]
