PD_1501 by Design2Pro

Stratasys has launched six PolyJet 3D printers expanding the accessibility to triple-jetting technology.

The Tolomatic RSA-HT high force rod-style actuator is designed for high duty-cycle performance in demanding applications.

See page > 7

See page > 24

PRODUCT DESIGN & DEVELOPMENT

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Designing a Personal Robot

JANUARY/FEBRUARY 2015 70 TH YEAR, ISSUE 1

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TableofContents

Engineering Answers

Designing a Personal Robot Jibo was designed on the premise of creating an affordable, adaptable, and aesthetically pleasing robot.

Brainstorm

Rapid Prototyping Materials What are the newest advancements in rapid prototyping materials? What are your expectations for future materials?

Engineering Answers

Smart Fabric Makes Wearables Look Good The BeBop Wearable Smart Fabric Sensor is the first and only ultra-thin wearable smart fabric sensor that measures all aspects of physicality.

Medical

6 Things to Consider as the Internet of Things Intersects Medical Devices We’re on the verge of a fascinating intersection as Internet of Things technology begins to encroach into the world of medical device development.

Departments 6

First Look

At Issue

New Products

Marketplace

FFi Final ina nal TTh Thought hoouugh ugghht

ViV iV Va piezo iez iez e o act ctu tuato atto tor can caan n be be en eng eng ngin ine ine neer eeri rriin ngg to to ffit fiit it n neearl arl ar rly any ny app aap pp p pllic liic icaati atttiion on ttha th h haat a soolle len en o en oid oi id id wou wou wo uld ld d. PRODUCT DESIGN & DEVELOPMENT® (ISSN #1084-7278, USPS #445-920), (GST Reg. #844559765) is a registered trademark of and published 9 times a year (monthly, except bi-monthly in January/February, July/August and November/December) by Advantage Business Media, 100 Enterprise Drive, Suite 600, Box 912, Rockaway, NJ 07866-0912. All rights reserved under the U.S.A., International, and Pan-American Copyright Conventions. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, photocopying, electronic recording or otherwise, without the prior written permission of the publisher. Opinions expressed in articles are those of the authors and do not necessarily reflect those of Advantage Business Media or the Editorial Board. Periodicals Mail postage paid at Rockaway, NJ 07866 and at additional mailing offices. POSTMASTER: Send return address changes to PRODUCT DESIGN & DEVELOPMENT, P.O. Box 3574, Northbrook, IL 60065. Publication Mail Agreement No. 41336030. Return undeliverable Canadian addresses to: Imex/Pitney Bowes, P.O. Box 1632, Windsor Ontario N9A 7C9. Subscription Inquiries/Change of Address: contact: Omeda Customer Service, P.O. Box 3574, Northbrook, IL 60065-3574, 847-559-7560, fax: 847-291-4816, email: abpdd@omeda.com. Change of address notices should include old as well as new address. If possible, attach address label from recent issue. Allow 8 to 10 weeks for address change to become effective. Subscriptions are free to qualified individuals. Subscription rates per year are $72 for U.S.A., $81 for Canada, $108 for Mexico & foreign air delivery, single copy $9 for U.S.A., $13 for other locations, prepaid in U.S.A. funds drawn on a U.S.A. branch bank. Notice to Subscribers: We permit reputable companies to send announcements of their products or services to our subscribers. Requests for this privilege are examined with great care to be sure they will be of interest to our readers. If you prefer not to receive such mailings, and want your name in our files only for receiving the magazine, please write us, enclosing your current address mailing label. Please address your request to Customer Service, P.O. Box 3574, Northbrook, IL 60065-3574. Printed in U.S.A.: Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever. The editors make every reasonable effort to verify the information published, but Advantage Business Media assumes no responsibility for the validity of any manufacturers' claims or statements in items reported. Copyright ©2014 Advantage Business Media. All rights reserved.

January/February 2015

(Image Credit : JIBO, INC.)

Some say they’re FAST...

But do they have the SCALE to deliver? At Proto Labs, we’re optimized to deliver quick-turn additive, machined and molded parts in as fast as one business day. Our three distinct services allow us to manufacture prototype and production parts for thousands of customers each day, many with dozens of designs that need to be simultaneously tested. Since 1999, we’ve shipped millions of parts to product designers and engineers around the world. Our proprietary software and automated technology let us make parts for you faster than anyone else, but we back it up with large-scale manufacturing facilities on three continents that house hundreds of 3D printers, CNC machines and injection-molding presses. Whether your project requires a single prototype or thousands of parts from 50 different designs, we have the capacity to meet your manufacturing needs every time.

2015 Cool Parts Calendar Request your free calendar at

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FirstLook First Look Color Detection & Inspection Baumer (Southington, CT) has expanded its VeriSens XC series vision sensor portfolio to include models capable of color identification and inspection. The new VGA and 1.2 megapixel models are suited for automation tasks in packaging, pick-and-pack, assembly monitoring, product encoding, and quality assurance applications. Features include: • An integrated flash controller with either 48 V or 4 A pulse-topower. • Actuate external illumination. • A configurable web interface.

Why Would I Specify? • Object colors and their shades are automatically identified and visualized in 3D as color spheres. The resulting absence of sphere collisions ensures reliable color inspection. • Parameter setting of the VeriSens XC series is simple using the VeriSens Application Suite software. • A patented FEX image processor provides stable image evaluation at varying light conditions or object colors. www.baumer.com

Voice Coil Actuator BEI Kimco Magnetics (Vista, CA) has added the model LAH0410-000A Linear Voice Coil Actuator (VCA) to its line of housed moving magnet actuators. Features include: • A peak force of nearly 0.5 lbs. • An outside diameter of 0.375”. • A total weight of 0.37 oz. • An operating stroke of 4 mm (0.157").

Why Would I Specify? • The moving magnet design offers heat dissipation. Any heat generated by the coil assembly can be readily conducted away. • No moving wires and a high heat dissipation makes the VCA well-suited for high duty cycle applications, such as pick-andplace machines, remotely controlled switching, medical and laboratory equipment, and military and aerospace applications. www.beikimco.com

January/February 2015

Servo Motor Controller maxon motor (Fall River, MA) has expanded its offering of miniaturized controllers with its latest OEM plug-in module. The 4-quadrant PWM servo motor controller is designed to command permanent-magnet-activated brushed and brushless DC motors with Hall sensors up to 48 W continuous output and 144 W peak output. Features include: • An operating temperature range up to +60°C (140°F). • An efficiency of 92%. • Speeds of up to 150,000 rpm. • Protective circuitry.

Why Would I Specify? • The entire maxon ESCON servo controller line now offers an RC servo signal evaluation for speed or current set values, current limiter and offset, or the option to predefine analog speed ramps. • The controller provides various functionalities with free configurable digital and analog inputs/outputs and can be operated in various modes. • A variety of functions and wizards, as well as an automated fine-tuning controller procedure, assist during commissioning, for configuration of inputs and outputs, and diagnostics. www.maxonmotor.com

Environmentally Sealed Connectors Anderson Power Products (APP) (Sterling, MA) has announced the Mini PL SPEC Pak series of compact, environmentally sealed connectors. The connectors are touch safe on both sides and feature a latching shell. Features include: • Power handling capabilities up to 23 A and 600 V AC/DC per pole. • A waterproof (IP68) shell. • Availability in 3- and 5-pole configurations.

Why Would I Specify? • The Mini PL SPEC Pak can be used in wire-to-wire and wire-to-panel applications and accommodates up to 12 awg (2.5 mm²) wires while maintaining a compact size. • Gold plated contacts are available down to 24 awg (0.25 mm²), and optional sequencing capabilities provide design flexibility. www.andersonpower.com

Digital POL Module GE Critical Power (Dallas, TX) has announced its new GDT080 GigaDLynx digital point-of-load (POL) module. Features include: • A deliverable 80 A current at a low controlled voltage. • A power density of 10.6 A/cm². • 20% more density.

Why Would I Specify? • The modules are capable of facilitating a higher current in a smaller space and over a wide input voltage range. • With the GDT080 modules, designers can quickly test and measure different configurations and software to determine the optimum combination of hardware and software. • The digital capabilities enable board designers to adjust the operating configuration on the fly to maximize performance under varying operating conditions. www.gecriticalpower.com

From the Cover Triple-Jetting 3D Printing Tech Stratasys (Minneapolis, MN) has launched six PolyJet 3D printers with compact and mid-size build envelopes, expanding the accessibility to triple-jetting technology. Features include: • Compact and mid-size build envelopes. • Fewer material changeovers and hot swapping for continuous part production. • Support for files exported from CAD as VRMLs, as well as STLs.

Why Would I Specify? • Stratasys’ triple-jetting technology is unique, allowing users to build products with up to three base materials in a single run, forming new digital materials, such as digital ABS or producing parts in vibrant colors. • Parts are printed in a single, automated build with up to 80 material properties per part, ranging from rigid to rubber-like in a range of vibrant colors and a range of Shore A values producing final-product realism. www.stratasys.com

Drop-In Replacement Sensor Bearing with EMC Filter The newly introduced SKF (Lansdale, PA) sensor bearing equipped with an electromagnetic compatibility (EMC) filter offers protection against potential damage to the bearing’s electronics from power surges or electric discharges. Features include: • A variety of monitoring capabilities for applications across industries. • Plug-and-play capabilities. • A shielded sensor and deep groove ball bearing.

Why Would I Specify? • The EMC filter is integrated in-line with the sensor bearing’s cable to protect the Hall sensor and other electronics used in the bearing. • Improved bearing reliability and service life. • The integrated design reduces development time associated with manufacturing and assembly. www.skfusa.com

PHD (Fort Wayne, IN) has released a drop-in replacement cylinder and linear slide targeted to the OEM market. The Optimax Series OCG Round Body Pneumatic Cylinders and Series OSX Light Duty Pneumatic Thruster Slides are designed to be versatile for use in the machine builders’ market. The OCG Cylinders feature: • 6 bore sizes with 10 stroke lengths. • Standard cushions to reduce end of travel impact. The OSX Slides feature: • 5 bore sizes with up to 7 travel lengths. • Standard shock pads that reduce end of travel impact. • Travel adjustment on retract.

Why Would I Specify? • Both the OCG Cylinders and OSX Sliders meet the global standard for drop-in imperial mounting and drop-in metric mounting, respectively. • Magnets come standard for switch sensing capabilities. www.phdinc.com

www.pddnet.com

AtIssue M e l i s s a

F a s s b e n d e r ,

he crowdfunding site Indiegogo was founded in 2008, and Kickstarter began a year later. Since then, millions of contributors have brought products just like Jibo, ‘The World’s First Family Robot,’ (page 26) to life. A company representative states that, "The benefits of Indiegogo go far beyond just raising funds. An Indiegogo campaign creates a unique opportunity for market validation, increased awareness, and an opportunity to reach potential customers directly. For product developers,

E d i t o r

The sites aren’t just being used for product development costs, and have increasingly become a source of R&D funds – at least a dozen Kickstarter projects have launched objects into space. These projects find themselves among the 75,798 successfully funded projects on the site, for which more than $1,447,093,105 total dollars have been pledged by more than 7,598,297 total backers. Indiegogo, on the other hand, has seen a 1,000% increase in funds raised. These

Crowdfunding the Future an Indiegogo campaign can provide proof of concept and mitigate risks." While these benefits also apply to Kickstarter, the big difference between both sites is that Kickstarter is “all-or-nothing” funding. The company explains that it’s less risk for everyone involved, which makes sense. If I was asking for $100,000 to complete a product, but only raised $3,000, I would still owe several backers a completed product and would be in a difficult place regarding production costs – a common reason for crowdfunding campaigns. Unfortunately, many projects have found themselves in this position, while others have raised hundreds of thousands, and never planned on delivering (the sites, like any company, are not immune to scams). Yet people continue to back projects, and it’s no longer limited to startups looking for initial funds, as successful company’s now turn to the site’s to help them launch specific products. Kickstarter and Indiegogo may be two of the most well-known crowdfunding platforms, however new sites have been appearing as crowdfunding catches on, including Dragon Innovation, a platform that is hardware specific. One of the most prevalent products looking for funding on the sites are 3D printers, with many of the campaigns raising millions of dollars. And with the 3D printing industry expecting to expand as the machines gain new capabilities (see this month’s Brainstorm, page 14) people will continue to turn to crowdfunding. 8

January/February 2015

numbers all support a shifting paradigm in product development. Working on my (mostly) weekly Kickstarter of the Week articles, gives me the chance to talk to many engineers, and many admit that they wouldn’t be able to have a product if it weren’t for crowdfunding. And while some of their products may be more practical (a redesigned joystick for paraplegic patients), and some more fun (a robotic bartender), the one thing they have in commons is a passion for innovation and new product development. Has crowdfunding become the best way to launch a new product? What industry will it take over next? Email me at Melissa.Fassbender@ advantagemedia.com.

70 th Year, Issue 1 General Manager | NICK PINTO nick.pinto@advantagemedia.com Editorial Director | DAVID MANTEY david.mantey@advantagemedia.com Editor | MELISSA FASSBENDER melissa.fassbender@advantagemedia.com Associate Editor | KAYLIE DUFFY kaylie.duffy@advantagemedia.com

SALES & EDITORIAL OFFICE 199 E. Badger Road, Suite 101, Madison, WI 53713 Phone: 973.920.7784; Fax: 973.607.5605 Regional VP Sales - Midwest MIKE FRANCESCONI Phone: 973-920-7742 mike.francesconi@advantagemedia.com Regional VP Sales -East GLEN SUNDIN Phone: 973-920-7038 glen.sundin@advantagemedia.com

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When we merged the country’s three leading service bureaus into one, we created Stratasys Direct Manufacturing—a powerful resource for designers and engineers to challenge conventional approaches to manufacturing. When Structural Integrity Engineering (SIE) set out to design Orbis International’s new Flying Eye Hospital, we partnered with their engineers to create unique solutions Mark Curran

using our FDM technology. The airplane’s 3D-printed duct system measured up to the design’s complex

Senior Engineer

geometry and met strict FAA regulations. Together, we produced a design that would have been impossible without our advanced manufacturing technologies. With the help of SIE, Orbis’s Flying Eye Hospital will be embarking on its work to transform lives through access to quality eye care. Solutions for a healthier world. The power of additive manufacturing. The power of together.

M E R G I N G T HE B E S T S E R V I C E B U R E A U S T O C R E AT E T HE N E W FA C E O F A D VA N C E D M A N U FA C T U R I N G .

PROJECT CLIENT

Learn how Stratasys is redefining manufacturing, download our recent white paper and explore more stories like SIE and Orbis. S T R ATA S Y S T O G E T HE R .C O M

AIR DUCT FOR FLYING EYE HOSPITAL

STRUCTURAL INTEGRITY ENGINEERING PA R T S

D AY S

ELECTRONIC COMPONENTS

NewProducts Coated Controllers & Modules

Electro-Set Boards

B&R (Roswell, GA) has announced coated variants of its compact controller and I/O modules for protection against condensation and corrosive gases. The special coating on the electronics module of the X20c series makes the modules suitable for use in corrosive environments. Features include: Compatibility with existing models. An operating temperature range from -25° to +60°C. Protection from effects of condensation and corrosive gases checked using the tests specified in BMW GS 95011-4 and EN 60068-2-6, test method 4. www.br-automation.com

Cardinal Components (Wayne, NJ) has introduced a new board-level product line for the Internet of Things called Electro-Set. The boards provide a standard unified 6 pin connector including I2C interconnect, allowing for rapid proof of concept design and prototyping. The boards are platform agnostic and can interface with a range of processor/ development boards on the market. Features include: An Arduino UNO interface board. A MicroChip PIC processor board with USB. USB and Bluetooth wireless connectivity. www.cardinalxtal.com

Multi-Core Embedded PCs Beckhoff Automation's (Savage, MN) new CX5100 series features the latest Intel Atom CPUs. The 22 nm technology found with the Atom processors results in higher performance while maintaining the same thermal balance and operating temperature range. Features include: Availability in 3 different processor and housing sizes. Automatic recognition of K-Bus I/O or EtherCAT Terminals. 2 independent Gigabit-capable Ethernet interfaces. 4 USB 2.0 ports and a DVI-I interface. A multi-option interface that can be equipped to support a variety of fieldbus systems. An operating temperature range from -25° to +60°C. www.beckhoffautomation.com

Industrial Wireless Transceiver

40 W DC/DC Converters

LPRS (UK) now offers the Circuit Design STD-503 2.4 GHZ wireless transceiver for integrating into industrial equipment. Features include: 2 antennas that face different directions. Dimensions of 40 x 29 x 5.5 mm. A maximum of 20 pre-set channels. Operation in the 2.4 GHZ band. www.lprs.co.uk

The new MPV4060S series, now available from MicroPower Direct (Stouchton, MA) is a family of 40 W DC/DC converters designed for applications that require a wide input voltage range. Features include: A 6:1 input range. A ±1% line/load regulation. An input/output isolation of 4,000 VDC. Robust filtering. Overload and over voltage protection. A compact 2.5 x 3.5 x 0.98", encapsulated case. An operating temperature range from -25° to +70°C. www.micropowerdirect.com

January/February 2015

XBee ZigBee Cloud Kit

High Temp Connector Series

Digi International (Minnetonka, MN) has announced the launch of the XBee ZigBee Cloud Kit, a new allin-one kit for the Internet of Things. The kit allows users to build a wireless hardware prototype, connect it to the Internet, and control it from the cloud. Each kit includes: 1 XBee Gateway – ZigBee to Ethernet/Wi-Fi. 1 XBee-PRO ZigBee 2.4 GHz module. 1 development board with breadboard. Basic prototyping components. A sample web application. www.digi.com

Harting's (Elgin, IL) new Han High Temp connectors are designed for hot manufacturing applications up to 200°C, such as mold machines and casting equipment. The connectors can be located right at the machine, saving on cabling. Features include: Aluminum die cast hoods and housings. A compressed surface with non-stick properties. Rugged inserts made of injection-molded, liquid crystal polymer plastic (LCP). Temperature-resistant contacts (crimp or screw termination). www.harting-usa.com

Anti-Vandal Switch

Piezo Switch

E-Switch (Minnispolis, MN) has announced the PV9 series illuminated vandal resistant switch. The switch features a long life expectancy and is water resistant to IP65 ratings. Illumination LED colors include red, yellow, orange, blue, green, and white, as well as bi-color options. It is available with dot or ring illumination and requires a 28 mm panel cutout size. Features include: An electrical rating of 2 A, 48 VDC. A mechanical life of 1,000,000 cycles. An electrical life of 50,000 cycles. A max contact resistance of 50 m. A minimum insulation resistance of 1,000 M at 500 VDC. A dielectric strength of 2,000 VAC. An operating temperature range from -20° to 55°C. www.e-switch.com

Schurter (Santa Rosa, CA) has announced a new, piezo switch family, PSE HI, offering raised symbols, letters and numbers in addition to various colors, or legend inscriptions. The robust switch provides a high impact resistance and long life. Features include: An ingress protection class rating of IP67. A robust metal housing. 0.1 A at 42 VAC/60 VDC. A service life of >20 million switching cycles. www.schurterinc.com

ELECTRONIC COMPONENTS

NewProducts

Ultra-Broadband 4-Way Power Divider Krytar (Sunnyvale, CA) has announced a new 4-way power divider offering high performance over the ultra-broadband frequency range of 3 to 40 GHz in a compact package. The divider can also be manufactured to meet military specifications. Features include: An insertion loss of <3.0 dB from 3 to 32 GHz and <3.6 dB from 32 to 40 GHz. A maximum input VSWR of 1.9 from 3 to 32 GHz and 2.5 from 32 to 40 GHz. A maximum output VSWR of 1.70 from 3 to 32 GHz and 2.0 from 32 to 40 GHz. A phase tracking of ±11° from 3 to 32 GHz and ±15° from 32 to 40 GHz. A compact package measuring 2.64 x 2.30 x 0.40". www.krytar.com www.pddnet.com

THE

BRAINSTORM

In the Product Design & Development Brainstorm we talk with industry leaders to get their perspective on issues critical to the design engineering marketplace. In this issue, we ask:

What are the newest advancements in rapid prototyping materials? What are your expectations for future materials? Gaurang Trivedi Engineering Consultant Hi-Tech Outsourcing Services The 3D printing industry has seen remarkable growth in the last decade, opening opportunities across diverse manufacturing dimensions. The idea of printing a 3D object is no longer a question of interest; the focus today, is on identification of new advanced materials to extend the reach of 3D printing across diverse domains. The immense contribution from researchers studying the feasibility of different materials has made it possible to predict a bright future for additive manufacturing technology. A breakthrough example is the use of human cells as a 3D printing material to develop tissues for testing during drug development. The bioink uses tens of thousands of cells printed over hydrogels, such as collagen or gelatin, which gets dissolved once the tissue is printed. Organova, a bioprinting pioneer, printed the first blood vessels using cells cultured from a single person, and is expecting to leverage the technology further to develop on-demand organs during surgical procedures. Additionally, an entire range of biocompatible materials, such as thermoplastics, photopolymers, and metals, are expected to be increasingly adopted to test 3D printing compatibility. Food ingredients can also be a good material for 3D printing food items. While this may sound a bit impractical on earth, printing food for long duration space missions can provide required food quality and nutrient stability, rather than today’s ready-to-eat pouches that are tasteless and lose nutrient stability over time. As a matter of fact, NASA is already funding a project which is expected to bring a breakthrough in food technology. From the manufacturing perspective, the pursuit to identify advanced materials for 3D printing applications is at its peak. More recent advancements, include the use of composite materials, such as carbon fiber, Kevlar, fiberglass, and nylon to print mechanical parts that require higher strength without adding weight. MARKFORG3D has demonstrated the use of these materials effectively by developing the world’s first carbon fiber 3D printer. The future of 3D printing materials is also greatly dependent on printing technologies. Two matured 3D printing techniques exist 14

January/February 2015

today: one focusing on details and surface finish, and the other focusing on structural strength, each having its own disadvantage. As such, future technologies of 3D printing will be more focused on fulfilling strength and surface finish. HP’s Multi Jet Fusion technology is one initiative that will help fill the gap in present additive manufacturing technology. Additionally, existing printing capabilities are restricted to only printing single materials. In order to develop more useful products, 3D printers will need to process multiple materials in a single build cycle. Although recent advances have made the use of multiple materials from a single family of materials possible, future efforts are still required to combine different families of materials, such as plastics and metals to build more innovative products.

Bill Camuel Project Engineering Manager RedEye Just this year, components made with FST-rated, fused deposition modeling (FDM) ULTEM 9085 were tested and verified for outer space at NASA’s Jet Propulsion Laboratory to function on the exterior of a satellite to be launched in 2016. Engineering-grade thermoplastics traditionally used in injection molding, such as UV-stable ASA for the FDM process, have recently hit the market for extended outdoor use. Moreover, flame retardant PEEK, an SLS material, is also used for enduse aerospace applications. Such advancements are a sign of the rising demand for more rugged, production-grade 3D printed products. The additive manufacturing industry has grown significantly and quickly in the last decade. When I initially started in this field, rapid prototyping with additive manufacturing was a crude process. The materials and technology weren’t as robust, and 3D printed parts were primarily used for visual verification and application uses were limited. Today, machines have become more reliable, repeatable and accurate; combined with evolving materials, we continue to move

Are you a thought leader in your industry?

To participate in the next Brainstorm, email Melisssa.Fassbender@advantagemedia.com This 3D printed rake was printed with ASA, an FDM material similar to ABS that is more UV resistance for use in outdoor applications. Image courtesy of Stratasys Direct Manufacturing.

away from the prototyping stage of product development and into production. 3D printing is claiming its place as a manufacturing tool â&#x20AC;&#x201C; for vacuum forming, paper pulp tooling, jigs and fixtures, and enduse parts â&#x20AC;&#x201C; and that is where the industry will grow. What weâ&#x20AC;&#x2122;re seeing now is a demand for materials to encompass more properties in a single 3D print. We have materials that print in multiple colors, durometers, and with a certain degree of diversity, but the next opportunity for growth lies in furthering the capability for completely consolidated manufacturing. I expect the next material development phase will be in assembled 3D prints, with both metals and plastics printed simultaneously. I see a trend expanding into assembled, functional, and involved units with multiple application uses built into a single print, this will transform production lines. Materials developed in the future will focus more on viable, long-term functions as a final product. New materials will take 3D printing further into true manufacturing.

Buddy Byrum Vice President of Product & Channel Management 3D Systems Advances in rapid prototyping materials include improvements in tear and thermal resistance, shape memory, stiffness, and photorealistic color. In terms of composite printing, 3D Systems has announced a new elastomer material, with up to 700% elongation, low Shore A value of 30, enhanced tear resistance, and excellent shape memory. This material can run in tandem with ABS-like or Polycarbonate-like rigid materials to produce 14 functional material composites with unique and specific physical properties. This material features exceptional toughness in single print jobs or as individual features on a single part. To suit the toughest, most demanding end use and functional prototyping applications, a new selective laser sintering (SLS) composite material uses both glass and aluminum. The glass filled nylon print material offers maximum stiffness and elevated ther-

mal resistance for applications that require the minimum material flexibility and higher temperature environments or exposures. The aluminum nylon print material has a high strength-to-weight ratio and enhanced thermal resistance for demanding applications where rigid articles are required, but weight reduction is desired, such as automotive and aircraft parts. 3D Systems has also developed a wax resin hybrid casting material to be used on the ProJet 1200 micro-SLA printer. This material enables non-technical direct investment casting using the same investment materials as common lost-wax casting, for parts such as jewelry and small medical devices. Also, new materials are printing jewelry mock-ups or counter-top samples without the expense of precious metals and casting, and a new clear material ideal for samples and prototyping. Additionally, new plastic-based powder and color binders for the ProJet 4500 and ColorJet Printers provide vivid, photorealistic color in a light-weight and durable plastic. This allows for the full color printing of parts with delicate features. Expectations for future materials include: faster imaging materials, closing the gap between conventional injection molding processes, improved mechanical properties and surface finishes, and long term stability. Additionally, it would be great to see expanded properties to enable new applications.

SLS chrome plated parts. Image courtesy of Stratasys Direct Manufacturing.

www.pddnet.com

ELECTRONIC COMPONENTS

NewProducts Surface-Mountable LED Osram Opto Semiconductors (Sunnyvale, CA) has launched the first LED with oval light-radiating characteristics for large-screen video walls, gas station price signs, and digital road signs. Features include: A compact housing measuring 2.1 x 2.7 x 1.5 mm (including lens). Low tilt tolerances per diode. A stable and homogenous color appearance. Availability in yellow, red, green, and blue. www.osram-os.com

COM-Based SBCs with Intel Core i7 Diamond Systems Corporation (Mountain View, CA) has announced the Vega COMbased SBC family with configurable CPU COMs and EMX I/O expansion. Features include: 5 PC/104 modules in a single board. CPU performance scalability with choice of COM Express COMs. A 7-36 V wide range highefficiency power supply. Up to 16GB 1.3MHz DDR3 memory via SO-DIMM. EMX (PCIe) stackable I/O expansion and PCIe MiniCard socket. An EmbeddedXpress Basic form factor with wings (4.92 x 3.74") An operating temperature range from -40째 to +85째C (-40째 to +185째F). www.diamondsystems.com

Digitally Programmable Attenuators Pasternack Enterprises (Irvine, CA) has announced new 5, 8, and 10 bit broadband PIN diode digital step attenuators with performance up to 40 GHz, depending on the configuration. The programmable, variable step attenuators are commonly used in electronic warfare, military and space communication systems, radar, and test and measurement applications. Features include: 30 and 60 dB values. An attenuation step resolution of 0.25 to 1 dB, depending on the model. A frequency range from 0.3 to 40 GHz. An insertion loss range from 4 to 8 dB. www.pasternack.com 16

January/February 2015

LED Panel-Mount Indicators VCC (Poway, CA) has expanded its allin-one FlexVolt Technology product offering to include IP67 and NEMA 6P rated panel-mount indicators. The CNX 722FV Series indicator can be used with voltages ranging from 5 to 28 VDC circuits. Designed for harsh environments, the 22 mm CNX 722FV Series is moisture sealed for outdoor applications. Features include: Direct sunlight visibility. A wide viewing angle for maximum light detection. A built-in LED. Resistance to shock and vibration. An optional bezel. RoHS-compliance. www.vcclite.com

Compact EPCOS SAW Duplexer TDK Corporation (Iselin, NJ) has announced the new EPCOS duplexer for LTE Band 1, which at 60 dB features high isolation for both the Tx and Rx paths. Based on SAW technology, the B8651 duplexer is suitable for applications such as smartphones, tablets, and LTE USB sticks for notebooks. Features include: The ability to be combined with envelope tracking power amplifiers without any additional prefiltering. An insertion loss of 1.9 dB in the Tx path. A footprint of 1.8 x 1.4 mm. www.tdk.com

Nothing comes (this) close. Introducing the award-winning VPL-GTZ1, the world’s first ultra-short-throw 4K laser light source projector. Immerse yourself in a gorgeous 4K image, four simultaneous HD images, or edge-blend several projectors* to create a seamless virtual environment. With a throw of just zero to seven inches,** project a 66 to 147 inch diagonal picture using floor, ceiling or rear projection – and get up close without blocking the light cone. You also get three-chip SXRD® performance for ultra-high contrast and the latest laser technology for up to 20,000 hours maintenance-free operation. Now, any other ultra-short-throw is just a throwback. Visit sony.com/4Klaser for more information or to schedule a demo. *Using 3rd party software. **From screen to edge of unit. © 2014 Sony Electronics Inc. All rights reserved. Reproduction in whole or in part without written permission is prohibited. Features and specifications are subject to change without notice. Sony and SXRD are trademarks of Sony.

TEST & MEASUREMENT

NewProducts Back-Side Illuminated CMOS Image Sensor Imec (Belgium) has announced a backside-illuminated (BSI) CMOS image sensor chip. Targeting imaging solutions in new markets such as life sciences, the 200 mm process line enables imec to offer design, prototyping, and low volume manufacturing of custom specialty chip solutions such as specialized CMOS image sensors. Features include: Anti-reflective coatings (ARC) targeting different regions of the light spectrum. Quantum Efficiency (Q.E.) values above 50% over the entire spectral range from 260 to 400 nm wavelength. www2.imec.be

Software-Defined Sensor Melexis (Belgium) has introduced a new, fully programmable, compact sensor IC capable of measuring changes in magnetic flux density along its X, Y, and Z axes. Based on the company's proprietary Triaxis technology, the MLX90393 is suitable for joysticks, slide switches, push/pull switches, levelers, linear swipe switches, rotary knobs, and 3D position sensing systems. Features include: Various operating modes. A linear sensitivity across a selectable 16-bit full-scale range from ±5 to ±50 mT. An operating temperature range from -40° to +85°C. A 3 x 3 mm QFN package. www.melexis.com

Touchless Rotary Sensors Novotechnik (Southborough, MA) has introduced the Vert-X 32E Series of programmable rotary angle sensors. The sensors are touchless magnetic angle sensors with a permanent magnet that can be secured to a rotating shaft, so that there is no direct mechanical linkage between the shaft and the measuring system, and therefore no wear. Features include: An 8 to 35 V supply range. A MTBF of 135 years. An ingress protection rating of IP 68. An operating range from -40° to +85°C. www.novotechnik.com 18

January/February 2015

CCD Image Sensors ON Semiconductor (Phoenix, AZ) has introduced a new class of CCD image sensor technology. Combining ON Semiconductor's Interline Transfer (IT) CCD pixel design with a newly developed electron multiplication (EM) output structure, the new technology enables image sensor solutions that deliver sub-electron noise performance with CCD-class image quality and uniformity for low-light imaging. The KAE-02150 image sensor, the first device available in the new technology, can capture 1080 p (1920 x 1080) video in scenes with varying lighting conditions, from sunlight to starlight and from highlights to shadows. Features include: An output circuit design that allows either conventional CCD or EMCCD outputs to be used on a pixelby-pixel basis within the same image. The TRUESENSE 5.5 µ IT-CCD platform. Global shutter. A high modulation transfer function (MTF). www.onsemi.com

Data Acquisition Modules Omega's (Stamford, CT) new 24-bit multifunction USB data acquisition models for temperature and voltage measurement are suitable for applications in chemical, water, HVAC, and R&D. Features include: Up to 16 single ended (SE)/8 differential (DIFF) analog inputs. 8 digital I/O and 2 counter inputs. A 24-bit resolution. www.omega.com

TEST & MEASUREMENT

NewProducts Submersible Level Transmitters AutomationDirect's (Cumming, GA) ProSense line of level sensors now includes SLT series submersible level transmitters designed for applications such as lift station monitoring, construction by-pass pumping, tank liquid level, wastewater, and slurry tank liquid level control. Available in two styles, the sensors provide liquid level measurement by continually sensing hydrostatic pressure produced by the height of liquid above the sensor and providing a 4-20 mA output signal compatible with PLCs, panel meters, data loggers, and other electronic equipment.

Modular Electronic Loads Intepro Systems (Tustin, CA) has announced its new line of 1800 W modular electronic loads. The ML1800 Series features an 8-inch TFT LCD color display with multiple language selection that is visible across the room. The 6-slot chassis can be specified with up to six 300 W or three 600 W modules. Modules are available with current ratings of 60 A or 120 A with voltages up to 80 V and 10 A or 20 A with voltages up to 500 V. Features include: 20 kHz transient test speeds with programmable rise, dwell, and fall times. 16-bit programming and measurement resolution. 10 user-programmable stored test sequences of up to 10 steps each. www.inteproATE.com

The SLT1 Series features: A 1" diameter housing. A ported bullet nose cap for protection of the sensor diaphragm. Availability in cable lengths ranging from 30 to 140 ft. Sensing ranges from 0-5 to 0-50 psig. The SLT2 Series features: A 2.75" diameter. A PTFE flexible diaphragm, surrounded by a 316 stainless steel non-fouling protective cage. Availability in cable lengths ranging from 30 to 100 ft. Sensing ranges from 0-5 to 0-30 psig. www.automationdirect.com

For Every Application... Ellsworth Adhesives

Multi-Head, High Speed Camera System Photron (San Diego, CA) has announced the FASTCAM Multi, a flexible, multi-head camera system that is tethered to a remote processor. The lens interface is compatible with 1-inch C Mount, Nikon G-type, and Micro Four Thirds (MFT) lenses. Features include: Megapixel resolutions of up to 6,000 fps. A full, high-resolution at 1280 x 1024 at 4,800 fps. 720 HD (1,280 x 720 pixels) to 6,000 fps. 8, 6, and 32 GB memory options. www.photron.com

1.800.888.0698 | ellsworth.com

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SENSORS

EngineeringAnswers

Smart Fabric Sensors Make Wearables Look Good By Kaylie Duffy, Associate Editor

ver the course of the past decade, wearable technology has become increasingly pervasive in the electronics industry. Fitness trackers, smart watches, and action camcorders are among some of the most prevalent wearable technologies on the market today.

According to one innovator, smart fabric is posed to become the future of clothing everywhere. Keith McMillen has been a leader in the music technology industry for almost 30 years; however, his new goal is to integrate smart technology into everyday clothing, active wear, and almost anything else that can be worn. In 2007, while developing a cylindrical sensor that could wrap around a violin bow to sense a player’s grip, McMillen realized that a conductive fabric would be the perfect solution. Since then he has been advancing smart fabrics through his company, Keith McMillen Instruments (KMI) based in Berkeley, California. KMI specializes in MIDI controllers and keyboards, and has more than one million sensors currently in use. About two years ago, a few companies approached McMillen, requesting his smart fabric technology. “They were in robotics and athletic measurements,” explains McMillen. “They just kept coming, so at the beginning of this year, we

decided we should do a spin-off company that does non-music sensors.”

New Beginnings The new company, BeBop Sensors, launched in late October, and according to McMillen, the response has been staggering. “It’s really been satisfying and scary with how many high level companies have approached us,” says McMillen. “It validated the need for such technology.” The young company’s first product, the BeBop Wearable Smart Fabric Sensor, is the first and only ultra-thin wearable smart fabric sensor that measures all aspects of physicality, including bend, location, motion, rotation, angle, and torque. According to McMillen, BeBop’s sensors aim to measure more than just heart rate and breathing. The company’s proprietary and patented monolithic design continuously provides real-time reporting on force, x/y location, bend, twist, size, stretch, and motion, all displayed as data 3D maps. This information is accessed from the fabric via Bluetooth or USB. “We provide a robust software developer’s kit that will help companies get a display that is useful for their customers without doing an enormous amount of research.” BeBop’s technology allows the company to embed their electronics into various fabrics. “We print circuits that are stretchable right onto the fabric,” explains McMillen. “We’ll be selling these sensor systems to companies who will put them into shoes, athletic wear, clothing, medical garments, and a number of other applications.”

Embedding Ink

BeBop’s smart fabric can be integrated into clothing to control smartphones using Bluetooth technology. 20

January/February 2015

At the beginning of 2014, McMillen experimented with printing conductors, resistors, and dielectrics directly onto fabrics. The results not only matched the performance of a normal circuit board, but were significantly better. “We’ve done a lot of work with DuPont Microcircuit Materials in the last year, and they’ve been very supportive,” says McMillen. “We’ve been their favorite guinea pig.”

doctors could evaluate not only how many times the athlete was hit, but also where the impact occurred. Loading BeBop’s pressure bases full of sensors, there would no longer be umpire disputes at baseball games. According to the company, the sensors can provide real-time reporting for markets, including clothing and protective wear, shoes, healthcare devices, athletic equipment, automotive, robotics, aerospace, gaming, biometrics, prosthetics, recycling monitors, and appliance markets.

Smart Fabric Future

BeBop’s sensor skullcaps measure where, how hard, and how many times an athlete's head was impacted. “Our inks act as an interconnect,” explains Steven Willoughby, DuPont Microcircuit Materials marketing manager. “Instead of a wire, you have a printed interconnect, and instead of just a sensor, you have a printed sensor made of a very specially designed conductive ink that offers stretchable, washable types of properties.” According to Willoughby, Dupont’s inks have been tested to withstand up to 100 wash cycles, along with proven stable electrical performance after repeated elongation. The final fabric is sealed in a micro-thin layer of thermoplastic polyurethane, and the printed sensors are hermetically sealed so no changes in moisture or environment will affect them. This special ink allows BeBop to create multi-layer circuit boards. “We can print on a variety of fabrics,” adds McMillen. “We’ve even been able to print circuits onto shoe insoles that are 0.5 mm thick. There are 20 sensors per sole, and they’re remarkably accurate, have dynamic range, and can sense roughly 50 grams to 100 kilograms.”

solve this problem, and protect your phone.” The company has also developed one mm shoe insoles that provide instant data about running style, pronation, gait, contact order, and fit. “We have received a lot of interest from sporting, athletics and metric groups,” explains McMillen. “They want to be able to understand movement, extension, and how the soles of your feet impact the ground.” Cylindrical sensors, skullcaps, and 0.5 mm thick pressure mats are also available for sports or medical applications. Considering the ever-worrisome conversation surrounding athlete concussions, a skullcap wearable could measure and diagnose head trauma. If the skullcaps were integrated into football helmets,

Hundreds of companies have already expressed interest in BeBop’s smart fabric; however, the company is currently looking to partner with companies that have experience with embedded sensors. “We want to have these technologies on the market in the next 12 months – not in five years,” explains McMillen. “So we want to work with companies that have the ability to work quickly and get new products to market in a short time cycle.” McMillen also hopes to work with companies that have a vision as to where wearable technologies can go and have open minds to new approaches. “I’d like to see our sensors in garments that people are buying because of the color or fit,” says McMillen. “I think the technology needs to be so smoothly integrated that it’s almost forgotten. A lot of wearables are bizarre looking things that people hang off their bodies. It really has to be beautiful and ignorable, and I think that’s a threshold we’ve already passed.” PDD

Sensor Solutions BeBop Sensors currently has a variety of solutions available for integration into new wearable products. For example, BeBop makes sensors that can be integrated into garments to control smartphones. “Think about anyone who’s ever gone skiing or snowboarding. Maybe you’re listening to music and you get a call, but by the time you pull your phone out, it’s too late,” says McMillen. “Integrating a small control area onto a garment would

BeBop also developed pressure mats in various resolutions and geometries. All image credit: BeBop. www.pddnet.com

HARDWARE

NewProducts AC/DC Power Supplies MicroPower Direct (Stoughton, MA) has annouced the MPG-120S series of high performance 120 W, open frame AC/ DC power supplies specifically designed to meet energy saving eco-design standards. Features include: A miniature 3 x 5" PC board. Availability in 6 standard models operating from a universal 85 to 264 VAC input. Regulated outputs of 12, 24, or 48 VDC. An 89% efficiency. Filtering to EN 55022 Class B, and PFC to EN 61000-3. Over voltage and short circuit fault protection. An operating temperature range from -20째 to +70째C (ambient). www.micropowerdirect.com

Stand-Alone 3D Printing RepRap (Germany) has announced its 3DPrintBox, allowing every 3D-printer with a USB interface to connect to a network (Ethernet and WLAN) and to be managed via a web browser. The integrated storage device in the 3DPrintBox also allows printing of models without any direct computer connection. Features include: OS-independent access for mobile phone and tablet control. An optional webcam to display real-time print progresses through the browser interface. www.germanreprap.com

Wireless Paperless Recorder Digital Multifunctional Environmental Meters Omega (Stamford, CT) has announced the RH87, a digital multifunctional environmental meter which combines the function of sound level, luminometer, relative humidity meter, and anemometer. Features include: CE compliance. A backlit LCD display. Data hold and auto-ranging. A carrying case and operator's manual. A portable mini-tripod and 9 V battery. www.omega.com

Yokogawa Electric Corporation (Newnan, GA) has announced the SMARTDAC+ GX20W wireless paperless recorder. Features include: An ISA100 wireless gateway function. A maximum of 100 wired inputs. The ability to receive signals from up to 50 field wireless devices. www.yokogawa.com

LCD Display Sharp (Camas, WA) has announced the availability of its new 20.1-inch (diagonal) LCD. The panel, part number LQ201U1LW32, offers images via a 1400:1 contrast ratio (typical), making it suitable for viewing high levels of detail in most ambient lighting situations. It also provides a drop-in replacement option in its size class for customers including manufacturers of medical, marine, and transportation products, among others. Features include: An LVDS interface. A built-in LED backlight driver. A 170째 (H)/170째 (V) viewing angle. www.sharpsma.com 22

January/February 2015

HARDWARE

NewProducts Temperature Scanner Indicator

Arbitrary/Function Waveform Generator Line B&K Precision (Yorba Linda, CA) has announced the rejuvenated 4075B Series of arbitrary/function waveform generators with higher frequency ranges, increased arb memory, and a color LCD. The new series offers 6 new models that directly replace the previous 4075 line with single- and dual-channel 30 MHz (4075B/4078B) and 50 MHz models (4076B/4079B) along with 2 additional single- and dual-channel 80 MHz models (4077B/4080B). Features include: Arbitrary waveforms with 14-bit amplitude resolution. A 200 MSa/s sample rate. Up to 16,000,000 points (depending on model). A menu-driven front panel keypad with rotary encoder knob and range selection buttons. Multi-unit/channel synchronization and external triggering capabilities. 8 full memory banks per channel for user-defined arbitrary waveforms. 49 locations to store/recall instrument settings. AM/FM/FSK modulation schemes. Built-in overvoltage and short circuit protection. www.bkprecision.com

The Sensor Connection (Troy, MI) has expanded its line of measurement and control instrumentation with the addition of the model PMD-MXT series of temperature scanner indicators. The 32 channel microprocessor-based temperature scanner provides continuous monitoring of thermocouple or RTD sensors. Features include: A 14 mm tall digit red LED display. 2 user-selectable HI/LO, HI/HI, or LO/LO alarm set points. Auto or manual scanning. Adjustable auto scan rates. Adjustable limit alarm trip points. Dual 2 A alarm relays. A case size of 6.3 x 3 x 7". www.thesensorconnection.com

DC12

Safe Power For Protection Class II

Enhanced COTS Subsystem Aitech Defense Systems (Chatsworth, CA) has released the enhanced A191, a rugged, compact COTS HPEC (High Performance Embedded Computer). The fully integrated subsystem combines a multi-core CPU to process overhead functions with an advanced GPGPU that focuses on executing heavyduty system requirements. Features include: Pre-installed drivers and operating system. A 4th Generation Intel Core i7 processor. An embedded frame grabber. A NVIDIA GeForce or AMD/ATI Radeon GPU. On-board 1 TB of Flash-based SATA mass storage. www.rugged.com www.pddnet.com

See us in booth #670

Medical devices used at home require an additional measure of safety. SCHURTER's latest DC12 offers a compact power entry solution: - Power input according to IEC 60320-1, Style C18 - 2-Pole switch for high in rush currents up to 100 A - Current ratings 1 A - 10 A @ 250 VAC - White or black, with optional matching V-Lock power cord - Designed for use in double insulated medical applications according to IEC 60601-1 & IEC 60601-1-11

schurter.com/emc_news 23

www.pddnet.com

MOTION CONTROL

NewProducts Watertight Power Converters

Off-the-Shelf Servo Drives

Absopulse Electronics' (Canada) HBC65-D3-IP66/67 Series offers a watertight, power supply solution with input ranges for heavyduty industrial, mining, marine, military, oil and gas, and transportation applications. Features include: 300 W of continuous output power. Typical output voltages of 12, 24, 48, 125 VDC, or custom. No interference with other electronic equipment. 4,300 VDC input-output isolation, inrush current limiting, and reverse polarity protection. A rugged diecast aluminum IP66 enclosure with sealed circular connectors. An operating temperature range from -25° to +55°C. www.absopulse.com

Weighing 8.5 g and capable of outputting 10 A peak and 5 A continuous, µZ's are the smallest off-the-shelf servo drives from Advanced Motion Controls (Camarillo, CA). The plug-in drives are designed for embedded applications in a range of industries. Features include: No need for a heatsink. Protection against over-voltage, under-voltage, over-current, over-heating, and short-circuits. RoHS compliance. www.a-m-c.com

From the Cover Motion Controllers ACS Motion Control (Israel) has developed a new line of motion controllers and EtherCAT masters that are comprised of a more powerful processor and 2 EtherCAT ports supporting ring topology. The SPiiPlusEC expands the capabilities of new and previously installed SPiiPlus controllers and EtherCAT masters. Features include: Control of up to 64 fully synchronized axes. A profile generation and EtherCAT cycle rate of up to 5 KHz. A suite of software tools. www.acsmotioncontrol.com

Heavy Duty Rod-Style Actuator The Tolomatic (Hamel, MN) RSA-HT high force rod-style actuator is designed for high duty-cycle performance in demanding applications while delivering the added control and consistency of an electric drive actuator. Features include: An IP67 option. A standard purge/breather port. A lubrication system. Availability in 3 sizes (32, 50, and 64). Strokes up to 60" (1,524 mm). Up to 12,900 lbf. www.tolomatic.com

Functional Safety Encoders New functional safety incremental encoders from BEI Sensors (Goleta, CA) can be used in industrial safety related applications up to SIL3/PLe Cat. 4, and are mechanically and electrically designed to safety standards EN ISO 13849-1, IEC/EN 61 508, and IEC/EN 62061. Other features include: Aluminum encoder housings for most standard industrial applications. Optional stainless steel housings to withstand harsh environments. An additional bearing in the cover on through shaft models for better overload capability. Positive shaft locks to prevent sliding of the encoder on motor shafts. Insulated secure sleeves to protect against stray currents. Accurate stator couplings and tether arms for safe mounting on the driving motors. www.beisensors.com 24

January/February 2015

Direct Drive Linear Motors

Linear Motion Systems

MotiCont's (Van Nuys, CA) DDLMs (Direct Drive Linear Motors) eliminate backlash and provide a solution for users requiring high acceleration, high speed, and long life. The motors are available in 3 off-the-shelf models. Features include: A compact design using threaded features on the front and rear faces of the motor, as well as each end of the shaft. Zero cogging, and a light mass of the moving part for high acceleration/ deceleration for a higher throughput. Direct coupling to the load for increased accuracy. www.moticont.com

Roll-Slide Mini carriage and rail linear motion systems are now available from LM76 (E. Longmeadow, MA) in lengths from 160 to 1,200 mm. For integration into an application, the systems have evenly spaced mounting holes in the rails, and the carriage has 4 drilled and tapped mounting holes. Features include: Travel from 88 mm (3.46") to 1,128 mm (44.41"). A height of 12 mm (0.47"). 440c stainless steel roller bearings. A low magnetic signature. Corrosion resistant stainless steel rails. Electrodeless nickel plated carriages. A maximum dynamic load of 80 N (45 lbs.) for a single carriage. An operating temperature range from -10째 to 50째C. www.lm76.com

MOTION CONTROL

NewProducts

Brushed DC Motors maxon motors (Fall River, MA) has added 4 more motor sizes to its line of brushed DC motors. The 14, 16, 22, and 26 mm diameter models are now each available in a long version (L), which offers higher continuous torque and higher continuous output power.

QUICK RELEASE

At the same time, maxon motor is introducing 4 new GPX planetary gearheads, in the sizes 14, 19, 26, and 37 mm, compatible to existing products in the program. The gearheads are designed with scaled gear stages. Each of the new 3-stage gearheads can be driven with the next smaller motor. www.maxonmotorusa.com

BALL-LOCK

PINS.

Ultraminature Ball Screws Steinmeyer (Burlington, MA) has unveiled ultraminature ball screws for various applications. The ball screws are equipped with 1 of 4 types of ball nuts, and with or without preload. Custom lengths are available with journals machined to a control drawing. Features include: Standard tool steel (52100). A stainless steel option. Availability in diameters as small as 3 mm with a choice of 2 pitches: 1 or 0.5 mm. www.steinmeyer.com www.pddnet.com

Fairlane Products, Inc. 33792 Doreka Drive Fraser, MI 48026 (586) 294-6100 FAX (586) 294-6822 800-548-2935 fairlaneproducts.com

Fairlane Products quick release fasteners and accessories in inch and metric sizes. The pins have a wide range of uses in fastening, locating and alignment applications and come in a variety of diameters, lengths and materials. Also available are wire rope lanyard assemblies. Call or go online to find a distributor in your area.

www.pddnet.com

CONSUMER ELECTRONICS

EngineeringAnswers

Designing a Personal Robot By Melissa Fassbender, Editor

ibo, “The World’s First Family Robot,” raised more than $2 million on the crowdfunding platform Indiegogo, making it one of the most funded projects in the site’s history.

Turning to crowdfunding with the hope to raise Jibo awareness, as well as the social robotics movement as a whole, Jibo founder and CEO, Dr. Cynthia Breazeal has been overwhelmed by the positive responses. “There is clear desire for a new, more humanized way to interact with intelligent technology in the home, both in the context of enlivening digital content with greater personalization and engagement, as well as a more friendly way to interface with home automation,” says Breazeal. Currently, Jibo can be an assistant, messenger, photographer, avatar, storyteller, and companion. However, Breazeal describes a much greater opportunity. “As the world’s first open social robotics platform, Jibo is uniquely positioned to be that humanized experience with technology in the home that is helpful, highly engaging, and extensible by third party developers,” she adds. Joining Breazeal in the development was a team of business developers, architects, designers, and programmers, combining expertise in social robotics, interactive character design, and animation. Rounding out the team was Huge Design, a San Franciscobased industrial design firm.

The Opportunity Jibo was designed on the premise of creating an affordable, adaptable, and aesthetically pleasing robot. To do this, the design team began with a mix of contrasting qualities, including sophisticated hardware and The best place to set Jibo is high quality interactive animation. where most of the household According to Bill Webb at Huge Design, activities happen, such as in one of the first major design decisions was the kitchen or family room. (All to make the robot stationary, reducing cost images courtesy of Jibo, Inc.) and increasing usability for a wide range of technical abilities. Adding to Jibo’s simplicity, all that is required for operation is power and a Wi-Fi connection. “You then follow the instructions to teach Jibo to recognize your face and voice, learn what he can do, and download the Jibo mobile app to connect it to your mobile devices,” explains Webb. Weighing six pounds, the robot stands 11 inches tall with a six-inch base. The team experimented with a variety of glass, metals, and plastics, to achieve a sturdy and lightweight design. The final iteration uses aluminum, ABS plastic, and glass for the face/screen. Sitting on a charging pad, it can run on battery power for up to 30 minutes. So if the grid goes down, hopefully you’re not too reliant on your personal robot assistant – although increased battery life is already being developed. Additionally, two high-resolution cameras see-and-track for facial recognition, photography, and video calling, and a 360-degree microphone allows for operation from any angle. While these are some of Jibo’s current abilities, the company designed the robot with an imbedded Linux-based software so developers can customize, adding new capabilities in the future. “If you buy a developer kit, your Jibo can be programmed for your exact needs,” says Webb. “We want this to be an open community where programmers can continuously contribute to the design and improvements.” 26

January/February 2015

All of these features combine with artificial intelligence algorithms to learn the user’s specific preferences and habits.

The Choreography “Most people visualize robots as being overly technical, cold machines with joints, motors, and sensors, striving to achieve skills and accomplish tasks that mimic human’s natural abilities,” says Webb. “The absence of unnecessary details on the final Jibo is certainly one of the design characteristics that we are most proud of – a fresh, approachable expression of the future generation of emotionally intelligent devices.” Resisting the temptation to add visual complexity was also one of the biggest design challenges, and the simplicity took the greatest amount of work and restraint to perfect. Webb credits a team with knowledge of the product development process and the ability to work closely with both mechanical and electrical engineers. While the design was kept simple, the most complex piece of engineering was the titled axis mechanism, which breaks Jibo’s body into independently controlled sections that rotate off-axis, relative to one another. “We wanted Jibo to move smoothly and seamlessly, eliminating all disjointed movements associated with most robotics,” says Webb. “We also wanted to eliminate the look of Jibo being overly designed. Creating seamless simplicity was difficult, but the result is a robot that moves and interacts freely and comfortably with families.” Working closely with animator Fardad Faridi, the team refined various concepts and tested several mechanical movements. Ultimately, it was determined that

Jibo went through several iterations before the team settled on a final design. Attaining the robot’s current simplicity was one of the most difficult challenges throughout the product development process.

a tilted axis strategy was the most effective and efficient solution. “The resulting movement has a precision and speed unrivaled by more traditional pivoting arm robotic movements allowing Jibo to quickly snap into position,” says Webb. “Jibo doesn’t just move, it dances.”

The Future

Size:

11” (H), 6” (Base)

Weight:

6 lbs.

Material:

Aluminum, ABS plastic, Glass

Sensors:

• 2 Color Stereo Cameras • 360° Sound Localization • Full-Body Touch Sensors

Movement:

• 3 Full-Revolute Axes • High Resolution Encoder • Feedback Control

Display:

HD LCD Touchscreen

Sound:

2 Premium Speakers

Lighting

Full-Spectrum Ambient LED

Power:

AC Adapter & Battery-Ready

A recent report from Business Insider Intelligence predicted the market growth for consumer and business robots to be $1.5 billion by 2019. This market is expected to grow at a compound annual growth rate of 17% until then, seven times faster than the manufacturing robot market. With these numbers, the future envisioned by Webb, Breazeal, and the rest of the Jibo team – with robots in children’s hospitals reading bed-time stories, and in homes assisting busy families, seems plausible. “We would love to see social robotics go from being a far-fetched and foreign idea, to a welcome addition to hectic 21st-century lives,” says Webb. “We absolutely see robots becoming a more regular part of everyday life. Jibo and other robots are designed to assist, not replace human interaction.” PDD

Connection: WiFi & Bluetooth Platform:

Embedded Linux-Based

Processor:

High-End ARM-Based Mobile

www.pddnet.com

MEDICAL

NewProducts

Things to Consider as the Internet of Things Intersects Medical Devices

By Dave Franchino, President, Design Concepts

e’re on the verge of a fascinating intersection—perhaps collision—as the world of Internet of Things (IoT) technology begins to deeply encroach into the world of medical device development. We’ve all experienced the remarkable impact of mobile apps in our daily lives, but when the consumer-based IoT begins to intersect with medical devices, things are going to get interesting.

Apple’s new iWatch is the latest in a string of sensorbased, connected devices that offer exciting new platforms for medical device development. Developments in higher-performance sensors that are lower in cost and power requirements, combined with mobile platforms, cloud connectivity, and big data can enable the creation of truly novel devices and systems. So what does this mean for the medically-focused design engineer? Big changes and new challenges. Tantalizing new opportunities are available in connecting medical devices more broadly with patients, clinicians, health information, and the healthcare infrastructure. Mobile platforms and accompanying sensor-based connected devices offer the promise of unprecedented levels of information, access, and feedback. When coupled with medical devices, the opportunity to reduce costs, improve patient outcomes, and positively change behaviors is too great to ignore. With this opportunity comes some peril and additional responsibility for the design engineer. What makes this particularly complex is how rapidly the technological, legal, security, privacy, and regulatory landscape is shifting. Here are six things to consider when entering this brave new world: 1. Have a Reason to Connect Your Device Start with deeply understanding the need and make sure you’re delivering a meaningful benefit. Complexity and risk rise dramatically as you integrate your product so the advantages of doing so should increase accordingly. Given the hype surrounding IoT, companies risk rushing to connected products in an attempt to follow trends. The most successful medical device IoT implementations will have compelling benefits including lowered cost of patient care, demonstrably improved patient outcomes, and reduced risk of error, misuse, or missed diagnosis. Implementations based on the subjective promise of improved quality of life or user experiences are plausible, but might face uphill battles in the cost-constrained, tightly regulated medical market.

As medical device developers, we’re entering uncharted territory. We have the potential to transform healthcare, potentially making life-saving services more accessible. That said, prepare for a challenging, bumpy ride. (Illustration courtesy of Design Concepts).

January/February 2015

2. Use a Human Factors-Centered Process Use formally designed and meticulously documented formative human factors studies and human-centered design principles to study users, tasks, tools,

prioritize, and document use and device risks along with their severity and likelihood. Use the hazard analysis as a defining tool to galvanize the development and validation of your strategy.

and environments. IoT medical devices may have completely new workflows, users, and user experiences. Too many firms wait until their design is finalized before studying usability and realizing that unseen risks are looming. For many medical devices, user-related hazards often dwarf device-failure hazards. Putting additional data into the hands of patients and clinicians can be incredibly powerful, but creates new challenges and risks for accurate collection, interpretation, storage, and dissemination that must be clearly understood. A human factors-centered design process including formative studies helps drive lower-risk implementations and establishes a culture and documentation focused on risk mitigation, user benefits, and compelling experiences. 3. Don’t Fake the Risk Analysis A careful hazard analysis should be the center of your development focus. Rigorously use tools, such as failure mode and effects (FMEA) and hazard analysis to provide a mechanism for the entire design team to identify, discuss,

4. Recognize New Risks & Adopt a Clear Strategy While connected med devices can provide benefits, they also pose new and sometimes unexpected risks. Make sure you and your team have carefully thought through the risks associated with: • • • • •

New clinical risks and possibilities for compromised care. Data privacy, management, and integration. Device integration, interoperability, and continuity of service. Technology churn and obsolescence. Hacking and device security.

5. Be Informed & Realistic about New Regulatory Challenges The Food and Drug Administration (FDA) is grappling with balancing the risks and rewards as it works to protect patients. Expect a rapidly shift-

ing regulatory environment and be prepared to build a compelling case for your product’s safety, security, and efficacy. A pre-market human factors review with the FDA can identify approval risks and help determine testing, validation, and submission strategies. 6. Remember, It’s Still a Medical Device The speed, fluidity, and flexibility of consumer product development practices is an alluring benchmark. This will lead to frustration at the perceived slow pace associated with medical device development. “Go fast, fail early” strategies are extremely valuable for need-finding and conceptual design phases but strategies, such as the minimally viable product and ability to refine based on early adopter feedback can be problematic with medical devices. Discipline is required for the validation stages of a project. It’s the responsibility of the design engineer to ensure that development proceeds rapidly, but in a safe, careful and organized fashion. PDD

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FASTENING & ASSEMBLY

NewProducts Combined Plastic/Aluminum Enclosures OKW (Bridgeville, PA) has launched its new SYNERGY electronic enclosures range featuring both plastic and aluminum for added strength and versatility. Typical applications include medical and therapeutic systems, measurement and control technology, home automation, peripherals, and building services electronics. Features include: Availability in a range of 36 individual enclosures. A fast-connect system based around 4 internal assembly pillars which hold each enclosure together. The ability to snap several pillars together to create custom heights in 0.20" increments. Various accessory options including, battery compartments, an extender kit for the PCB pillars, and a wall suspension kit. www.okwenclosures.com

Mini IDC Connector FCI (Singapore) has announced the Griplet miniature IDC connector for wire-toboard terminations. The connector is suitable for harsh and industrial market applications where direct connection between individual wires and PCB are required. Features include: A low profile and compact design. A footprint of 4 x 6.1 mm. A design for a stackable pitch up to 12 positions. www.fci.com

Pin Socket Connector Fischer Connectors (Switzerland) has extended its miniature connector with a pin socket version. With the product range extension, the Fischer MiniMax Series is now available both in 19 and 24 pin configurations. The connector is suitable for handheld or body-worn applications, instrumentation, and test equipment. Features include: Availability as a standalone connector or as a complete pre-cabled solution. Push-pull, screw lock, and quick release latching systems. A profile of <7 mm inside the box. Sealed IP68 (2 m/24 h), both mated and unmated. A keying system that withstands >4 Nm of torque. Over-molded assemblies that are able to withstand 40 kg of pull (break-away) force. www.fischerconnectors.com 30

January/February 2015

Latching Airtight XLR Socket Cliff (Benica, CA) has announced a new latching female XLR socket. The industry standard connector is used for audio inputs and is the latest addition to Cliff's range of professional audio connectors. The connector range is fitted with an integral latch to prevent accidental disconnection by vibration or tension on the cable. Features include: Active loudspeakers fitted with internal amplifiers. A supplied sealing gasket. Completely sealed connection pins. 3 mounting types offering vertical or 90째 PCB mounting or solder bucket for wired connection. Gold plated contacts rated at 5 A nominal, 15 A max up to 250 VAC max. www.cliffinc.com

Stabilized & Non-Stabilized Connectors Noshok (Berea, OH) has announced new SZ Series Stabilized and Non-Stabilized Connectors. The connectors are designed to reinforce the entire installation by shifting radial-stress load away from the NPT connections, and are available in 3-3/8" and 5" lengths. Features include: Availability in zinc-nickel plated carbon steel and 316 stain-less steel. Slotted bolt holes that allow for 2-1/8" and 2-1/4" bolt spacings. www.noshok.com

FASTENING & ASSEMBLY

NewProducts Ready to Ship Circuit Board Shields Leader Tech (Tampa, FL) has introduced a selection of Quick Ship board level shields. Depending on the specific shielding requirements and delivery deadlines, customers can choose from a selection of off-the-shelf surface mount shields (SMS) or a selection of shapes and sizes from the company's standard circuit board shield (CBS) line. Features include:

Weather Resistant Circular Power Connectors Hirose (Simi Valley, CA) has released a new series of small, light-weight plastic power connectors. The HR41A Series is IP68 rated with advanced lightning surge protection (15 kV), and is suited to power applications in outdoor and other harsh environments. Features include: A waterproof gasket design. A cable and housing assembly. A crimp termination method. A 3-step sequential mating structure. An operating temperature range from -40° to + 105°C. A contact resistance of 5 m max at 1 A. An insulation resistance of 5,000 M max at 500 VDC. A rated voltage of 250 VAC and 350 VDC, with a rated current of 10 A. A withstanding voltage rating of 2,200 VAC. www.hirose.com/us

Ball Shaped Door Catches J.W. Winco (New Berlin, WI) now offers EN 450 Ball Shaped Door Catches, in metric sizes. The RoHS-compliant door catches were designed for use with both shutter doors and sliding doors. The ball-shaped door catch consists of a catch body to be fixed to a frame and a ball to be fixed to a door. Features include: Constant performance for >20,000 cycles. Availability in basic spacing distances of 5, 10, and 15 mm. Combinations of spacers to provide distances of 20, 25, and 30 mm. www.jwwinco.com

1- and 2-piece design styles. A shielding effectiveness up to 60 dB. Cover retention of 1.5-2.5 lb./linear inch in the 2-piece configuration. Standard as well as tape & reel packaging options. www.leadertechinc.com

XYθ Alignment Stages Optimal Engineering Systems' (OES) (Van Nuys, CA) low profile, XYθ (theta) stages are designed for high precision alignment applications. The stages move in an XY-plane and rotate around the center of the XY-plane. Features include: Availability in 12 models and in 2 precision grades. Linear travels from +/- 2 x +/- 2 mm, up to +/- 30 x +/- 30 mm. A typical normal repeated positioning accuracy from +/- 1.75 to +/- 2.5 µm. A typical precision repeated positioning accuracy from +/- 0.7 to +/- 1.0 µm. A parallelism as low as 30 µm. The ability to handle dynamic loads up to 600 kg (1,323 lbs.) with the larger stages. Treated surfaces to ensure durability. www.oesincorp.com

Cordsets for Mobile Hydraulic Applications Phoenix Contact (Middletown, PA) now offers Deutsch and Superseal connectors as pre-molded cordsets. The connectors are 100% factorytested and ready for use in mobile hydraulic applications. Features include: A measure of 18 AWG (2 x 0.75 mm2). Construction with PUR black cable. IP65/IP67 protection. An operating temperature range from -20° to 85°C. www.phoenixcontact.com www.pddnet.com

HYDRAULICS AND PNEUMATICS

NewProducts Subminiature Pressure Switch Gems Sensors & Controls (Gems) (Plainville, CN) has announced the global market launch of its Model PS61P OEM subminiature pressure switch, offering medium-to-high pressure monitoring within space constrained applications. Features include: A hardened alloy steel piston actuator for expanded overpressure performance. A 24 mm diameter hex footprint. The ability to monitor standard pressures from 510 to 4350 psi (35 to 300 bar). A burst pressure rating of 22,000 psi (1517 bar). www.gemssensors.com

Needle Valves Clippard (Cincinnati, OH) has announced its GNV Series Needle Valves. The new series is available with 1/8, 1/4, and 3/8" port sizes with flow rates of up to 60 scfm at 100 psig. Features include: Bidirectional flow control. A rotating input for 360째 positioning. A rugged and compact design. Multiple mounting options. www.clippard.com

Compact Pneumatic Lever Clamp DE-STA-CO's (Auburn Hills, MI) new 8700 series pneumatic lever clamp is a lightweight, spacesaving alternative to traditional pneumatic toggle and swing clamps. Features include: A construction with hard-coated aluminum A hard chrome piston rod, alloy steel pivot pins, and selflubricating bearings. The availability in 4 bore sizes: 25, 32, 40, and 50 mm. Clamping forces from approximately 45 to 170 lbs., depending on the bore size. www.destaco.com

Single-Jet Totalizing Water Meters Clark Solutions' (Hudson, MA) new Model Series CLXC-P single-jet dry type totalizing water meters are suitable for a range of sub metering applications. Produced in an ISO9001 certified production facility, the water meters are constructed in conformance with AWWA standard C712-10, and meet ANSI/NSF 61 for materials safety and ANSI/NSF 372 for lead free compliance. Features include: Availability with or without reed switch output. A 50% glass fiber reinforced engineering thermoplastic material. A maximum operating pressure of 150 psi. A nominal accuracy of 1.5%. An operating flow range from .22 to 22 GPM. www.clarksol.com 32

January/February 2015

No Drip Internal Mix Atomizing Nozzles Exair's (Cincinnati, OH) No Drip Internal Mix Atomizing Nozzles are available in 5 patterns: narrow angle round pattern, wide angle round pattern, flat fan pattern, deflected flat fan pattern, and 360째 hollow circular pattern. They are for pressure fed applications that don't require independent air and liquid control. Features include: Adjustability to minimize air and liquid consumption. Interchangeable liquid and air caps. CE compliance. www.exair.com

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PRODUCT DESIGN & DEVELOPMENT

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FinalThought

Is Trial & Error Obsolete?

homas Edison conducted more than 100 different material trials before landing upon a viable solution for the light bulb. There were many more trials involved in identifying the need for a vacuum within the bulb, and a process for massproducing the filaments. Clearly, with persistence, and the right resources, trial and error can be an effective means of developing a new solution. That said; given what we know today and our access to the Internet, any of us with a resourceful mindset and an engineering background could have eliminated a great many of Edison’s trial-and-error experiments with a little research. With access to powerful computing tools that enable us to run simulations and calculate outcomes, trial-and-error is obsolete – or so we are expected to believe. Let us first examine some reasons why we might choose to use simulations and probabilistic analyses instead of trial-and-error as a means of testing and improving our designs. 1. Trial-and-error is time consuming Conducting experiments can rapidly chew through a development schedule. It’s rare that we are developing something that facilitates a simple declaration of, “Turn it on, let’s see what happens,” as a means of testing our design. We must execute changes to the system or manufacture the materials and devices to test. We must carefully plan our experiment so that we might learn what we need. Experiments can be very time-costly. 2. Trial-and-error is expensive Many of the same elements that cost us time, also cost us money. System changes, manufactured elements, personnel, services, expertise, and transportation of such things all cost money. The more we demand those things, the more money we spend. 3. Trial-and-error isn’t always informative If we get too excited to test and break our latest iteration, and we don’t carefully plan how we intend for that experiment to produce information, data, or knowledge, we can very easily find ourselves with another broken prototype and nothing to show for it. Alternatively, we can run a test and get a result that is precisely what we expect. If that is our final product test prior to launch, or our final system test prior to turn-on, that’s great. However, if we are in development and only proving what we already know, we are wasting time and money.

January/February 2015

ry Adviso Board

member

4. Trial-and-error is a neverending, unsatisfying method It is easy to get carried away conducting trial-and-error experiments. It is fascinating to run out and test each and every adjustment to see what impact it has on the design and the developing solution. If we allow that behavior, without carefully controlling how much experimentation we conduct, all of the problems mentioned above become exacerbated. When we can acquire much the same information concerning our solution’s probable performance from models, simulations, analyses, calculations, and probabilistic estimations, we can often save ourselves much of the cost and time demanded by trial-anderror methods. However, there are two fundamental limitations to substituting simulations and calculations for trial-and-error. First, our simulations and calculations are based entirely on what we already know. As soon as we broach an inference space outside of information and data already available, we can’t build a model for our solution. Second, we must either have a model or a calculation already on-hand, or we must be able to develop one. Sometimes, the development of a simulation to model our solution’s behavior can take more time and money than a trial-and-error experiment. Often that challenge depends upon the information and data available. While there are several things that can make trial-and-error methods undesirable, we should keep two common sense axioms in mind. 1. We learn more from our mistakes than our successes. 2. There is nothing more informative than watching a phenomenon take place before your eyes. Do not just assume that analyses, models, and simulations are as good as or better than trial-and-error. Instead, consider for each scenario you encounter which will be better. Trial-end-error should, in my opinion, be preferred any time that it can be accomplished in less time than a simulation for comparable cost. It is rare that an experiment would cost less than a simulation, but look for that opportunity anyway. Absolutely conduct the experiment if there is doubt that the

calculation or model is representative of By Alan Nicol what will actually occur. Use the information to update the model when you are done. If time is not a limited resource and the cost is not prohibitive, choose trial-and-error over simulations. Simulations are based on what we already know. Sometimes they don’t show us what unfolds; they only show us the end result. A physical experiment, occurring before your eyes can be much more informative to a developer. Seeing what actually happens can inspire valuable and creative enhancements. In other words, if you have the luxury of choosing between a simulation and an experiment, and resource limitations don’t dictate one over the other, choose the experiment. Don’t let the stigma of antiquated practice deter you from considering trial-and-error as on option. Just because it’s been around longer doesn’t automatically mean it’s obsolete. Instead, make it a habit to consider if it might be a better option. Stay wise, friends. If you like what you just read, find more of Alan’s thoughts at www.bizwizwithin.com. PDD

EDITORIAL ADVISORY BOARD • Tim Balz, Founder & President, Freedom Chairs • Marty Boykin, Ph.D., Director of Consumer Durables & Tritan, Eastman Chemical Company • Robin Gray, Chief Operating Officer & General Counsel, Electronic Components Industry Association (ECIA) • Ron Jr. “Reg” Gustafson, Vice President of Business Development, Clinkenbeard • Mike Littrel, President & Founder, C.ideas • Harry Moser, President, Reshoring Initiative • Alan Nicol, Executive Member, AlanNicolSolutions, LLC • Mike Rainone, Co-Founder, PCDworks • Drew Rink, Senior Manager of Manufacturing Marketing, NVIDIA • Paul Scheidt, Product Marketing Manager, LED Components, Cree • Lanny Vincent, General Partner, Vincent & Associates, Ltd • Anna Zevelyov, Director of Business Development, Artec Group www.PDDNET.com

Call for

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