Computer modeling and simulation has been used in engineering for many decades. At this point, anyone working in R&D is likely to have either directly used simulation software or indirectly used the results generated by someone else’s model. But in business and in life, “the best laid plans of mice and men can still go wrong.” A model is only as useful as it is realistic, and sometimes the spec changes at a pace that is difficult to keep up with.

Modeling and Simulation Is Great, But…

One of my favorite parts about working at a multiphysics software company is getting to see up close all of the clever and innovative ways our customers use simulation to move the world forward. There was the loudspeaker engineer who talked about turning an idea in their head into a viable product that passed both the technical spec and looked good, and they credited simulation for turbocharging their design iteration process. Another time, I spoke with someone who used our software for automating their process of designing boat landings for offshore wind turbines by creating their own library of parts, combining their learned experience with structural analysis. Someone else invited me into their impressive test lab where they showed off how they run experiments to generate material data, which they later used in their true-to-life computer models.

The benefits of getting a preview of the real-world outcome before you commit to a project plan or design transcend industry and product offerings. There are countless examples of how modeling and simulation speeds up innovation and reduces overall costs. That said, using simulation in the way it’s largely been done over the past 30 years has required specific expertise and training on how to use the software of choice. So while companies that use it have a lot to gain, the total gain is still limited by the number of employees who have learned the necessary skills to build computational models. But that doesn’t need to be the case.

Taking Simulation to Greater Heights Through Custom Apps

Take a company that produces speakers for luxury cars, for instance. Today’s consumers expect a lot more from their ride than safely going from point A to B, sound quality being one of those things. By using multiphysics modeling, it’s much faster and easier to visualize how different designs will sound in specific car cabins before going to production. You can make a perfect replica of a particular car design to test your loudspeakers in, but if that car is still in the process of being designed, your replica can become outdated very quickly. The way sound bounces off the interior might go from acoustic bliss to tinny tunes if the car door design changes or the customer chooses a different type of trim. Do you really want to go back and forth updating and rerunning the full-fledged model every time? And what about the lag between learning about the changes from the team designing the interior to actually being able to update your model to reflect those changes? In the case of one supplier of audio technology for car manufacturers, the team worked in different time zones and the lag was a real pain point. They needed something better.

What did they do? They built their own custom simulation apps based on the full-fledged model. Instead of constantly going back and updating large models to account for interior design changes, their global and cross-functional team could enter the changes into input fields in a custom user interface — built by them in-house, exactly to suit their own needs. Since the app is powered by their own underlying acoustics model, they could then quickly and easily visualize how their loudspeakers would sound inside the car environment, design changes and all.

An example of a custom app for designing a heated car seat, where the user inputs relevant data into restricted fields and the results combine the inputs with an underlying computational model.

Now, in this case, the apps were built by and for R&D teams to improve their own work. While this benefited the company and the team, it’s still “just” another example of using modeling and simulation for R&D. Apps have the potential to break far beyond the traditional simulation software user groups and we’ve already started seeing real examples of that. 

Making Decisions in the Field, Factory, and Lab

Let’s imagine a construction company. Building more leads to more revenue, but hiring enough contractors for the job and motivating them to work fast does not guarantee a larger profit. The world at large is powered by laws of physics and chemical reactions that intertwine and affect each other. The same is true for concrete, which is easily affected by temperature in the air and soil during the curing phase as well as internal temperatures based on chemical reactions when water and cement are combined. Choices made at the construction site determine how fast the concrete will harden and ultimately how strong and durable it will be going forward. Without predictive analysis, picking the best concrete mix and deciding when to remove the supporting framework involves mostly intuition and guessing. Multiphysics simulation would give you a more accurate estimate of how fast the concrete will cure, especially if you can incorporate information such as what part of the building is being cast, what material surrounds the concrete, and what the weather conditions are like on site, both now and in the forecast. This type of information can really only be gathered in the moment, out on the construction site. It’s not practical or realistic to send a simulation engineer out with the construction crew nor is it realistic to teach the crew how to use simulation software. But it is possible to have a simulation engineer build a custom app for the onsite crew to use. You can have the best concrete in the world, but if it doesn’t set right, the project cannot be deemed successful. Contractors make in-the-moment decisions that will eventually determine whether a project is on track or delayed, profitable or not. Simulation apps would allow them to test their choices virtually before picking the best mix and curing time based on both science and their local onsite conditions. This is not a fictional example, by the way: one of the world’s largest suppliers of cement, aggregates, and precast concrete rolled out an app for this use a couple of years ago, and they are only continuing to expand on their use of simulation apps today.

A simulation app for determining concrete mix and casting timeline based on onsite conditions.

Next, let’s consider a company focused on manufacturing. In that case, weather is not as big of a concern, because an indoor environment can be more tightly controlled. However, there are still many uncertainties at play that can impact production outcomes and if you can predict them in advance, the business will be better off. Let’s take an additive manufacturing factory producing parts via metal powder bed fusion as an example. Back at the office, simulation engineers can optimize the designs ahead of production, but the end result might still not match the model if the facility conditions are not ideal at the time of production. Heat and humidity inside the facility can cause the metal powder to oxidize and pick up moisture while in storage, and this will alter how it flows, melts, picks up electric charges, and solidifies. Furthermore, the powder is flammable and toxic, even more so when it dries out. In other words, measuring and managing humidity levels in the factory impacts both product quality and worker safety. One such company modeled their own factory and built simulation apps around it to monitor and predict factory conditions based on variables such as outside climate, how many machines are running, and how machines are positioned. Their staff can then use the apps on the spot to figure out how to adjust ventilation and production schedules to create the conditions they need for the best production results.

Now, if you are running direct experiments in a lab or using test rigs, you can, of course, see exactly what the real outcome is based on carefully selected inputs and a controlled setup. By coupling experimental testing with simulation, though, you can improve understanding and make faster predictions using your lab-generated results. For example, if you’re researching thermal elastohydrodynamic lubrication of gear contacts, you might learn through observation that a diamond-like carbon coating on the gears’ surface improves their efficiency, but that only shows you what happens, not why. In this case, having a simulation app in the lab would allow you to easily input the details of your actual setup and get a multiphysics simulation of how the heat flows inside the system. A research team that did exactly this, understood from the model that the efficiency improvement stemmed from the fact that the coating traps heat in the contact, which lowers the lubricant’s viscosity and thereby decreases friction. They would not have known this using only the naked eye.

Simulation can be used as an effective decision-making tool in the office, field, factory, and lab. When organizations build and distribute their own custom apps, everyone in the workforce will be able to make decisions based on forecasts that account for real-world complexities and the underlying laws of physics — without having to first learn how to use simulation software or take up a lot of someone else’s time. The world is ever changing and simulation apps help companies and teams of all kinds keep pace. 

If you’d like to learn more about simulation apps, here’s a suggested resource: https://www.comsol.com/benefits/simulation-apps

Fanny Griesmer is the chief operating officer of COMSOL, Inc., which develops, markets, and sells the COMSOL Multiphysics® simulation software.

The post It’s Time to Rethink How You’re Using Simulation appeared first on Engineering.com.

Importance of RGD resistance

Rapid Gas Decompression is a critical consideration for sealing materials used in applications where exposure to high-pressure gaseous environments is prevalent. RGD can lead to material failure if seals are not designed to withstand sudden changes in pressure, which can occur during operational scenarios or system failures.

Rapid Gas Decompression (RGD) resistance is essential for elastomers used in high-pressure gas applications across various industries, including Oil & Gas, Chemical Processing, Automotive, and Renewable Energy.  RGD can happen during sudden drops in pressure, putting significant stress on sealing materials, which can lead to leaks and safety risks. In the oil and gas sector, for example, preventing leaks in downhole or surface equipment is crucial to protect the environment, while in aerospace, maintaining system integrity is vital for safety. Elastomers designed to resist RGD help ensure reliable sealing and compliance with safety regulations, providing peace of mind for operators and users alike.

As the world shifts towards cleaner energy sources, the importance of RGD-resistant materials grows, particularly with the increasing adoption of hydrogen in power generation and transportation applications, such as fuel cell vehicles. These materials are key to ensuring safety and durability in gas compression, storage, dispensing, and on-board fueling systems. By prioritizing RGD resistance, companies not only enhance the reliability of their products but also contribute to a more sustainable future. This commitment to safety and performance is vital as industries navigate the challenges of modern gas handling and strive to meet the demands of a changing energy landscape.

Typical applications requiring RGD resistance

Valves: Ensuring reliable sealing in high-pressure systems.

Pressure relief devices: Maintaining safety and integrity during pressure fluctuations.

Instrumentation equipment: Providing accurate and safe operation in critical measurement applications.

Manifolds: Facilitating safe gas distribution in complex systems.

Storage tanks: Guarantee seal longevity in rapid release of pressure. 

And many more: Applications across various industries, including oil and gas, chemical processing, and renewable energy.

Testing results

The following Parker compounds have completed industry standard RGD testing per ISO23936-2:

All tested compounds passed with excellent results, confirming their suitability for applications involving exposure to rapid decompression scenarios. This achievement underscores Parker’s commitment to providing high-quality sealing solutions that meet the stringent demands of modern industries.

Conclusion

Parker’s successful RGD testing results for our VG109, VX365, KA183, and E0962 compounds in 100% Hydrogen and 100% Carbon Dioxide environments highlight the dedication to innovation and safety for sealing technologies. These compounds are engineered to excel in demanding conditions, ensuring operational integrity and reliability in critical high pressure gaseous applications.

For further information on Parker’s sealing solutions and RGD testing, please contact your local Parker representative or visit Parker Hannifin’s website.

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The ongoing evolution of hydrogen fuel systems for vehicles has necessitated robust standards to ensure reliability, and performance. Among the most critical of these standards is CSA/ANSI HGV 3.1:22, which outlines requirements for compressed hydrogen gas fuel system components in North America. Globally, ISO 19887:2024 is emerging as a de facto standard, borrowing heavily from HGV 3.1 while introducing its own specific parameters. For design engineers, understanding the differences between these standards is essential for designing solutions that meet diverse market requirements.

At Parker, our approach is shaped by decades of experience in compressed natural gas (CNG) systems, where we’ve cultivated a pragmatic, customer-centric methodology. This has taught us that simply meeting standards is not enough. To lead in the hydrogen market, we must go beyond compliance to anticipate real-world challenges, address customer concerns, and balance innovation with commercial viability.

Key differences between HGV 3.1 and ISO standards

HGV 3.1, revised as recently as 2022, sets validation testing benchmarks for a range of components, including check valves, manual and automatic valves, pressure regulators, hoses and fittings. ISO 19887 applies to a broader global market. Its stricter requirements in certain areas, such as permeation limits for hoses and material compatibility, challenge engineers to adopt innovative solutions. For example, while HGV 3.1 allows a hose permeation rate of up to 500 cc per meter per hour, ISO 19887 caps it at 20 cc, making material selection and design optimization critical.

For valves, ISO 19887 specifies 125% pressure at ambient temperature, including a filling cycle section, whereas HGV 3.1 mentions nominal working pressure without referencing a filling cycle. ISO also allows manufacturers to define lower limit voltage for valves to prevent unexpected activation due to leakage current, a provision absent in HGV 3.1. Both standards allow manufacturers to determine specifications like minimum operating temperature and maximum pressures. The key advantage of ISO 19887 lies in its status as an international standard, potentially offering broader acceptance compared to HGV 3.1.

Design engineers must recognize that decisions made for one standard may not automatically comply with the other. For instance, hoses using PTFE liners may struggle to meet ISO’s stringent permeation criteria. This illustrates the importance of aligning design decisions with target markets and their associated regulations.

Parker’s pragmatic approach: lessons from CNG

Our specialization in CNG systems serves as a valuable foundation for hydrogen fuel system development. With CNG, we faced similar challenges: sealing tiny, high-pressure molecules, ensuring durability under fluctuating temperatures and addressing risks around flammable gases.

Hydrogen, however, raises the bar. The molecule’s small size increases leakage risks, while its reactivity can weaken certain metals over time. Recognizing these unique challenges, we prioritize the following:

Exceeding standards

While HGV 3.1 and ISO 19887 provide a baseline, some of our products require additional validation for extreme applications, including extreme cold (-60°C) and rapid fueling/defueling cycles. For instance, our Seal-Lok fittings have been rigorously tested to exceed HGV 3.1’s requirements, ensuring reliability even in harsh environments.

Material innovation

Through collaboration across our business units, we’re developing advanced elastomers and thermoplastics tailored for hydrogen applications. These materials address concerns like rapid gas decompression and long-term exposure to high-pressure hydrogen.

Customer collaboration

By involving customers in the development process, we ensure our solutions address specific application needs without unnecessary overengineering. This approach accelerates time to launch and reduces iterations while building trust with end-users.

Balancing innovation and commercial viability

Hydrogen’s potential to decarbonize transportation is undeniable, but its path to widespread adoption faces hurdles, from infrastructure challenges to consumer perception. Risk reduction is a particularly significant concern, with fears around leakage and flammability affecting market acceptance.

Parker’s strategy emphasizes balancing cutting-edge innovation with practical, market-ready solutions. By leveraging our CNG experience, we’re developing hydrogen components that are not only reliable but also scalable for high-volume production. For example, our hydrogen dispensing hoses, already proven in commercial applications, reflect our commitment to delivering solutions that meet both current and future demands.

Preparing for the future

As hydrogen standards continue to evolve, Parker remains committed to staying ahead of the curve. By aligning our testing methods with ISO’s global perspective while exceeding HGV 3.1’s benchmarks, we’re positioning ourselves as a trusted partner for hydrogen system designers worldwide.

For engineers working in this emerging space, the following is clear: understand the standards, embrace pragmatism and focus on delivering value. With hydrogen poised to reshape the transportation industry, now is the time to build systems that inspire confidence and drive adoption. Parker’s decades-long commitment to innovation and quality ensures that as the hydrogen economy grows, our customers will have the tools and expertise to succeed. Whether designing valves, fittings or hoses, our focus remains the same: exceeding expectations, one application at a time.

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This blog post describes the key factors to be considered when selecting a single-use system for final fill operations.

1. Compatibility with product and process

SUS materials must not interact with the product because the resulting extractables and leachables (E&Ls) could compromise the quality and/or safety of the product. Therefore, the chemical compatibility of the SUS materials with the product is crucial. In addition, the SUS should integrate seamlessly with existing processes to ensure that it does not disrupt production workflow or efficiency.

2. System sterility

Sterility is one of the most important factors for final filling. The selected SUS should ensure robust sterility throughout its lifecycle – from manufacturing and packaging to implementation in the process. The design of the SUS should support the objective of mitigating the contamination risk by reducing the number of connections as potential points of contamination and incorporating aseptic connectors and transfer systems. For pre-sterilized systems, validated methods must be used to ensure that each step has been proven to effectively minimize the risk of contamination.

3. Flexibility and scalability

The ability to adapt to varying production volumes without compromising quality or efficiency is critical. An ideal SUS for final filling should be scalable, enabling easy adjustment to different batch sizes and fill volumes, and facilitating seamless scale-up or scale-down. Flexibility in design using various materials such as TPE and silicone to accommodate different product types and fill volumes is also essential.

4. Regulatory compliance

The selection of an SUS for final filling of biopharmaceuticals requires thorough understanding of and compliance with the regulatory framework including compliance with FDA and EMA standards and the specific requirements of Annex 1 relating to the manufacture of sterile medicinal products. The selected SUS must comply with current regulations and be flexible enough to accommodate future regulatory changes, particularly those that emphasize risk management and quality assurance. In addition, suppliers must provide detailed validation documentation to demonstrate that the system complies with these regulations. This documentation, covering sterilization methods, system integrity, and compatibility assessments, is critical for regulatory submissions and ensures that the SUS supports both compliance and the highest standards of product quality and patient safety.

5. Assembly and closed system design

The move toward closed single-use systems significantly improves sterility and process efficiency. SUS should be designed to ensure a completely closed system from the container to the filling needle. The integration of overmolding technology is a key innovation in achieving a truly closed SUS. It replaces traditional barbed connections and reduces the number of connections required. Overmolding not only creates a more reliable, leak-proof connection but also plays a critical role in maintaining the integrity of the closed system in line with Annex 1 requirements emphasizing the importance of closed systems in the manufacture of sterile products. This technology significantly reduces potential points of contamination, ensuring a higher level of sterility.

 6. Supplier reliability, support and customization capacity It is important to work with a supplier that understands that every final fill process is unique and that can offer flexible solutions tailored to specific operational requirements. This ensures that the implemented single-use system is of high quality and perfectly aligned with the customer’s process requirements, improving both efficiency and compliance. A supplier’s ability to provide comprehensive support throughout the lifecycle of the single-use system – from initial design to final implementation – can have a significant impact on the success of the customer’s final fill operations.

Bottom line

Selecting the right single-use system design for final filling is a critical choice that can have a significant impact on product quality, regulatory compliance, and manufacturing efficiency. Prioritizing considerations such as compatibility, sterility assurance, flexibility, regulatory compliance, and supplier reliability can improve final fill operations and ensure product safety. It is important to partner with a supplier who understands the various requirements and challenges. In this context, Parker has demonstrated its reliability with its PureTain® final fill single-use solution. Get in touch with us. Our team of process specialists will be happy to discuss your requirements and work with you to find the best single-use solution for your final fill application.

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In today’s rapidly evolving automotive landscape, the push for environmental sustainability and the reduction of greenhouse gas emissions has become paramount. While the passenger car industry is increasingly turning to electrification as a solution, this technology often does not deliver the performance required for many heavy-duty truck and off-highway applications. As a result, these markets are exploring alternative fuels to diesel, such as ethanol, methanol, natural gas, biodiesel, and hydrogen. However, this transition brings forth a unique challenge: the need for effective sealing solutions that can accommodate multiple fuel types. Enter fuel agnostic sealing materials—an innovative solution that offers numerous advantages for OEMs.

The challenge of diverse fuels

Traditionally, different elastomers were required to seal each type of fuel, leading to increased complexity in manufacturing processes. Each fuel has unique chemical properties that can affect the performance of sealing materials, requiring OEMs to source and manage a variety of elastomers. This not only complicates the production line but also increases costs and the risk of errors.

The solution: fuel agnostic sealing materials

Parker, a leader in sealing technology, has developed a series of fuel agnostic sealing materials designed to be compatible with a wide range of fuels. These innovative materials provide a robust solution for OEMs looking to streamline their production processes while maintaining high performance standards.

Key advantages of fuel agnostic sealing materials

1. Increased manufacturing efficiency
   By integrating fuel agnostic material seals into their designs, OEMs can significantly enhance manufacturing efficiency. When a single sealing material can be used across multiple fuel platforms, it becomes easier to switch production from one fuel type to another. This flexibility allows manufacturers to respond quickly to market demands without the need for extensive retooling or retraining.
2. Reduced inventory complexity
   Fuel agnostic materials reduce the number of different parts that need to be kept in inventory. With fewer elastomers to manage, carrying costs are lowered, and the complexity of inventory management is simplified. This not only streamlines operations but also minimizes the risk of stock shortages or excess inventory.
3. Minimized installation errors
   The use of a single, versatile sealing material reduces the chance of installing the wrong seal during assembly. This is crucial for maintaining quality control and reducing rework and warranty costs. By minimizing errors, OEMs can enhance customer satisfaction and protect their brand reputation.
4. Shortened design and validation time
   Developing new engine platforms often involves extensive design and validation processes. Fuel agnostic sealing materials can significantly reduce the time required for these phases. With fewer materials to test and validate, OEMs can accelerate their time-to-market, gaining a competitive edge in the industry.

Focusing on hydrogen as a fuel option

Among the various fuel types compatible with fuel-agnostic engines, hydrogen stands out as a promising option for achieving zero-emission mobility. Hydrogen can be utilized in both fuel cells and internal combustion engines, each offering unique advantages for different applications. As the hydrogen economy develops, the demand for reliable sealing solutions that can withstand the specific challenges of hydrogen operation becomes increasingly important.

Fuel-agnostic internal combustion engines that utilize hydrogen require sealing solutions capable of handling the unique properties and challenges associated with hydrogen as a fuel. Parker O-Ring & Engineered Seals Division offers a range of advanced sealing materials specifically designed for these applications. Here’s a closer look at some of our top-performing materials suitable for hydrogen that have passed ISO 23936-2, rapid gas decompression (RGD) tests at 100°C with 100% hydrogen:

1. KA183-85: This material is known for its excellent resistance to a wide range of fuels, including hydrogen. KA183 provides superior sealing performance in high-temperature applications, making it ideal for hydrogen and natural gas fuel systems.
2. E0893-80: A versatile elastomer, E0893 is designed for compatibility with various low and zero carbon fuels. Its durability and resistance to wear make it an excellent choice for sealing applications in hydrogen engines, ensuring long-lasting performance. E0893 is a cost effective, low temperature option for applications only concerned with ethanol and methanol fuels. 
3. VG109-90: Formulated for aggressive environments, VG109 offers exceptional chemical resistance, making it suitable for applications involving hydrogen and renewable natural gas (RNG). Its ability to maintain seal integrity under pressure contributes to the overall efficiency of hydrogen systems.
4. VM330-75: A fluorocarbon (FKM) material that excels in high-temperature environments, VM330 is flexible and resilient, making it ideal for sealing applications in hydrogen engines where maintaining a tight seal is crucial for performance. VM330 is a moderate, high temperature option for applications with hydrocarbon material exposure that cannot accommodate higher durometer compounds.
5. VX365-90: Known for its superior thermal stability, VX365 is engineered to withstand extreme conditions often encountered in hydrogen applications. This material provides excellent sealing capabilities, ensuring that hydrogen engines operate efficiently and reliably.

Conclusion

As the heavy-duty and off-highway industries continue to evolve toward more sustainable fuel options, the importance of innovative sealing solutions cannot be overstated. Fuel agnostic sealing materials represent a significant advancement in this area, providing OEMs with the flexibility, efficiency, and cost savings required to thrive in a competitive marketplace. By adopting these materials, manufacturers can not only meet regulatory demands but also position themselves as leaders in the transition to a more sustainable future. Embracing low and zero carbon intensity fuels is not just a smart business decision; it is a necessary step towards a greener, more efficient transportation industry.

Parker’s sealing solutions enhance reliability and performance

Parker’s rubber materials are designed to deliver reliability, longevity, and safety in fuel agnostic applications. By utilizing our advanced sealing technologies, manufacturers can ensure that their internal combustion engines maintain optimal performance while transitioning to low and zero carbon fuels. Our materials are engineered to withstand the unique challenges presented by each fuel type, including hydrogen, with its high diffusivity and potential for embrittlement in certain metals.

As the transportation industry moves toward more sustainable practices, fuel-agnostic engine platforms represent a significant step forward. With hydrogen emerging as a key player in the future of clean mobility, Parker O-Ring & Engineered Seals Division is committed to providing high-quality sealing solutions that enhance the performance, reliability, and economic viability of these innovative engines. By choosing Parker’s advanced sealing materials, manufacturers can confidently embrace the future of low and zero carbon transportation. For more information on our sealing solutions and how they can benefit your fuel-agnostic engine applications, contact us at oesmailbox@parker.com or visit us online at the Parker O-Ring & Engineered Seals Division today!

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The next generation of technology in the military, such as high-powered radar jamming systems and hypersonic weapons, requires a large amount of processing power. As a result, processors in this technology contain many heat-generating components. Design engineers must find ways to reliably transfer and dissipate heat from these components to ensure the overall systems continue to operate effectively. In commercial applications, thermal management failure can mean a faulty smartphone. In the military, it can mean mission failure and even the loss of life.

Thermal management in these cutting-edge systems is multifaceted. It includes hardware such as heat sinks and liquid cooling devices – but also thermal interface materials (TIMs). Thermal interface materials transfer heat from hot components, such as transistors in chip packages, to
cooling hardware. They come in different forms, including pads, putties, phase-change materials, thermal greases, and thermally conductive insulator materials. For the military, reliability is the watchword. To maximize reliability, TIMs need three characteristics:

1. Wide operating temperature range: The environments in the processors that drive the military’s most advanced technology are harsh and feature extreme and frequent temperature spikes and dips. TIMs therefore must operate reliably in an environment where temperatures can hit 300 degrees Fahrenheit and drop in short order to -50degrees Fahrenheit. This temperature cycling can take a toll on TIMs. Engineers therefore require TIMs designed to withstand these regular temperature fluctuations over a long period of time.
2. Durability to withstand harsh substances: TIMs in military applications may rest near harsh liquids or vapors (jet fuel, missile fuel, deicing fluid) that can eat away at the silicone base of these materials. Engineers need to therefore design in a way that shields TIMs and their edges from exposure to harmful substances while also looking to TIM manufacturers to continue exploring the use of more durable materials.
3. Resistance to deterioration: Outgassing in TIMs can hinder the performance of optical lenses, and NASA has stringent outgassing requirements. Manufacturers can use a post-cure process to minimize outgassing. Further, if silicone breaks down and “bleeds,” it can hinder the adhesiveness of surrounding surfaces. Design engineers must pay close attention to the formulation of materials within a TIM, which determines its level of resistance to these forms of deterioration.

Materials science creativity is the key to ensuring TIMs meet the evolving needs of military and aerospace design engineers. At Laird, we are constantly adjusting the material makeup of TIMs to enhance temperature stability and prevent outgassing and bleed from the interface. We also tap robust thermal modeling and testing capabilities to measure the effectiveness of TIMs and devise custom solutions for military applications.

To meet the military’s stringent requirements and enable effective thermal management in new, advanced systems, design engineers also need to adopt a system-level design approach. This approach allows engineers to account for all possible thermal and electromagnetic challenges and address them together, early in the design process. It’s well past time to move away from the model of siloed EMI and thermal teams addressing these issues discretely. Signal and heat issues are increasingly intertwined, and space within processors is limited. Therefore, design engineers need to come together to devise creative and space-saving solutions to these increasingly complex challenges.

Though every industry seeks innovation, the push toward the cutting edge is amplified within the U.S. military. After all, the military is in a constant race for supremacy against adversaries around the world – and the stakes are high. Therefore, design engineers are always working to push the boundaries of performance in military technology. But as warfighting capabilities advance, thermal management challenges grow. Military design engineers therefore need to tap into the latest materials science innovations and improve their internal design processes. Reliable thermal management is one piece of the continued advancement of electronics systems in the military – but it’s a crucial one. And TIMs play an essential role in the effort to manage heat in next-gen military technology. To ensure the U.S. military stays a step ahead of its enemies, the industry needs continual improvements in the makeup and capabilities of TIMs.

Learn more about Laird Performance Materials from TTI, Inc.

Sponsored Content by Laird Performance Materials and TTI, Inc.

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By Heilind in partnership with Molex

Consumer expectations and advancing technologies are fueling a significant shift toward smaller, more capable devices across various industries. From wearable technology to industrial machinery, the demand for compact designs that deliver enhanced performance continues to grow. This transformation is further driven by the widespread adoption of the Internet of Things (IoT) and the increasing integration of advanced sensors. These trends require devices to process vast amounts of data efficiently while fitting into increasingly smaller spaces. Engineers face the challenge of meeting these requirements without sacrificing the performance, reliability, or durability of the devices they design.

Compounding this challenge is the reality of modern operating environments, which are often unpredictable and harsh. As electronic systems expand into more diverse and demanding applications, they must endure extreme conditions such as constant vibration, wide-ranging temperature fluctuations, and exposure to moisture, dust, and other contaminants. These elements push the limits of electronic components, making ruggedness and reliability not just desirable features but critical requirements. For many applications, particularly in automotive, industrial, and consumer electronics sectors, durable performance in challenging environments is essential to ensure long-term functionality and user satisfaction.

To address these challenges, Molex offers innovative solutions specifically designed to excel under these demanding conditions. The MX150 connector system is a prime example of Molex’s commitment to rugged and reliable technology. Engineered as a sealed connector solution, the MX150 delivers exceptional performance in environments where moisture, vibration, and extreme temperatures are a constant concern. Its robust design makes it ideal for automotive and industrial applications, where dependability under harsh conditions is paramount. The MX150 eliminates the need for additional sealing components, reducing assembly time and complexity while ensuring long-lasting reliability.

For applications requiring compact yet resilient connections, Molex’s DuraClik connectors offer a tailored solution. With a design focused on high vibration resistance and space efficiency, DuraClik connectors provide robust, secure connections in tight spaces. This makes them particularly well-suited for consumer electronics and IoT devices, where the trend toward miniaturization demands components that combine durability with a small footprint. These connectors also meet the needs of applications requiring frequent and reliable signal transmission, ensuring consistent performance even in challenging environments.

The importance of rugged, high-performance components like the MX150 and DuraClik connectors cannot be overstated in today’s landscape. As devices and systems become more sophisticated, they are increasingly tasked with performing in environments where failure is not an option. Whether it’s an automotive system navigating extreme weather, industrial equipment exposed to heavy vibrations, or a consumer device used daily in varied conditions, these components provide the reliability necessary to maintain optimal functionality and user confidence.

Moreover, Molex’s solutions go beyond just addressing immediate needs—they enable engineers to innovate without compromise. By providing products that deliver both compact designs and exceptional durability, Molex empowers designers to push the boundaries of what’s possible in modern electronics. Engineers can focus on creating groundbreaking solutions that meet consumer and commercial demands while ensuring their devices remain reliable under the most demanding conditions.

Molex’s expertise in rugged, reliable connectivity extends across a broad range of applications and industries. The company’s deep understanding of the challenges faced by engineers allows it to develop products that not only meet but exceed expectations. This commitment to innovation and quality ensures that Molex products are trusted by industry leaders worldwide to deliver unmatched performance and dependability.

As the need for smaller, more capable devices grows, the demand for reliable components that can withstand harsh environments will only increase. Molex is at the forefront of this evolution, providing the tools engineers need to overcome design challenges and deliver solutions that are both durable and efficient. Whether it’s enhancing the performance of a wearable device, ensuring the reliability of an industrial machine, or enabling seamless connectivity in a smart home system, Molex’s rugged and reliable products are paving the way for the future of technology.

In an era where consumer expectations are higher than ever, and technology continues to advance at a rapid pace, engineers require partners they can trust to deliver innovative, reliable solutions. Molex stands as a leader in the field, offering products like the MX150 and DuraClik connectors that set the standard for rugged performance and compact design. These solutions not only meet today’s demands but also anticipate the challenges of tomorrow, making Molex a critical partner in the development of next-generation devices and systems.

By integrating Molex’s cutting-edge connectivity solutions into their designs, engineers can confidently address the demands of modern applications. Whether in automotive, industrial, or consumer electronics, Molex ensures that devices are equipped to handle the rigors of real-world environments while maintaining peak performance. With a legacy of innovation and a commitment to quality, Molex continues to drive the evolution of rugged, high-performance technology, empowering engineers to create solutions that meet and exceed the expectations of a rapidly changing world.

To learn more about Rugged and Reliable Connectors by Molex, download our RUGGED AND RELIABLE On-Demand Webinar

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A better future is a key focus for all manufacturers in the aviation industry, and every manufacturer is working toward that solution in their own way. Austin Major, Group Vice President of Business Development and Global Support at Parker Aerospace, highlights what this approach means in a conversation.

Q. Recently, Parker joined the consortium to advance aviation liquid hydrogen – can you tell us more?

A. Together with Marshall, GKN and Academic Partners, Parker is embarking on the HyFive project, the goal of which is to develop and implement scalable hydrogen fuel propulsion systems for aircraft ranging from small regional to single aisle. This initiative aligns with our commitment to next-generation technologies and our sustainability strategy. 

The consortium focuses on five areas related to supporting hydrogen-electric propulsion and hydrogen combustion powertrains: filtration, sensing and monitoring, transporting, fuel gauging/indication, and thermal management.

We believe these hydrogen fuel propulsion systems will be critical as our industry works toward net zero emissions and a sustainable future.

Q. How have the last couple of years been for the company? Recently, Parker Hannifin also adjusted its forecast for more profit.

A. We have experienced significant growth and an expanded portfolio with the acquisition of Meggitt. We have a positive outlook on the future of Parker Aerospace in large part due to our innovative technologies, passionate team members who make a difference every day and our comprehensive Win Strategy that guides everything we do. 

Parker is in a leading position in the global Motion and control industry. Across Parker Hannifin, we offer a broad portfolio of interconnected technologies that allow us to offer the best solutions to our customers. 

Q. How has the progress been on Alice since its first flight? What is the status of the project from Parker’s perspective?

A. The first flight of Eviation’s Alice all-electric commuter aircraft in September of 2022 began a new era in aviation. We are proud to be a partner in this incredible achievement. 

Eviation continues to make progress, as demonstrated by the completion of a formal Conceptual Design Review with wind tunnel testing in April. We are working with them closely on state-of-the-art technology for Alice by developing technologies for the future that will help bring more people together across the world in an accessible, responsible way.

Q. A lot of the focus in the commercial aerospace sphere is on electric and sustainable options today. What is Parker doing in that sphere?

A. Electrification is anticipated to be a key component of the expansion of the aviation industry. Not only is this important for our environmental responsibility, but it will reduce the cost of flight and allow for more regional and local opportunities.

We are proud to be part of this future. Parker currently has the biggest and broadest portfolio of electric technologies, and we offer other solutions like lighter weight technologies that enable more sustainable aircraft. Parker has extensive hydrogen solutions, and we have developed an extreme temperature range sealing solution that is compatible with traditional fuel and SAFs – these innovations, and a number of other green technologies, demonstrate our commitment to supporting our customers as they work toward their sustainability goals.

Q. How do Parker products contribute towards a safer environment?

A. Safety, unparalleled reliability, and zero defects are embedded in everything we do, and they are at the core of Parker’s operational philosophy. But our focus extends beyond quality and includes advanced safety systems.

At the show this year, we will be showcasing some of these technologies. This includes Verdagent, the first non-halon fire suppression agent developed and qualified in the world. We are also sharing our e-brake technology, a proprietary system that eliminates hydraulics from braking systems and is a safe, smart solution for the future. We also have a solution that addresses sealing for SAF, which can be used in a number of ways – including aircraft, engines and airports looking to develop ways to reduce their carbon footprint. 

Responding to the call for decarbonizing aviation, fuel providers are blending SAF with conventional jet fuel in ever-increasing amounts. As the composition of current and future SAF formulations may vary significantly, compatibility of all types of SAF with some traditional seal materials is a concern.

Q. What are the key product innovations that Parker has done in recent years? 

A. We are proud to offer a broader, deeper and more interconnected portfolio than we ever have in the past, and we can do this because of our focus on innovation and the combination of Parker Aerospace and Parker Meggitt.

In addition to the products I already mentioned, we are excited to share more exceptional advancements we have made at Parker. This includes an impressive suite of solutions that help solve challenges with thermal management systems and are complete, cost-effective and efficient. 

We have CoolTherm technology that helps prevent overheating and improves reliability and performance for electric vehicles, including aircraft. We also have our smart fan technology on display. These smart fans are made using no permanent magnets meaning they are cost and energy efficient. Smart controls seen on the fans can also be applied to pumps and other components.  Our passionate people with deep engineering expertise, together with our breadth of differentiated technologies, ensure that we make the extraordinary happen and continue to shape the future of aviation in partnership with our customers.

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Parker Aerospace is proud to continue supporting the pioneering Alice all-electric aircraft developed by Eviation. This partnership demonstrates Parker’s dedication to sustainability, innovation, and the future of aviation. Parker Aerospace has been a key supplier to this groundbreaking project, which brings zero emissions and incredibly efficient air travel closer to becoming a reality.

Electrification and Parker Aerospace’s commitment to a sustainable future

Alice first flew on September 27, 2022, a landmark event in modern aviation history. Alice, designed for both commuter and cargo markets, demonstrated the ability to perform short flights without producing carbon emissions. The successful flight marks a significant step toward more sustainable flight.

Eviation’s Alice is designed to revolutionize regional travel, and Eviation will be offering a viable solution for routes ranging from 150 to 250 miles with models including a nine-passenger commuter model, a six-passenger executive cabin, and an eCargo version.

Parker’s advanced engineering and state-of-the-art solutions have helped support the evolution of the Alice aircraft.

With the largest portfolio of technologies that support electrification, Parker is dedicated to building the future and supporting aviation industry leaders as we work toward a greener future. Alice, which operates with zero emissions and minimal noise, provides a sustainable alternative to conventional air travel. This initiative aligns with Parker’s Purpose to develop innovative solutions that benefit the environment and communities around the world.

Driving innovation in the aviation industry

Alice is a testament to the power of progress and collaboration. The aircraft features cutting-edge electric propulsion units and advanced battery technology. Parker’s contributions highlight a commitment to pushing the boundaries of aerospace engineering.

For Parker, involvement in the Alice project is more than just a business venture; it reflects the company’s core values, which highlight the belief that the future of aviation lies in sustainable and revolutionary solutions. Parker’s work with Eviation on Alice exemplifies this, embracing engineering challenges that strive to create cleaner, more efficient flight for future generations.

Looking forward

Parker remains dedicated to advancing aerospace technology through sustainable practices. Our ongoing support for the Alice project demonstrates a commitment to innovation and environmental responsibility, paving the way for a cleaner, greener tomorrow.

Parker is proud to be at the forefront of this pioneering project, helping to shape the future of aviation for the betterment of our world.

About Parker Aerospace At Parker Aerospace, we develop technologies and innovative solutions that enable reliable, efficient and increasingly sustainable flight for the lifecycle of the aircraft, including aftermarket support. Parker stands at the forefront of aviation technology with an expanded range of products and services that sit nose-to-tail across the entire aircraft. Our passionate people with deep engineering expertise, together with our breadth of differentiated technologies, ensure that we make the extraordinary happen and continue to shape the future of aviation in partnership with our customers.

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What were you thinking about the last time you traveled on a plane? Your seat assignments, the weight of your suitcase or finding the right gate? Perhaps you were worried about takeoff or experiencing turbulence on your flight. But did you ever stop to wonder about the braking system, about if—or how—the plane would land and stop safely?

For the millions of passengers flying in and out of airports every day, it’s easy to take touchdown for granted. But for the team members in Parker’s Aerospace Group, braking has the potential to revolutionize air travel and pave the way for a better tomorrow.

“The hardest part is not making the airplane fly,” explains Grant Puckett, group chief engineer for electrification at Parker Aerospace. “We’re focused on making sure you land safely and continuing to provide the assurance society expects from the airplane industry.”

Now imagine boarding a plane where the brakes are as efficient and reliable as those in your electric car. While consumers may still be relatively early in their adoption of electrification technology, the aerospace industry has been working towards electric planes for decades, seeking ways to increase efficiency and reduce environmental impact. And Parker’s new electric braking system (Ebrake®) not only enhances safety and efficiency but also reflects progress toward greener, more sustainable air travel.

“Airplanes need to be able to stop when they land in all imaginable conditions,” says Puckett. “Our Ebrake uses electronic power to do that. This development is crucial because it provides electronic control for anti-skid algorithms and unique diagnostic capabilities, all while using less power and contributing to overall fuel savings.”

Traditional hydraulic braking systems are powerful but complex, and often require extensive maintenance. In contrast, the Ebrake’s electro-mechanical actuation is simpler, more reliable and more efficient.

“By eliminating hydraulic systems we reduce the plane’s weight, leading to significant fuel savings and easier maintenance,” Puckett adds. “This not only benefits airlines but also helps the environment by reducing carbon emissions​​.”

Indeed, Parker’s acquisition of Meggitt in 2022 has created a synergy of complementary technologies, particularly in electrification.

“The blend of Parker and Meggitt offers us the opportunity to think about vertical integration and draw on each other’s strengths to deliver superior solutions to our customers,” summarizes Jennifer Osbaldestin, general manager of Parker Aerospace’s Braking Systems Division.

The system’s successful implementation on the Airbus A220 is proof positive: “The Ebrake system is not only reducing maintenance needs but also enhancing safety by eliminating the need for hydraulic oils,” says Osbaldestin. “This innovation aligns with the growing demand for more sustainable and efficient aviation solutions​​.”

It also aligns with Parker’s Purpose, Enabling Engineering Breakthroughs that Lead to a Better Tomorrow. “Our Ebrake system is not just about efficiency; it’s about making a real impact on our environment,” emphasizes Puckett. “By reducing fuel consumption and emissions, we’re helping to create a more sustainable future for aviation.”

Looking ahead, there are several opportunities on the horizon, with advancements in air mobility and sustainable technologies leading the way. Osbaldestin shares her optimism: “The advanced air mobility sector is booming, and Parker is at the forefront with our innovative Ebrake technology. We’re committed to providing smarter, easier-to-maintain solutions that support our sustainability goals.” By combining the strengths of Parker and Meggitt and focusing on innovative solutions, Parker is not only improving the efficiency and safety of air travel but also setting a standard for future technological advancements. This purpose-driven approach ensures that every engineering breakthrough contributes to a better, more sustainable world.

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