Michael Zeagler

This week at the Automate Show I had a really great conversation with Alvin Clark, a Sr. Developer Relations Manager at NVIDIA. My connection to NVIDIA is actually not new; they used to be my customer when I was the Silicon Valley Sales Manager at CST (now part of the Dassault Systemes - Simulia Software Portfolio) and also a partner for the development of high-performance engineering simulation using GPUs. I joined the NVIDIA Inception Program while developing supply chain AI at Algo - this program has now grown to a global network of over 18,000 technology startups! Fast forward a few years, after some twists and turns, now I get to partner with NVIDIA to learn and share ideas about innovation in robotics and AI for supercharging the manufacturing and automation industries, which I love! Based on Alvin's recommendations I managed to visit a few NVIDIA partner booths to see the practical applications being developed with their tech and it's a mix of industry heavy weights and newer startups: Universal Robots - dare I say the King of Cobots? Siemens - needs no intro Intrinsic - an easy to use developer platform for robotics & automation Axiomtek USA - IPC vendor Apera AI - 4D Vision for Robotic Automation A few that I missed that I am interested in learning more about: Instrumental Inc. - Find and fix manufacturing issues with Data and AI Invisible AI - an on-premise computer vision platform that captures data from manual assembly work Dori AI - an AI-powered video intelligence platform who I realize I also missed last week in Nashville at the Assembly Show South 🤦🏻‍♀️ Anna-Katrina Shedletsky I would love to invite you to the Automation Ladies Podcast and anyone else from these companies interested in having a conversation please reach out 😊 #automationcommunity #aiinmanufacturing #aiinrobotics #smartmanufacturing #automate2024 #partnerships NVIDIA Robotics

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THE ULTIMATE REUSABLE HEAT SHIELD FOR MARS: MATECH’s 5000F C/ZrOC TPS offers the ultimate in reusability. While LEO returns don't require 5000F capabilities, this ability guarantees 3000F performance for hundreds of safe missions. Reusability is the key to mission affordability. For more ambitious missions, Lunar return and Mars return, MATECH C/ZrOC is absolutely imperative! According to a very recent press release [1] and article in CompositesWorld [2] by Grace Nehls, Sierra Space has selected a layer of C/SiC ceramic matrix composite (CMC) on top of light-weight and highly insulative silica-based tiles, modelled after Space Shuttle tiles. For the lower heat flux of LEO return, this may be a viable heat shield solution. As Damond Benningfield wrote for the Smithsonian Magazine, for LEO return, “the tiles exposed to reentry temperatures of up to 2,300 degrees Fahrenheit [3].” Benningfield also stated “Tiles are too brittle to attach to the orbiter directly.” This underscores two inherent challenges to the very light-weight and highly porous silica-based Space Shuttle heat shield tiles. They are not high temperature capable enough for Lunar or Mars return, and they are also fragile and weak. For more aggressive mission requirements, such as Mars return, envisioned by SpaceX, what worked for the Space Shuttle simply won’t work. Consider the fact that the reentry velocities for LEO return are much lower than Lunar and Mars return [4, 5]. “The atmospheric entry interface velocity upon return from the Moon is approximately 11.1 km/s (36,500 ft/s; 40,100 km/h; 24,900 mph) whereas the more common spacecraft return velocity from low Earth orbit (LEO) is approximately 7.8 km/s (25,649 ft/s; 28,000 km/h; 17,000 mph) [5, 6].” Mars return velocity is much higher at 12.5 km/sec (41,104 ft/s; 44,800 km/h; 27,200 mph). To date, no reusable non-ablative heat shield has ever been demonstrated for either Lunar or Mars return. Yet, this is EXACTLY what Elon Musk is seeking. In his tweet of November 19, 2024, Elon Musk wrote “The biggest technology challenge remaining for Starship is a fully & immediately reusable heat shield. Being able to land the ship, refill propellant & launch right away with no refurbishment or laborious inspection. That is the acid test [7].” He’s absolutely right. MATECH has the solution for Starship. In the figure below, under identical conditions and a surface temperature of nearly 5000F, C/SiC CMC is compared to MATECH C/ZrOC CMC. The difference in ablation is dramatic [8]. Under very extreme heat flux conditions at AFRL’s LHMEL facility, the ablation rate of fully dense C/SiC is 100 times higher than MATECH C/ZrOC. This is exactly what Starship needs. MATECH’s C/ZrOC can be artfully combined with existing materials to produce a composite structure that is extremely high temperature capable, reusable, mechanically tough, light weight, and highly insulative, thereby meeting all of Starship’s Lunar and Mars return requirements.

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Want to master CAD software? Stop watching endless tutorials. The real magic happens when you pick a project and dive in. I spent thousands of hours in Boeing courses, but the true learning came when I started building, editing, and modifying real things. It’s in the doing that you pick up the tools, understand the nuances, and refine your skills. Here’s the key: find something you’re passionate about creating. Then, start manipulating, extruding, and surfacing. Each mistake is a lesson, each success a stepping stone. Over time, your toolbox of skills expands, and mastery follows. Learning by doing isn't just a method; it's the path to excellence. What’s the next thing you’re going to build?

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Want to master CAD software? Stop watching endless tutorials. The real magic happens when you pick a project and dive in. I spent thousands of hours in Boeing courses, but the true learning came when I started building, editing, and modifying real things. It’s in the doing that you pick up the tools, understand the nuances, and refine your skills. Here’s the key: find something you’re passionate about creating. Then, start manipulating, extruding, and surfacing. Each mistake is a lesson, each success a stepping stone. Over time, your toolbox of skills expands, and mastery follows. Learning by doing isn't just a method; it's the path to excellence. What’s the next thing you’re going to build?

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Parts I designed were the second to be printed on this machine!

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Discover the fascinating journey of Roopinder Tara, a trailblazing leader in engineering publishing, as he shares insights on the evolution of CAD, the potential of AI in design, and the power of journalism to shape the industry. 

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Lockheed Martin continues to invest in additive manufacturing and to imbed it into production on key programs of record.

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Automated CNC pairs beautifully with #generativedesign Requirements▶Deisgn▶Analysis▶Fabrication of a large, complex, CNC machined part in less than 48 hours is truly enabling. 🚀 Think about CNC for Generative Design rather than just AM!

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Lockheed just unveiled a new fleet of Nikon SLM Solutions NXG XII 3D metal printers! These are pivotal in manufacturing complex parts for their hypersonic missile, orbital satellite, and other aerospace programs!

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One cool concept that doesn't fully meet the eye here is the idea of "induced mass", meaning the component mass on the Starship/Super Heavy vehicles required to support Raptor operations. Not only is v3 a massive streamline of the engine, but it incorporates startup, cooling, and fire/heat mitigation features that simplify other Starship systems and thereby cut "induced mass". A truly impressive score for the Starship program that translates directly to higher payload capability!

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#Starship 6 flight should be very exciting! In addition to once again catching the boost stage with the "chop sticks" successfully, it'll be a major advance if SpaceX can also land the Starship vehicle itself fully intact. It'll tell us much more about the performance of the #heatshields and the flaps. As John Kraus stated below, they will be looking at " *Reduced* heat shield tiles on sides of Ship to test design changes ahead of future catches/landings of Ship; slightly new landing trajectory to test flap control." These are definitely not trivial changes from flight 5! Exciting times we live in!

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3D printing has become the new normal, transforming how we turn designs into functional components. At Cloudone AI Robotics Lab, it has allowed us to bypass lengthy design review cycles and directly create prototypes, saving both time and capital. With this, we can design swappable components that are rapidly replaceable, enhancing adaptability in our autonomous UAV systems. Working closely with Small-Spacecraft Systems and Payload Centre | SSPACE - IIST-ISRO, we’ve integrated 3D printing into various stages of development: • Prototyping: Quickly test and refine designs. • Tooling: Manufacture custom jigs and fixtures. • End-Use Parts: Produce lightweight, complex structures. • On-Demand Repairs: Reduce downtime by printing replacement parts. Despite its advantages, 3D printing does have its setbacks such as - not all materials meet aerospace-grade strength and durability standards, the components often require post-processing for a smoother finish, printing large parts can be challenging and time-consuming, and initial setup costs-high-quality printers and materials require significant upfront investment. While these challenges exist, the benefits of 3D printing far outweigh its limitations, making it an essential tool in modern aerospace engineering. #3DPrinting #AdditiveManufacturing #Aerospace #Innovation #UAV #Engineering #Technology #Prototyping #AdvancedManufacturing #Automation #DesignOptimization #Collaboration #RapidDevelopment

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3D printing gurus...how do you modify .stls? It feels like the transition from native CAD to 3D printable files is a one-way trip. - Is that actually the case? - Is there a tool I don't know about that can "fill" the shell of triangles to convert the part to a solid body? - How can I split this model at the line and make this 3D scan of a human heart into a vase? This is a surprisingly difficult answer to find, hoping one of you has done this before!

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Exciting news from Lockheed Martin! They've expanded their Additive Manufacturing capabilities with a state-of-the-art facility in Grand Prairie, Texas. With advanced 3D printing tech, like the NXG 600E machines, they're pushing the boundaries of innovation, enabling faster production of lightweight, complex parts while cutting down on waste.   This expansion is part of their 1LMX digital transformation, ensuring engineering teams can rapidly innovate and bring designs to life. It’s inspiring to see how additive manufacturing is reshaping aerospace and defense.   Innovation in action—way to lead, Lockheed Martin!👏 Check out the full Metal AM article here: https://lnkd.in/gYqwS-uy.   #AdditiveManufacturing #Innovation #AerospaceEngineering

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One of the really awesome things we've learned recently via simulation is that the so-called "Rotating Wall" technique from Penning trap science (https://lnkd.in/gT3gD-rd) also works in Orbitrons and can be used to stabilize both ion and electron rotating modes. Essentially this involves splitting up the walls into azimuthal sections and using phase lagged sinusoidal voltages so that the plasma sees "a rotating wall" which can be used to apply torques to the plasma and speed up or slow down the particles. This is super cool and a really big deal for future Orbitron plasma stability control! Video below of a simulation we did recently using rotating electric fields to stabilize a ring of electrons confined in an Orbitron.

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In the past decade of talking with leading aerospace companies I've seen three key metric pairs for success: 1. Tech Advancements & Integration 2. Operational Efficiency & Cost Reduction 3. Market Adoption & Customer Impact Let me explain my thought process... Some of the greatest aerospace companies today(SpaceX, Blue Origin, Lockheed Martin, Northrop Grumman, Boeing, Aerojet Rocketdyne) are all on a relentless pursuit of improvement. This means that they have no other option than to chase continuous advancements. They also need to refine and improve process better/faster than anyone else. so.... They are continuously developing and integrating custom technologies from light weighting to advanced propulsion and avionics. At the same time they are reducing their operational costs and improving efficiencies across legacy programs to support new tech growth. The loop is closed with an understanding of customer requirements and knowing the overall impact that new tech has on the customer. I'm looking forward to watching the continued pursuit of new tech in aero! It would be cool to hear from some of these company employees in the comments.

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Is cutting and pasting from NASA's CEA code causing your pointing finger to become a workplace injury? Does having to repeat the same thermo-chemical equilibrium calculations over again after a slight propellant change give you nightmares? Want to calculate the optimum mixture ratio for a dual-fuel system, but don't have the time to perform the calculations to minimize NOx? Then give Cequel and pyrho a try. Cequel performs all of CEA's calculations as a dynamic Excel spreadsheet function, allowing for fast parametric studies or supplying problem specific parameters without cutting and pasting. Need Isp, ratio of specific heats, C* or the mass fraction of CO2? Multiple parameters can be returned with one function call. Once your spreadsheet is set up how you want to solve the problem, it can be easily updated for future problems. Pyrho is a python library that provides the same functionality to both python and MatLab scripts. By encoding your analysis according to how you want to solve the problem, when a change happens, just tweak the input parameters to re-perform the calculations. A tri-propellant mixture parameter plot is included as an example. For more information and to request a free 30 day demo, please visit www.praqsys.com.

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SpaceX wants Starbase to become an official city in Texas SpaceX is hoping to officially make its Starbase facility a new city in South Texas. The private spaceflight company submitted a petition to local authorities on Dec. 12, requesting an election on incorporating the Starbase launch site as its own city. The Starbase facility located near Boca Chica, Texas, has seen some of SpaceX's most ambitious launches, including the recent Starship rocket catch, and will become the company's new headquarters in a move from California to Texas. "To continue growing the workforce necessary to rapidly develop and manufacture Starship, we need the ability to grow Starbase as a community," SpaceX said in the petition, which was shared in a post on X (formally Twitter). "That is why we are requesting that Cameron County call an election to enable the incorporation of Starbase as the newest city in the Rio Grande Valley." The petition was addressed to Cameron County Judge Eddie Treviño Jr., the county's top elected official. The next step will be for officials to review the petition to determine if it complies with statutory requirements. Then, an election would be held to incorporate Starbase. Starbase serves as SpaceX's primary launch site for Starship test flights, which demonstrate its reusable rocket technology. The most recent launch on Nov. 19 represented the sixth test flight of the Starship launch vehicle, which proved successful with the first in-space burn of a single Raptor engine for deorbiting processes. SpaceX is preparing for a seventh test flight in January 2025, which will attempt another booster recovery at the launch site. Thousands of SpaceX employees work at Starbase, with several hundred living on-site. The company credits the generation of "hundreds of millions in income and taxes for local businesses and government" to the launch facility. Given the remote location of the launch site, SpaceX already helps manage the area's roads and utilities, and assists with schooling and medical care for residents through agreements with the county. With Starship expected to "fundamentally alter humanity's access to space," SpaceX aims to make the area of the Starbase launch site the "Gateway to Mars," the company wrote in the petition. This is not the first time turning Starbase into its own city has come up. SpaceX founder Elon Musk previously proposed the idea on social media in 2021; however, it was not until Dec. 12 that a petition was officially filed with the support of Starbase residents. "Incorporating Starbase will streamline the processes required to build the amenities necessary to make the area a world class place to live — for hundreds already calling it home, as well as for prospective workers eager to help build humanity's future in space," SpaceX officials said in the petition.

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