3D Printed Auto Parts—The Future Is Now

Overview

3D printing (also known as “additive manufacturing”) affords manufacturers the ability to create custom parts that fit together perfectly.  Utilized for decades in the medical products and aerospace parts industries, 3D printing is increasingly being used in other industries as well, including the relatively recent advent of 3D printed metal auto parts.

 New and Replacement Auto Parts

Automakers have made use of 3D printing processes since the late 1980s, with the initial output comprised primarily of plastic parts.  Manufacturers such as Ford, BMW, Bugatti, Chrysler, Honda, Toyota, among others, have embraced 3D printing in their research and development efforts, including the production of working prototypes.  While the automobile industry is currently unable to mass produce an all 3D printed vehicle, carmakers are already producing 3D printed parts, with the eventual goal, as soon as is feasible, of more fully integrating 3D printed parts into the original manufacture of future generations of automobiles.

Availing themselves of 3D printing processes for producing auto parts allows manufacturers to generate parts that are lightweight (which can improve fuel efficiency) and customizable, and that can be created quickly, enhancing the lean manufacturing focus on just in time inventory.  Although plastic has traditionally been the material most often used in printing parts, as advances in additive manufacturing have been made, so too has the use of alternative materials.

For instance, in 2018, French luxury automaker Bugatti announced that it had developed a new 3D printed titanium brake caliper prototype which, it claimed, was the largest functional titanium component produced with a 3D printer.  DS Automobiles, Citroen premium brand, has created 3D titanium printed parts for the ignition elements, as well as 3D printed titanium door handles, to give their DS 3 Dark Side edition vehicle a sleek, high tech feel.

Gas Usage In 3D Printing Process

To prevent corrosion, and to keep out impurities that can negatively impact the final product, 3D printed parts must be produced in an environment made free of oxygen, typically by the use of argon (and sometimes nitrogen) within the building chamber. That creates a stable printing environment, prevents fire hazards by keeping combustible dust inert, and controls thermal stress in order to reduce deformities.

Oxygen Monitors Can Improve Safety in Additive Manufacturing Processes

Dust from materials used in additive manufacturing, such as titanium, is, when exposed to oxygen, highly combustible and, therefore, requires monitoring to prevent possible explosions.Argon and nitrogen, while used in 3D printing for their oxygen depleting properties, require monitoring to ensure both the integrity of the finished part, and the safety of manufacturing personnel.

PureAire Monitors 

For quality control purposes, PureAire Monitoring Systems’ Air Check O2 0-1000ppm monitor has a remote sensor that can be placed directly within the printing build chamber, to continuously monitor the efficiency and purity of the O2 depleting gases (e.g. argon and nitrogen) used therein.

Moreover, to ensure employee safety, PureAire’s Oxygen Deficiency Monitors should be placed anywhere argon and nitrogen supply lines and storage tanks are located. In the event of an argon or nitrogen leak, a drop in oxygen will cause the built-in horn to sound and the lights to flash, thereby alerting employees to evacuate the area.  PureAire’s Oxygen Deficiency Monitors measure oxygen 24/7, with no time-consuming maintenance required. PureAire’s monitors feature long-lasting zirconium sensors, which are designed to give accurate readings, without calibration, for up to 10 years.

Winemaking - A Must Read

Background

The art and science of winemaking have been around for thousands of years. Winemakers rely on their instincts, palettes, and a thorough knowledge of the nuances involved in every stage of the winemaking process as they strive to achieve the flavors and qualities that they desire.Even a cursory overview of certain elements of the process underscores the critical role played by gases…from fermentation to first sip…in preserving the flavors created and nurtured by the winemaker’s skills.

From Harvesting to Fermentation

Since grapes do not continue to ripen after they have been picked, winemakers must carefully monitor the fruits when still on the vine, to ensure that they are harvested when flavor and ripeness are at peak levels. To protect the fragile grapevines, harvesting is typically done by hand, a laborious but important undertaking.

Once grapes are harvested, they are sorted and, sometimes, destemmed, and then crushed. At one time, grapes were crushed by hand (or, rather, by foot), but winemakers today crush them by using mechanical presses, which improves sanitation and the lifespan of the wine “must” (derived from the Latin phrase vinum mustum, or “young wine”), which is the industry term for the mixture of grape juice, seeds, and skins(and, in certain red wines, stems) that is the result of crushing.

The wine must is blanketed with nitrogen to reduce excessive levels of oxygen, which can oxidize the must, leaving it discolored and overly tart.For white wines, solids in the must are quickly removed after the crushing, in order to preserve the pale color of the juice.  For reds, solids are left in the must, to create a more flavorful wine.

Next, the young wine is transferred to fermentation tanks. The fermentation process begins when yeast is introduced to the must.  Most winemakers today use commercial yeasts, so they can control the predictability of the final product, though some winemakers (much like certain Belgian beermakers) continue to use the old-fashioned method of allowing wild yeasts to mix with the wine must. In either case, during fermentation, the yeast converts the grape sugars into alcohol. A byproduct of the fermentation process is carbon dioxide.  Too much carbon dioxide in the fermentation area can displace oxygen and create potential health and safety risks to employees.

The fermentation process can take anywhere from ten days to a month or more.  To maintain sweetness, some wines are not allowed to fully ferment, which leaves higher levels of sugar in the wine.

Once fermentation is complete, the wine is clarified or filtered, in order to remove residual solids and any other undesired particles. At that point, the fermented wine is transferred into aging vessels, most often either stainless-steel tanks or oak barrels.

Aging and Bottling

Exposure to oxygen can negatively impact a wine’s flavor, longevity, and overall quality. Inert gases, including argon, nitrogen, and carbon dioxide, may be used to flush oxygen out of the environment during storage, to help preserve the flavor and quality of the wine.

Flushing fermentation vessels, aging tanks, barrels, and bottles with an inert gas before filling with wine helps prevent oxidation, which is much dreaded by winemakers, as it produces discoloration, unpleasant aromas, and off flavors reminiscent of vinegar.

Oxygen Monitors Can Protect Winemakers and Their Employees

The same property--oxygen displacement --that makes inert gases ideal for winemaking, can be deadly if gas leaks from the supply lines or storage containers, or if there is a dangerous buildup of carbon dioxide during the fermentation stage. Employees could suffocate from breathing oxygen-deficient air and, since inert gases lack color, and odor, there is no way, absent appropriate monitoring, to determine if there has been a leak.

PureAire Monitors 

PureAire Monitoring Systems’ line of oxygen and dual oxygen/carbon dioxide monitors offer thorough air monitoring, with no time-consuming maintenance or calibration required. A screen displays current oxygen levels for at-a-glance reading by employees, who derive peace of mind from the monitor’s presence and reliable performance.

Built with zirconium oxide sensor cells and non-dispersive infrared sensor (NDIR)cells, to ensure longevity, PureAire O2 and O2/CO2 monitors can last, trouble-free, for over 10 years under normal operating conditions.

As such, the use of PureAire’s monitors will enable winemakers, in a cost-effective manner, to preserve both the quality of their wines and the well-being of their employees.

New requirements for safe use and storage of liquid nitrogen and dry ice

The College of American Pathologists ("CAP")recently imposed new requirementsto address risks related to the use and storage of liquid nitrogen ("LN2") and dry ice.

Background

The new requirements come after a deadly incident in 2017, when liquid nitrogen leaked at a Georgia lab that was not accredited through CAP.  Emergency responders were called to the scene when an employee suffered burns and, moreover,lost consciousness from oxygen deprivation caused by the leak. While the employeeeventuallyrecovered from her injuries, one of the first responders died of asphyxiation as a result ofthe nitrogen leak.

That unfortunate incident illustrates the dangers of nitrogen leaks,which are inherent in the storage and use of LN2. Indeed, there are several cases reported nearly every year of laboratory personnel who die of asphyxiation caused by exposure to nitrogen gas.
Asphyxiation riskis present in dry ice usage as well since, if it is stored in areas without proper ventilation, dry ice can replaceoxygen with carbon dioxide, potentially causing workers to rapidly lose consciousness.

CAP’s New Regulations

Despite their safety risks, both dry ice and LN2 have many beneficial uses in commercial and lab settings, including hospital and research facilities. As such, CAP’s new focus on utilizing best practices to increase employee safety and reduce the danger of nitrogen leaks is vitally important.
Before the regulations were changed, lab directors had greater personal discretion in selectingthe types and deployment of safety equipment utilized in their facilities. Now, laboratories are required to place oxygen("O2") monitors at human height breathing levels anywhere liquid nitrogen is used or stored, and they must place signage warning of safety risk regarding, and train all affected employees on safe handling of, LN2 and dry ice.

Pathologists understand that oxygen/carbon dioxide monitors must be placed appropriately anywheredry ice or LN2 are used or stored.  Even a couple tanks of liquid nitrogen kept in a supply closet pose a safety risk, because even a small leak can quickly displace a large amount of oxygen.

Oxygen Monitors Protect Laboratory Workers

While many people realize that the use and storage of liquid nitrogen and dry ice can present health risks, they may fail to grasp the speed at which circumstances can become dangerous.  It takes only a few breaths of oxygen-deficient air for one to lose consciousness.

AS CAP recognized, oxygen and carbon dioxide monitors offer an effective solution to the health and safety risks posed by nitrogen leaks and inadequatedry ice storage. O2/CO2 monitors continually monitor the air, and they will remain silent so long as oxygen and carbon dioxideremain within normal levels.However,in the event that oxygen is depleted to an unsafe level (19.5%, as established by OSHA), or carbon dioxide levels rise to an unsafe level, alarms embedded in the monitors will sound, alerting employees to evacuate the area and summon assistance from qualified responders.

PureAireMonitors

PureAire Monitoring Systems’ line of oxygen and dual oxygen/carbon dioxide monitors offerthorough air  monitoring, with no time-consuming maintenance or calibration required., The monitors function well in confined spaces, such as closets, basements, and other cramped quarters.  PureAire’s monitors can handle temperatures as low as -40 C, making them ideally suited for environments, such as laboratories, that utilize liquid nitrogen or dry ice. A screen displays current oxygen levels for at-a-glance reading by employees, who derive peace of mind from the monitor’s presence and reliable performance.
Built with zirconium oxide sensor cells and non-dispersive infrared sensor (NDIR)cells, to ensure longevity, Pure Aire O2 monitors can last, trouble-free, for over 10 years under normal operating conditions.  That makes PureAire a cost-effective choice forprotecting employees and complying with the new safety regulations affecting labs and hospitals.
Learn more about oxygen monitors and best practices for their use at www.pureairemonitoring.com.

From Farm to Market: Fruit Ripening

Fruit has a brief window where it is perfectly ripe. If farmers waited until every piece of fruit was ripe before harvesting, farming would be more labor-intensive as farmers rushed to pick ripe fruits. Prices might crash due to a short-term glut of fruit on the market. To ensure a steady supply and demand, keep prices competitive, and reduce food waste, farmers use artificial ripening procedures. One method for ripening fruit after harvest involves ripening chambers. Ripening chambers using ethylene, a natural plant hormone, enable the fruit to be harvested, stored, and transported to where it will be marketed and consumed. While ethylene ripening chambers are beneficial, they are not without risks.

How Ethylene Ripening Chambers Work

While there are other ways to artificially ripen fruit in ripening chambers, ethylene has become a favorite, since it occurs naturally in fruit.
Ethylene is a natural hormone found in plants. Fruits begin to ripen when exposed to ethylene, whether the exposure occurs naturally or artificially. In ethylene ripening chambers, unripe fruits are laid out, and the chamber is sealed.Ethylene gas is then piped into the sealed chamber. As the fruit is exposed to ethylene, the fruit
“respires”,which involves intake of oxygen andemission of carbon dioxide. For the ripened fruit to have the right color and flavor, the ripening should occur in a controlled atmosphere in which the temperature, humidity, ethylene, oxygen, and CO2 concentrationaremaintained at optimum levels.
However, there is a risk of combustion from the ethylene gas, as well as decreased levels of oxygen and increased levels of carbon dioxide inside the chamber.

How Oxygen/Carbon Dioxide and LEL Combustible Monitors Protect Employees

Low oxygen levels cause respiratory distress. If oxygen levels drop below the safe threshold for breathing, which could happen in the event of an ethylene gas leak, employees could suffocate. Suffocation is also a danger when there is too much carbon dioxide in the air. Ethylene gas used in ripening chambers would be hazardous if an employee were to enter the chamber before determining that oxygen and carbon dioxide were at safe levels.

A dual oxygen/carbon dioxide (O2/CO2) monitor detects the levels of oxygen and carbon dioxide within the chamber and sounds an alarm should the oxygen level falls to an OSHA action levelor if the carbon dioxide rises to an unsafe level.  By checking the monitor’s display, an employee will know when it is safe to enter the chamber.

PureAire Monitoring Systems has developed its dual O2/CO2 monitor with zirconium oxide and non-dispersive infrared sensor (“NDIR”) cells. The cells are unaffected by changing barometric pressure, storms, temperatures, and humidity, ensuring reliable performance.  Once installed, the dual O2/CO2 monitor needs no maintenance or calibration.

Ethylene is a highly flammable and combustible gas. If the gas lines used to pipe ethylene into the ripening chambers were to develop a leak, the chamber could fill with ethylene and reach combustible levels. A combustible gas monitor, which takes continuous readings of combustible gases, would warn employees of an ethylene leak within the chamber.

PureAire Monitoring System's Air Check LEL combustible gas monitor continuously monitors for failed sensor cell and communication line breaks. The Air Check LEL gas monitor is housed in an explosion-proof enclosure. If a leak or system error should occur, an alarm will immediately alert employees.

To learn about PureAire Monitoring Systems’ dual O2/CO2 monitors or the Air Check LEL Combustible monitor, please visit www.pureairemonitoring.com.

IVF Cryopreservation and Safe Handling Practices

Couples that want to have a baby but have not been able to conceive naturally are drawn to invitro fertilization (IVF) treatments.

In an IVF treatment, several eggs are fertilized at once, which creates multiple embryos. While more than one embryo may be implanted, to spur the odds of pregnancy, there are inevitably some unused embryos.

The remaining embryos may be preserved cryogenically, for use later, rather than destroyed. There are many reasons couples may select cryopreservation of embryos, including:

• A second chance if the IVF treatment fails the first time around
• The desire to have another child
• As a precaution before undergoing medically necessary procedures that might the reduce the odds of a successful pregnancy, such as cancer treatment
• Opportunity to use embryos in medical research
• Opportunity to donate embryos to another couple

The National Embryo Donation Center estimates that there are over 700,000 human embryos currently stored in the United States.

The cryogenic process relies on cryoprotective agents (or CPAs), which protect the embryo from damage while it freezes. Damage may occur as ice crystals form during the freezing process. Without the use of CPAs, the ice crystals could pierce the embryo wall, causing embryo failure.

Cryopreservation facilities may use either a slow or fast method to freeze the embryos. In the slow method, embryos are frozen in stages, with protective agents added in slow doses over time. The frozen embryos are then preserved in liquid nitrogen until they are slowly thawed for use.

The fast-freezing method combines higher concentrations of CPAs to the embryo, after which the embryo is quickly plunged into liquid nitrogen. The process is so quick that ice is unable to form, thus protecting the embryo from damage.

Wherever liquid nitrogen is used, there are risks associated with nitrogen leaks. Nitrogen displaces oxygen, and a leak would rob the air of oxygen, thereby creating a health hazard for medical staff. When there is not enough oxygen in the air, persons working in the area can suffocate due to the lack of oxygen. Since nitrogen lacks color and odor, there is no way to detect a leak using the senses. In addition, a nitrogen leak could lead to failure of the cryopreservation tanks storing the embryos. In order to ensure the safety of employees, and the viability of the embryos, cryopreservation facilities need to rely on oxygen monitors.

How Oxygen Monitors Protect Employee Health in IVF Facilities

Oxygen monitors continually sample the air, taking periodic readings of current oxygen levels. In the event of a nitrogen leak, and a drop in oxygen to an OSHA action level, the built-in horn will sound, and lights will begin to flash, thereby providing notification to the employees that they must exit the area.

Best practice calls for oxygen monitors to be placed wherever nitrogen is used or stored. Not all oxygen monitors currently on the market are suitable for use in confined spaces or in freezers.

PureAire Monitoring Systems oxygen monitors are uniquely suited for use in an IVF facility, because the monitors can withstand temperatures as low as -40C.

PureAire Monitoring Systems monitors feature long-lasting zirconium sensors, which are designed to provide accurate readings, without calibration, for up to 10 years. Busy IVF facilities will appreciate the ease of use, and low maintenance of PureAire Monitoring Systems products.

To learn more or to view product specs, please visit www.pureairemonitoring.com

New Solar Cell Technology to Help lower prices for the consumer

Inkjet Perovskite solar cells may help shape the future of energy production by lowering costs, and transparency.

Solar panels used to be costly and time-consuming to produce—and quite expensive on the consumer side. New technologies have driven costs as well as production time down, to the benefit of consumers. See what's new with solar panels and where the solar cell technology is going. 

New Solar Panel Developments

In traditional solar panels, silicon acts as a semiconductor. By doping the silica material with gallium and arsenic impurities, the silicon-based solar panel is able to capture solar energy and convert the sun's energy to electricity. While there are other materials that can act as semiconductors for solar energy, silicon is ideal because is forms an oxide at high temperatures. The oxide makes it easy to product consistent, high quality solar panels. The latest generation of solar cells use perovskite rather than silicon.

In 2009, researchers first discovered that perovskite could also be used to make photovoltaic solar cells. Despite the potential of this discovery, perovskites weren't considered a good choice for solar panels, because the materials needed to be heated to such high temperatures that very few materials could be coated with the perovskite solution. Glass could withstand the high heat, but a glass solar panel would be an impractical product for obvious reasons.

A young scientist recently discovered a new way to work with perovskites. Using an evaporation method, Polish scientist Olga Malinkiewicz, was able to coat flexible foil with perovskites. To speed the substrate drying process, nitrogen was used. By blowing dry nitrogen gas over the wet perovskite film, the resulting evaporation happened faster and more consistently. Without utilizing nitrogen in the process, the panels could have an inconsistent coverage, which would lead to poor energy conversion rates. 

The resulting solar panels were thin and flexible, both in their material application and their use cases. Imagine a portable solar panel that could attach to a laptop, drone, or car, something that could capture the sun's energy indoors or outdoors and travel with you, to power whatever you needed. 

Since her initial discovery, Malinkiewicz has refined the approach. The latest generation of perovskite solar cells are created with an inkjet printing procedure which makes them faster and cheaper to produce. With mass production feasible from an economic perspective, the perovskite solar cells can be a popular option to add electricity to areas that do not have an underlying power grid, whether that's rural communities or developing countries.

The technology is still being refined, so you won't see widespread perovskite solar cells just yet. However, researchers are cheering the innovation and its potential to revolutionize energy distribution.

One thing to consider moving forward with perovskite solar panels is the use of nitrogen in the process. Anywhere nitrogen is used, there's a safety risk should the gas leak from supply lines. 

How an Oxygen Monitor Can Help Detect Nitrogen Gas Leaks

Nitrogen leaks create health risks because nitrogen displaces oxygen, which humans need to breathe. Undetected, a nitrogen leak could create oxygen-deficient air, leading to respiratory distress and eventually death via asphyxiation. Nitrogen gases is both colorless and odorless, which means it would be impossible to detect a leak relying on the senses.

The easiest way to detect a leak is to measure ambient oxygen using an oxygen monitor. Oxygen monitors continually track levels of oxygen, sounding an alarm if levels fall to the OSHA threshold where safety is at risk. With flashing lights and a loud alarm, workers will be able to exit the room before the onset of health problems. 

PureAire creates industry-leading oxygen monitors that last for 10 or more years, with no calibration or maintenance needed. Learn more or view product specs at www.pureairemonitoring.com.

Pepsi Is Launching the First Ever “Nitro Soda”

Nitrogen-infused or nitro beverages have been among the biggest trends in the beverage industry. There's been no shortage of nitro cold brew coffees and nitro beers, but never a nitro soda—until now, with the launch of Nitro Pepsi. The new beverage was sampled at the 2019 Super Bowl and while you won't find it on tap just yet, here's what you can look forward to.

Introducing Nitro Pepsi 

Nitro Pepsi aims to revolutionize the most signature aspect of soda, which is the carbonation.

CO2 gas is responsible for creating the tangy bubbles that give soda its texture and mouthfeel. Nitrogen creates bubbles that are smaller and softer, for a creamier mouthfeel in the drink. The creamy experience naturally complements sweet, malty beer styles like stouts and porters, as well as cold brew coffees.

Translated into Pepsi, the nitrogen bubbles create a beverage that's reminiscent of an ice cream float (with that creamy sweetness). The drink will be available in two flavors, original Pepsi and vanilla. Pepsi recommends drinking the Nitro Pepsi cold, but not over ice.

With its new nitro soda, Pepsi hopes to transform the soda drinking experience, much the way that craft beer and coffee have been transformed by nitro drinks, and introduce their brand to a new audience of consumers.

While there's a lot of excitement around the new beverage, there are also some risks to consider, due to the use of nitrogen gas. Nitrogen is naturally dense and will displace oxygen in the environment. If the bottling plant experiences a nitrogen leak, this means that oxygen within the bottling plant will be pushed out of the air, creating a public health hazard.

Nitrogen gas is colorless and odorless, so employees would not be able to spot the leak. When oxygen levels first begin falling, employees will not notice any symptoms. By the time oxygen levels dip to the point where health is at risk, employees may begin to experience cognitive confusion or suffer respiratory distress. With oxygen deprivation, there's a risk of losing consciousness or suffering death via asphyxiation.

Preventing Nitrogen Leaks With a Dual O₂/CO₂ Monitor

While the nitrogen leak cannot be detected, what can be tracked is the level of oxygen in the room. By paying attention to oxygen levels and alerting employees when levels fall below the safe threshold, as defined by OSHA, a dual O2/CO2 monitor protects public health. Not only are these alarms required by OSHA where inert gases like nitrogen are used, they are the easiest way to protect employees from workplace hazards and deliver peace of mind in the plant bottling area.

The O2 monitor works by sampling the air to check oxygen levels. As long as oxygen levels are within the safe zone, the monitor is silent. With PureAire products, the monitor always displays readouts on a screen, so employees can check oxygen levels at a glance.

If a nitrogen leak develops and oxygen starts to fall, the monitor will flash lights and sound an alarm so that employees have ample warning to evacuate the area. Plant workers can then alert emergency services, who can respond to the leak.

There are many O2 monitors on the market, but PureAire's are unique for their construction. PureAire O2 monitors and dual O2/CO2 monitors feature zirconium sensors, which offer 10 or more years of reliable performance with no calibration. PureAire monitors do not need calibration or maintenance. All that's needed is to unbox the monitor, mount it on the wall, and plug it in to enjoy continuous oxygen monitoring and superior leak detection.

PureAire's O2 monitors are industry leading for their quality, construction, and performance. To learn more about PureAire’s dual O2/CO2 monitor or oxygen monitor, visit www.pureairemonitoring.com.