Quality Assurance Standards Exist for Good Reasons. Not Following Them Can be Disastrous
Quality assurance standards are essential. Ignoring them can lead to serious problems. A few years ago, a company created ultrapure plastic packaging for semiconductors. Business was strong, but I became concerned about its engineering and manufacturing practices. The company declined over time, which made me wonder whether it still exists. Like many firms, this one […]
You Rejected the Part for THAT??
When Part Rejections Go Too Far: Lessons from Over-Tolerancing Years ago, I worked with a machined plastic part that cost about $200 each. The drawing called for tight tolerances across most features — and rightly so. But this part got rejected for something minor: a tiny burr on an outer edge. The drawing specified a […]
Design Tolerances Must Correspond to What is Needed
Critical design reviews are crucial. They help with dimensioning and tolerancing for parts and assemblies. Years ago, I spoke with a machinist friend in his shop. We discussed our professions—mine in mechanical and aeronautical engineering. Soon, we talked about sensible design practices. He told a story about a mechanical design engineer. The engineer set a […]
The Wing on the C-5 Galaxy- A Sad Tale of How Engineering and Politics Do Not Mix
The C-5 Galaxy: How Politics Overrode Engineering When Politics Shapes Airplanes The Lockheed C-5 Galaxy, one of the largest military transport aircraft ever built, remains a case study in what happens when politics intrudes on engineering. Massive programs like the C-5 rely on political support. Congress. Senators and governors want contracts for their districts—design, testing, […]
Fix It… Just Don’t Change Anything
Managing Design Changes Late in the Process Engineers often face a tough challenge: making design changes when an assembly is close to production. At this stage, every adjustment has consequences. On one hand, the change is necessary. On the other, the question arises: “Who will I upset if I make this adjustment?” Large-scale changes […]
Fatigue Analysis
Understanding Material Fatigue Analysis: History, Methods, and Real-World Failures Durable goods and critical infrastructure rely heavily on fatigue analysis. By understanding how and when materials fail, engineers can design safer, longer-lasting products. From early aircraft engines in the 1920s to modern bridges and airplanes, fatigue analysis has shaped how we approach reliability. A Brief History […]
Rapid Prototyping
Beyond Plastic: My Journey into 3D Printing with Metals, Ceramics, and Glass Introduction For years, I believed 3D printing (also called rapid prototyping) was limited to plastics. I had heard whispers about metal applications, but never looked deeply into them. Recently, I was surprised to learn that glass and ceramics can also be used […]
An Ounce of Prevention Can Save a Ton of Money Down the Road!
Why the R-3350 Engine Caught Fire: A Critical Design Lesson in Aircraft Engineering Introduction In 1937, the Curtis-Wright R-3350 radial engine ran its first test. At the time, it was the largest double-row, air-cooled radial ever built, and later versions produced over 3,000 horsepower. The U.S. military used the R-3350 during World War II, […]
Fighter Aircraft Transition to Remotely Piloted Vehicles
The Case for Pilotless Fighter Aircraft A Turning Point in Fighter Aircraft Design Fighter aircraft design is at a crossroads. Pilotless aircraft — drones and remotely piloted vehicles (RPVs) — have been in service for years. The technology is ready: GPS navigation, advanced autopilots, and fully automated takeoff and landing systems already exist. The question […]