ELECTRONICS
larger, stiffer samples. In contrast, electronics favour strip-shaped specimens for thin, flexible polymers, as they reduce stress concentrations and better reflect real use.
Drop tower systems are a common tool for tensile impact testing. These provide controlled, repeatable impact velocities across a wide range of impact energies. In a typical setup, the specimen is gripped vertically between fixtures, and a weighted striker is dropped from a specified height to apply a sudden tensile load, simulating real-world dynamic stress events like crashes or drops.
Digital image correlation (DIC) can be integrated with the drop tower testing to enhance outputs by mapping strain fields in real time. This is especially useful for composites, where force measurements alone may not capture local deformations due to the material’s high anisotropy.
Instron’s 9450 Drop Tower system addresses these challenges with a versatile velocity range of 0.77 to 24 m/s and selectable impact energies between 0.3 and 1.800 J. Accessories for tensile impact testing include integrated load cells measuring forces from 0.45 to 30 kN, ensuring high accuracy in both low- and high-force applications from films to composite materials.
The 9450 also integrates with high-speed cameras and DIC software, producing CAE-ready (computer aided engineering) data to help engineers optimise designs and reduce physical prototyping needs.
HOW TENSILE IMPACT TESTING ENHANCES MATERIAL DESIGN Tensile impact testing guides engineers in materials selection at every stage, from raw polymer formulation to choosing the most suitable processing method. For example, nanoporous polymer films in lithium-ion batteries must balance porosity for ion transfer with the strength necessary to maintain functionality. Testing across strain rates and temperatures helps fine-tune mechanical properties for safe, reliable performance. In plastics, tensile impact testing can reveal the glass transition temperature, informing design decisions that enhance durability and safety.
From thin films in electronics to reinforced structures in vehicles, tensile impact testing bridges the gap between material science and real-world performance. By simulating dynamic impact loads, it helps engineers identify failure modes early, refine designs and choose the appropriate materials. for a deeper dive into test setups and methodologies, visit
Instron.com and see how tensile impact tests can be performed using the Instron 9450.
Instron
www.instron.com
UKManufacturing Summer 2025
AI IS TRANSFORMING CONNECTOR AUTOMATION
Automation and AI are no longer futuristic concepts reserved for tech giants. Across industries like retail, manufacturing and logistics, these technologies are driving change. The connector industry is no exception. As AI integrates into operations, it can enhance efficiency, streamline processes and offer greater customisation. But in a field requiring precision and human expertise, can AI truly complement human skills? Lee Slater, European operations manager at connector specialist PEI-Genesis, explores how AI is reshaping connector assembly and balancing with human expertise.
P
icture a vast warehouse filled with thousands of autonomous guided vehicles (AGVs), each moving at high speed, picking products with precision and efficiency. Algorithms dictate their every move, reducing errors and speeding up processes. This is not science fiction—it is happening right now in the retail and logistics sectors. Warehouses are evolving into hyper-efficient, AI-driven hubs, showcasing what is possible when humans and machines collaborate. Could the connector industry follow a similar path?
AI AS AN ENABLER, NOT A REPLACEMENT
At PEI-Genesis, AI is being used not to replace humans, but to assist in optimising processes that are traditionally labour- intensive. For example, AI can improve warehouse operations by calculating the most efficient route for picking components, ensuring that the process is both faster and safer. AI brings intelligence into the mix, tracking performance, improving safety and reducing wear on machinery. One standout example is an intelligent staking machine used on PEI’s assembly lines. This AI-driven machine applies the precise amount of force required to assemble connectors, while also gathering data on wear and tear, helping to predict maintenance needs before a breakdown occurs. The result? Increased reliability,
fewer disruptions and consistently high- quality output.
The real strength of connector
manufacturing, however, lies in the balance between technology and human expertise. At PEI-Genesis, our business model allows us to deliver highly customised connectors with minimal order quantities, often within just 48 hours. While AI assists in managing high-volume, repetitive tasks, the complex, bespoke orders still rely on skilled engineers to meet exacting standards.
UPSKILLING FOR THE AI REVOLUTION
Rather than displacing jobs, AI opens up opportunities for growth. At PEI-Genesis, we see it as a way to upskill our workforce and create new roles in automation and data analysis. As AI continues to integrate into our processes, our employees are being trained to work alongside it, enhancing our operational efficiency while maintaining our high levels of customisation. Looking ahead, AI and human expertise will work hand in hand to drive innovation in connector manufacturing. The challenge for the industry will be finding the right balance, ensuring that technology enhances human capability rather than replacing it. In doing so, the future of connector automation looks set to be as much about people as it is about machines.
PEI-Genesis
www.peigenesis.com
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